Special Instructions of 416-5705 Guard Kit on Certain D-Series Models {7150, 7153, 715L} Caterpillar

Compact Track Loader

259D (S/N: LW51-UP; FTK1-UP; GTK1-UP; FTL1-UP)

279D (S/N: TP51-UP; GTL1-UP; PPT1-UP; RCX1-UP)

289D (S/N: WE51-UP; WCT1-UP; TAW1-UP; A9Z1-UP)

Multi Terrain Loader

257D (S/N: EML1-UP; FMR1-UP; D5T1-UP; EZW1-UP)

277D (S/N: NTL1-UP; FMT1-UP; MLT1-UP)

287D (S/N: TLK1-UP; HMT1-UP)

Skid Steer Loader

236D (S/N: K2D1-UP; SEN1-UP; MPW1-UP; BGZ1-UP)

242D (S/N: HFB1-UP; DML1-UP; DZT1-UP; A9W1-UP)

246D (S/N: PN51-UP; BYF1-UP; JSL1-UP; HMR1-UP)

262D (S/N: RE51-UP; DTB1-UP; KTS1-UP; LST1-UP)

Track-Type Tractor

D6N (S/N: STL1-UP)

Introduction

This Special Instruction provides information for installation of the 416-5705 Guard Kit.

Reference Section

Reference: Special Instruction, SENR3130, "Torque Specifications"

Parts Required

Refer to Table 2 for required parts.

Removal Procedure

Show/hide table

Illustration 1	g06376091
(1) Plate (A) Knockout plate A (B) Knockout plate B

1. Remove the correct knockout plate on 416-5706 Plate As that corresponds to engine in machine. For HRC engine, remove inside knockout plate (A). For LRC engines, remove outer knockout plate (B).
   Show/hide table

   Illustration 2	g06376100
   (2) Air Cleaner (3) Air Lines

2. Remove 345-3499 Air Cleaner Gp (2) and 378-6695 Air Lines Gp (3) from the machine to improve installation access for turbo guard kit.

   Note: These components will need to be reinstalled after guard installation is complete.

   Show/hide table

   Illustration 3	g06376113
   (4) Ladder Clip

3. Remove bolt, washer, and ladder clip (4) holding the engine wiring harness from exhaust manifold to the engine.

   Note: The bolt and washer are no longer needed but save the ladder clip to be installed later.

Installation Procedure

Show/hide table

Illustration 4	g06376577
(5) Bracket Assembly (6) Bolts and Washers

1. Install 416-5708 Bracket As (5) on the engine by using two 345-4709 Bolts and two 8T-4121 Hard Washers (6). Torque the bolts to 55 ± 10 N·m (41 ± 7 lb ft). Orient bracket assembly (5) as shown in Illustration 4 .
   Show/hide table

   Illustration 5	g06376595
   (7) Bracket Assembly (8) Bolts and Washers (9) Ladder Clip

2. Install 416-5707 Bracket As (7) to the engine block using two 8T-4189 Bolts and two 8T-4224 Hard Washers (8). Orient bracket as shown in Illustration 5. Install previously removed ladder clip (9) with the lower bolt and orient as shown. Torque the bolts to 28 ± 7 N·m (21 ± 5 lb ft).
   Show/hide table

   Illustration 6	g06376599
   (10) Bracket Assembly (11) Bracket Assembly (12) Bolt and Washer

3. Install 416-5709 Bracket As (9) to 416-5708 Bracket As (10) using one 8T-4908 Bolt (11) and one 8T-4224 Hard Washer. Orient bracket as shown in Illustration 6. Torque the bolt to 28 ± 7 N·m (21 ± 5 lb ft).
   Show/hide table

   Illustration 7	g06376601
   (13) Bolts and Washers (14) Plate Assembly (15) Ladder Clips

4. Align the slots of 416-5706 Plate As (14) with the weld nuts of bracket assembly. Attach the plate with four 8T-4908 Bolts and four 8T-4224 Hard Washers (13). Install two 4P-8134 Clips (15) on bottom bolts and orient clips as shown in Illustration 7. Hand tighten all four bolts first to allow 416-5706 Plate As (14) to be correctly adjusted and installed and then torque all four bolts to 28 ± 7 N·m (21 ± 5 lb ft).
   Show/hide table

   Illustration 8	g06376606
   (16) Bracket Assembly (17) Ladder Clip

5. Reconnect engine wire harness to the 298-0663 Ladder Clip (17) using a tie strap and route speed sensor wire between 416-5707 Bracket As (16) and flywheel housing geometry as shown in Illustration 8.
   Show/hide table

   Illustration 9	g06376607
   (18) Ladder Clip

6. Connect Mass Airflow Sensor (MAF) sensor wire from the engine wire harness to the 298-0663 Clip (18) in the location shown in Illustration 9. Use tie straps as needed to prevent harness rubbing on guard or any other components.
   Show/hide table

   Illustration 10	g06376608
   (19) Ladder Clip

7. Connect AC compressor line to the 298-0663 Clip (19) with tie strap to prevent hose rubbing against turbo guard in the location shown in Illustration 10.

8. Reinstall air lines and air cleaner back into machine. Torque all bolts to correct specification. Connect speed sensor wire and MAF sensor wire.