Procedure For Replacing The Harness Between The Chassis And The Hitch{1408} Caterpillar

Introduction

This Special Instruction provides information for replacing the harness that extends between the chassis and the hitch on the machines that are listed above.

Important Safety Information

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 hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not specifically recommended by AVSpare is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Required Parts

The parts that are required for the replacement of the harness are listed in Table 1.

Installation Procedure

Illustration 1	g01923276
The harness is located along the right side of the hitch. The harness extends from the cushion-hitch valve to the top of the case in order to connect to the transmission harness.

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Illustration 2	g01923280
Locations of parts that must be removed

1. Remove the 286-1865 Switch Harness As . Also, remove the clips, ties, and the related components. Refer to Illustration 2 for the location of the parts.

   Note: Do not discard all of the components. Some of the components must be retained in order to be used during the reassembly of the new harness.

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Illustration 3	g01923376
(20) 4P-7581 Clip (21) 4P-8134 Clip (22) 130-5300 Clip (23) 5S-7379 Bolt (24) 8T-4896 Hard Washer (25) 8M-2773 Clip

2. Remove all of the clips, nuts, bolts, and the cable straps that are located in this area.

   1. Retain the following parts:
      • One 4P-7581 Clip (20)

      • One 130-5300 Clip (22)

      • One 5S-7379 Bolt (23)

      • Two 8T-4896 Hard Washers (24)

   2. Discard the following parts:
      • One 4P-8134 Clip (21)

      • One 5S-7379 Bolts (23)

      • One 8M-2773 Clip (25)

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Illustration 4	g01923395
(23) 5S-7379 Bolt (24) 8T-4896 Hard Washer (25) 8M-2773 Clip

3. Remove all of the clips, bolts, and washers that are located in this area.

   1. Retain the 8M-2773 Clip (25) .

   2. Discard the 5S-7379 Bolt (23) and the 8T-4896 Hard Washer (24) .

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Illustration 5	g01927524
(24) 8T-4896 Hard Washer (25) 8M-2773 Clip (26) 5M-3062 Bolt

4. Remove all of the clips, bolts, and washers that are located in this area. Discard all of the parts.

   1. Discard the following parts:
      • One 8T-4896 Hard Washer (24)

      • One 8M-2773 Clip (25)

      • One 5M-3062 Bolt (26)

5. Disconnect both ends of the harness after all of the components have been disassembled.

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Illustration 6	g01923538
Forward side of the cushion-hitch valve (2) 3S-2093 Cable Strap (5) 4P-7428 Clip

6. Install the 4P-7428 Clip (5) by using the existing bolt and the washer for the hydraulic flange. Use a 3S-2093 Cable Strap (2) in order to connect the wires for the solenoid to the clip.

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Illustration 7	g01923553
Interior side of the cushion-hitch valve (14) 130-5300 Clip

7. Install a new 130-5300 Clip (14) by using the existing bolt and the washer for the hydraulic flange. Use the clip in order to secure the connector for the cushion-hitch solenoid and the new harness assembly.

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Illustration 8	g01923576
Rear side of the cushion-hitch valve (1) 2W-7940 Bracket (2) 3S-2093 Cable Strap (4) 4L-6454 Bolt (7) 5P-9297 Clip (8) 5S-7379 Bolt (9) 6V-8801 Nut (11) 8M-2770 Clip (13) 8T-4896 Hard Washer (20) 4P-7581 Clip (22) 130-5300 Clip (23) 5S-7379 Bolt (24) 8T-4896 Hard Washer

8. Install the 2W-7940 Bracket (1) to the rear of the mounting bracket for the cushion-hitch valve.

9. Install the following components along the bracket:
   • The 130-5300 Clip (22) that was retained

   • The 4P-7581 Clip (20) that was retained

   • The 8T-4896 Hard Washer (24) that was retained

   • The 4L-6454 Bolt (4) that is new

   • The 5P-9297 Clip (7) that is new

   • The 3S-2093 Cable Strap (2) that is new

   Note: Install the 130-5300 Clip (22) so that the clip faces the bracket in order to secure the connector for the auger filter. Install the 4P-7581 Clip (20) so that the angle faces away from the 130-5300 Clip (22). Use two 3S-2093 Cable Straps in order to secure the harness to the clip. Refer to Illustration 8.

10. Install one 5P-9297 Clip (7) at the top of the bracket by using one 5S-7379 Bolt (8), two 8T-4896 Hard Washers (24) and one 6V-8801 Nut (9) .

    Note: Ensure that you use a washer on each side of the bracket.

11. Attach the 8M-2773 Clip (11) by using the 5S-7379 Bolt (23) and the 8T-4896 Hard Washer (24) that were retained during the disassembly. Attach the clip, the bolt, and the washer to the boss that is located at the bottom of the mounting bracket for the cushion-hitch valve.

12. Use a 3S-2093 Cable Strap in order to secure the connector for the arc suppressor to the main harness bundle. Ensure that the connector is down when you secure the connector.

13. Connect the harness to all of the clips. Refer to Illustration 8 for the correct mounting configuration.

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Illustration 9	g01923613
(3) 4K-8302 Clip (25) 8M-2773 Clip

14. Install the 8M-2773 Clip (25) that was retained during the disassembly by using one of the bolts and washers from the clamp.

15. Install the 4K-8302 Clip (3) by using one of the bolts and washers from the support bracket. Refer to Illustration 9.

    Note: Ensure that the new harness is clipped at the locations that are marked with green tape.

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Illustration 10	g01923633
(2) 3S-2093 Cable Strap (6) 4S-1962 Clip (10) 7V-6571 Grommet (12) 8T-2502 Bolt (15) 132-7551 Spacer (24) 8T-4896 Hard Washer

16. Install the 4S-1962 Clip (6) at the top of the case near the saddle for the pin by using one 7V-6571 Grommet (10), one 132-7551 Spacer (15), one 8T-2502 Bolt (12) and one 8T-4896 Hard Washer (24) that was retained from the disassembly.

    Note: Install the 132-7551 Spacer (15) under the clip.

17. Use a 3S-2093 Cable Strap (2) in order to secure the lead for the hydraulic oil temperature sensor to the main harness. Refer to Illustration 10.

    Note: For machines with serial numbers S/N:DFJ1-252 the technician will need to replace the Hydraulic Oil Temp Sensor with an updated sensor. Refer to Required Parts Table 1.

18. Connect the new harness to the transmission harness.