Installation Instructions for the Handrail and Step Gp (Kit) (Cab, Front Access) {7254, 7256} Caterpillar

Wheel Loader:

950G Series II (S/N: AXR1-UP; AXX1-UP)

962G Series II (S/N: AXS1-UP; AXY1-UP)

966G Series II (S/N: ANT1-UP; ANZ1-UP)

972G Series II (S/N: AWP1-UP; ANY1-UP)

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

Introduction

Do not perform any procedure and do not order parts that are outlined in this publication until you have read the information that is contained in this document. Do not perform any procedure and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

This information lists the procedures that are required in order to install the front access platforms on the following models:

• 950G Series II

• 962G Series II

• 966G Series II

• 972G Series II

• 980G Series II

The 277-6345 Handrail and Step Gp (Kit) (Cab, Front Access) is for the 950G and the 962G Series II Wheel Loaders.

The 277-6348 Handrail and Step Gp (Kit) (Cab, Front Access) is for the 966G and the 972G Series II Wheel Loaders.

The 271-7614 Handrail and Step Kit (Kit) (Cab, Front Access) is for the 980G Series II Wheel Loader.

A complete listing of the parts that are contained in this kit are listed in the Parts Manual, SEBC1456.

This supplemental product support literature should be used with other product support literature that is available for the model that is being worked on.

Install the 244-8785 Tube As

Illustration 1	g01314002
Front view of cab

1. Remove the left hand bracket and mirror (A).

2. Use the following hardware and install the 244-8785 Tube As in the place of the left hand bracket and mirror:
   • Two 8T-4121 Hard Washers

   • Two 8T-4136 Bolts

3. Remove the mirror from the old bracket and install the mirror onto the 244-8785 Tube As .

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Illustration 2	g01438004
Mirror

4. With the handle of the 258-7370 Latch As (1) in the Open position, insert the shaft through the washer and the hole in hinge (2) .

5. Place the rubber bushing, the 8T-4224 Hard Washer and the 3F-2617 Locknut over the shaft.

6. With the handle of the 258-7370 Latch As (1) in the Open position, loosely tighten the 3F-2617 Locknut (3).

7. When the handle of the 258-7370 Latch As (1) is in the Open position, the rubber bushing should pass through the hole in the hinge in order to allow the mirror to be lifted out of the way.

8. When the handle of the 258-7370 Latch As (1) is in the Closed position, the rubber bushing should expand in order to hold the hinge in a locked position.

9. With the handle of the 258-7370 Latch As (1) in the Closed position, tighten the locknut in order to properly secure the latching mechanism.

Remove Handrails

Illustration 3	g01188513
View of frame with handrails

1. Remove handrails (B) and (C) .

Weld the 257-1719 Block Group to the Front Frame of the 950G Series II or the 962G Series II Wheel Loaders

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Illustration 4	g01314004
Views of the front frame for the 950G Series II or the 962G Series II Wheel Loaders (A) 304 ± 1 mm (11.9685 ± 0.04 inch) (B) 147 ± 1 mm (5.7874 ± 0.04 inch) (C) 110 ± 1 mm (4.3307 ± 0.04 inch) (D) 249 ± 1 mm (9.8031 ± 0.04 inch) (E) 101 ± 1 mm (3.9764 ± 0.04 inch)

1. Refer to Illustration 4 for welding instructions and the location of the blocks. Weld the following blocks onto the front frame:
   • One 252-9884 Block (1)

   • One 253-3261 Block (2)

   • Two 256-8662 Blocks (3)

Weld the 253-4866 Block Group to the Front Frame of the 966G Series II or the 972G Series II Wheel Loaders

