Installation Procedure to Retrofit Overhead Guard and Front Window Guard Upgrade Kits on the Cab of Certain D Series Excavators {7159} Caterpillar

Excavator

312D (S/N: SKA1-UP; XGK1-UP; RHL1-UP; KES1-UP)

315D (S/N: BZN1-UP; JGS1-UP)

319D (S/N: ZCA1-UP; AYF1-UP; KFM1-UP; RJP1-UP)

320D (S/N: HJC1-UP; DHE1-UP; TDH1-UP; KLM1-UP; SPN1-UP; GDP1-UP; EJT1-UP; GMX1-UP; PCX1-UP)

323D (S/N: WNE1-UP; ZMF1-UP; CWG1-UP; NES1-UP)

324D (S/N: MND1-UP; JAT1-UP; PYT1-UP)

328D (S/N: SWF1-UP; RMX1-UP)

329D (S/N: YFW1-UP; DTZ1-UP)

336D (S/N: WRK1-UP; PGW1-UP)

345D (S/N: BYC1-UP)

349D (S/N: WTD1-UP)

349D2 (S/N: XAC1-UP)

374F (S/N: NFJ1-UP; MFL1-UP; DNM1-UP)

390F (S/N: HJD1-UP; TYE1-UP; MGF1-UP; HSM1-UP; GAY1-UP)

Material Handler

390F MHPU (S/N: B371-UP)

Introduction

This Special Instruction outlines the installation procedure to retrofit a 471-1984 Overhead Guard Upgrade Kit and a 471-1983 Front Window Guard Upgrade Kit on the cab of certain D Series Excavators listed above.

Do not perform any of the procedures or order any parts until you have read and understand the instructions contained in this publication.

Safety Section

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

Parts List

Machine Preparation

Illustration 1	g02280104

1. Park the machine on a level surface. Refer to the appropriate Operation and Maintenance Manual, "Parking" for the proper procedure.

2. Make sure that all mounting surfaces are clean and free of debris.

Installation Procedure

Overhead Guard Upgrade Kit

Illustration 2	g03740519
471-1984 Overhead Guard Upgrade Kit (1) 7X-0515 Hard Washer (2) 8T-4121 Hard Washer (3) 8T-4137 Bolt (4) 219-0305 Film (5) 336-1197 Guard As (6) 349-5364 Bracket As (7) 447-1706 Bolt (8) 459-1736 Film

1. Install guard assembly (5) by using four bolts (7) and four hard washers (1).

   Note: The weight of the guard assembly is approximately 60 kg (132 lb).

2. Install bracket assembly (6) by using two bolts (3) and two hard washers (2).

Front Window Guard Upgrade Kit

Illustration 3	g03739868
471-1983 Front Window Guard Upgrade Kit (1) 4E-1487 Knob (2) 5D-4822 Retaining Ring (3) 6V-7357 Bolt (4) 7Y-0623 Locknut (5) 8T-4121 Hard Washer (6) 8T-4136 Bolt (7) 8T-4223 Hard Washer (8) 8T-4224 Hard Washer (9) 8T-4908 Bolt (10) 8Y-5745 Latch As (11) 9X-6165 Washer (12) 9X-8256 Washer (13) 095-1207 Nut (14) 127-3947 Bumper (15) 172-5291 Screw (16) 186-3782 Boss (17) 201-4534 Bolt (18) 203-4457 Grommet (19) 219-0305 Film (20) 336-1159 Support As (21) 336-1160 Support As (22) 336-1161 Guard As (23) 336-1163 Bracket As (24) 342-3715 Bracket As (25) 342-3717 Bracket As (26) 342-3723 Gas Spring As (27) 346-7367 Pedal As (28) 346-7370 Pedal As (29) 357-3956 Striker As (30) 416-0862 Cushion (31) 451-2175 Hard Washer (32) 459-1734 Film

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Illustration 4	g03739877

1. Install support assembly (20), two screws (15) and two hard washers (5) on the top right cab front frame.

2. Install support assembly (21), two screws (15) and two hard washers (5) on the top left cab front frame.
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   Illustration 5	g03739886

3. Install a bracket assembly (23), two screws (15) and two hard washers (5) on the bottom right and on the bottom left cab front frame.
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   Illustration 6	g03739890

4. Install a latch assembly (10) by using bolt (3) and washer (11) with Loctite 242.

5. Install pedal assembly (27) by using a boss (16), a cushion (30), bolt (3), and washer (11).
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   Illustration 7	g03740035

6. Install a grommet (18) and knob (1).

   Note: Tighten knob (1) by hand.

7. Install a bumper (14) by using two nuts (13) and two hard washers (7).
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   Illustration 8	g03740074

8. Install a latch assembly (10) by using bolt (3) and washer (12) with Loctite 242.

9. Install pedal assembly (28) by using a boss (16), a cushion (30), bolt (3), and washer (11).
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   Illustration 9	g03740146

10. Install a grommet (18) and knob (1).

    Note: Tighten knob (1) by hand.

11. Install a bumper (14) by using two nuts (13) and two hard washers (7).

    Note: The bumper position will be adjusted when installing the guard assembly.

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    Illustration 10	g03740184

12. Before installing guard assembly (22) to the cab, install striker assembly (29) and gas spring assembly (26) to the guard assembly.

13. Install a striker assembly (29) to the bottom right, and to the bottom left, of guard assembly (22) by using three bolts (9) and three hard washers (8).

    Note: The striker position will be adjusted when installing the guard assembly.

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    Illustration 11	g03740208

14. Install a gas spring assembly (26) on the bottom right, and on the bottom left, of guard assembly (22) by using a retaining ring (2).
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    Illustration 12	g03740245

15. Install guard assembly with striker assembly and gas spring assembly on the cab by using two bolts (17), two hard washers (31), and two locknuts (4).

    Note: The weight of the guard assembly is approximately 84.5 kg (186.3 lb).

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    Illustration 13	g03740443

16. Loosen three bolts (9). Adjust striker assembly (29) position for smooth operation of the latch.

17. Tighten three bolts (9) to secure striker assembly (29) at the appropriate position.
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    Illustration 14	g03740460

18. Loosen nuts (13). Adjust bumper (14) position so that the bumper contacts the guard assembly when latched in order to prevent rattles.

19. Tighten nuts (13) to secure bumper (14) at the appropriate position.
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    Illustration 15	g03740485

20. Apply film (19) and film (32) on top of the front guard.

Film Installation

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Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing the vapors in enclosed areas without adequate ventilation and do not smoke. Isopropyl alcohol is flammable. Do not use near open flame, welding operations, or around heated surfaces exceeding 482°C (900°F).

Surface preparation is important in the installation of films. The surface must be clean and dry in order for the films to adhere to the machine. Be sure that oil, grease, and dirt have been removed before you install the new films. The installation instructions that follow are recommended:

1. A 50:50 mixture of isopropyl alcohol and water is generally an adequate cleaning agent for cleaning the mounting surface.

2. Apply solvent to the contact area. Wipe the surface with a lint free cloth until the surface is dry.

3. Carefully remove the liner from the back of the film. Avoid touching the adhesive.

4. Apply the film to the surface.

   Note: The film cannot be repositioned once the film is applied. If the film is installed incorrectly, the film must be removed and discarded. Start again and use a new film.

5. Press the film firmly into place. Apply pressure evenly across the entire surface of the film. The use of a hand roller or a squeegee is recommended in order to ensure maximum adhesion to the mating surface. Remove any bubbles that remain under the film.