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Illustration 5	g01314007
View of the front frame for the 966G Series II or the 972G Series II Wheel Loaders (A) 304 ± 1 mm (11.9685 ± 0.04 inch) (B) 168 ± 2 mm (6.6142 ± 0.08 inch) (C) 121 ± 2 mm (4.7638 ± 0.08 inch) (D) 220 ± 2 mm (8.6614 ± 0.08 inch) (E) 120 ± 2 mm (4.7244 ± 0.08 inch) (F) 660 ± 2 mm (25.9842 ± 0.08 inch)

1. Refer to Illustration 5 for welding instructions and the location of the blocks. Weld the following blocks onto the front frame:
   • One 252-9884 Block (1)

   • One 253-4864 Block (2)

   • Two 253-4865 Blocks (3)

Weld the 257-1720 Block Group to the Front Frame of the 980G Series II Wheel Loader

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Illustration 6	g01309713
View of the front frame (A) 602 ± 1.5 mm (23.70 ± 0.06 inch) (B) 226 ± 1.5 mm (8.90 ± 0.06 inch) (C) 82.6 ± 1.5 mm (3.25 ± 0.06 inch) (D) 130 ± 1.5 mm (5.12 ± 0.06 inch) (E) 38 ± 1.5 mm (1.50 ± 0.06 inch) (F) 270 ± 1.5 mm (10.63 ± 0.06 inch) (G) 94 ± 1.5 mm (3.70 ± 0.06 inch)

1. Refer to Illustration 6 for welding instructions and the parts location. Weld the following parts onto the front frame:
   • One 252-9884 Block (1)

   • Four 5G-8480 Lugs (2)

Weld the 270-6773 Plate to the Left Hand Platform of the 980G Series II Wheel Loader

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Illustration 7	g01309716
Views of the left hand platform assembly (D) 215 ± 1.5 mm (8.46 ± 0.06 inch)

1. Refer to Illustration 7 for welding instructions and the location of the plate. Weld the 270-6773 Plate (1) onto the left hand platform assembly.

Installation of the Handrails, Step and Platform

Illustration 8	g01314013
View of cab and front frame with handrails

Install Handrails

Note: Refer to Illustration 8 for the following steps.

1. Use the following hardware and install the two 251-9893 Handrail As (6) :
   • Four 8T-4223 Hard Washers (18)

   • Two 8T-4139 Bolts (16)

   • Two 8T-4956 Bolts (19)

2. Use the following hardware and install the 251-9885 Handrail As (4) on the left hand side of the cab:
   • One 7X-0589 Hard Washer (12)

   • One 8T-4136 Bolt (14)

   • One 8T-4139 Bolt (16)

   • One 8T-4223 Hard Washer (18)

3. Use the following hardware and install the 251-9886 Handrail As (5) on the right hand side of the cab:
   • One 7X-0589 Hard Washer (12)

   • One 8T-4136 Bolt (14)

   • One 8T-4139 Bolt (16)

   • One 8T-4223 Hard Washer (18)

4. Use the following hardware and install the 251-9886 Handrail As (5) on the front of the cab:
   • Four 8T-4192 Bolts (17)

   • Four 8T-4223 Hard Washer (18)

Install Brackets and Steps

Note: Refer to Illustration 8 for the following steps.

1. Use the following hardware and install the 256-8629 Bracket As (8) and the 256-8630 Bracket As (9) :
   • Four 8T-4121 Hard Washers (13)

   • Four 8T-4137 Bolts (15)

2. Use the following hardware and install the two 234-1531 Steps (1) :
   • Four 5P-1076 Hard Washers (11)

   • Eight 8T-4139 Bolts (16)

   • Four 8T-4223 Hard Washers (18)

Install the Platform

Note: Refer to Illustration 8 for the following steps.

1. Use the following hardware and install the 258-6363 Platform (10) :
   • Four 8T-4121 Hard Washers (13)

   • Four 8T-4137 Bolts (15)

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Illustration 9	g01310591
Top view of left hand platform

Note: Refer to Illustration 9 for the following step.

2. Use existing hardware and install the 257-0143 Handrail As (20) .