Installation Of A New Rollover Protective Structure (ROPS){7325} Caterpillar

Track-Type Loader:

953D (S/N: LBP1-173,175-222,224-749,751-805,808-824)

963D (S/N: LCS1-860)

Introduction

This special instruction will provide the rework procedure for replacing the old cab on the D-Series Track-Type Loaders with the new 327-7787 Cab Kit . This rework procedure is not required for the following machines:

• 953D (S/N: LBP174,223,750,806-807,825-UP)

• 963D (S/N: LCS861-UP)

Illustration 1	g01592331
New cab on shipping pallet

Safety

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Tilting the cab while the cab is occupied could result in serious personal injury or death. Before the cab is tilted, remove all loose articles from the cab, and secure all the cab windows and the cab doors. Be sure that the cab is not occupied before the cab is tilted. The improper securing of a tilted cab can cause the cab to fall suddenly which could result in personal injury or death. Before you work under a tilted cab, be sure to install the lock pin in order to prevent the cab from falling. Refer to the Operation and Maintenance Manual for the correct procedure for tilting the cab.

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Crush Hazard! Improper securing of a tilted cab can cause the cab to fall resulting in serious injury or death. Install the safety lock pin to prevent the cab from falling before working under a tilted cab. Refer to the Operation and Maintenance Manual for the correct cab tilting procedure.

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The use of unapproved replacement parts on the cab may result in unexpected motion of the cab which could result in serious injury or death. Only use replacement parts on the cab that are approved by Caterpillar.

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Performance of the cab tilt procedure with foreign objects inside of the cab or with personnel inside of the cab may result in serious injury or death. Before you perform the cab tilt procedure, ensure that the cab is free of all foreign objects, and ensure that the cab is unoccupied. Do not attempt to climb on the cab once the cab is tilted.

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Tilt the cab only as instructed in the Operation and Maintenance Manual. Failure to properly follow the instructions for the cab tilt procedure may result in damage to the machine and/or serious injury or death. The cab tilt procedure must be followed exactly as stated in the Operation and Maintenance Manual.

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If the proper torquing procedure is not used when reinstalling the ROPS structure, the ROPS structure may be weakened which could result in serious injury or death. Ensure that all contact surfaces are clean before reinstalling the ROPS structure. Ensure that the correct torquing procedure is followed when reinstalling the ROPS structure.

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If the cab tilt cylinder is connected and a crane is used to tilt the cab instead of the cab tilt cylinder, serious damage to the machine and/or serious injury or death may occur. Ensure that the cab tilt cylinder is disconnected from the cab when using a crane as the lifting device to tilt the cab.

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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
The weight of the cab is approximately 1400 kg (3085 lb). Use a crane that is capable of lifting the weight of the cab. Use rotating hooks that are capable of lifting the weight of the cab.

Required Parts And Required Tools

Illustration 2	g01626223
Loose parts are in a bag that is located in the tool box inside the cab.

Table 1

Required Parts
Part Number	Description	Qty	Sales Model
327-7787	Cab Kit	1
205-3237	Film	1	953D
281-1561	Film	1	953D
205-3239	Film	1	963D
281-1562	Film	1	963D
9X-7380	O-Ring Seal	3
9X-7381	O-Ring Seal	3
9X-7382	O-Ring Seal	1
4C-2959	Air Conditioner Oil	100 cc (3.4 oz)
289-1133	Bracket	1
289-1074	Panel	1
8T-4224	Hard Washer	2
8T-4200	Bolt	2
218-0651	Film	1
283-9265	Film	1
147-1445	Connector Plug As	1

Table 2

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2
B	151-6320	Wire Removal Tool	10

Rework Procedure

Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.

System Checks

Note: All of the information that is recorded in this step will determine failed parts or faulty parts before the installation of the new cab. This special instruction will not cover the failed parts.

1. Perform a check of all the functional systems and the electrical systems. Check for any fault codes with Caterpillar Electronic Technician (ET).

   1. Record any problems with the functional systems.

   2. Record all options that were not factory installed.

   3. Record any rework that has been completed on the cab.

   4. Record all fault code from Cat ET.

   5. Record all failed electrical components.
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      Table 3

      Check with the key in the OFF position
      Item	Switch Position	Operational
      		Yes	No
      Horn switch
      Dome light
      Beacon switch-on headliner
      Light switch	1 (1)
      	2 (2)
      Optional attachment flood lights (if equipped)

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      ( 1 )	Backlight on switches and backlight on cluster
      ( 2 )	The front and rear flood lights, the backlight on the switches, and the backlight on the instrument cluster.

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      Table 4

      Check with the key in the ON position
      Item	Operational
      	Yes	No
      Check Messenger
      Instrument cluster
      Seat (raise and lower) (1)
      12 V power outlet 1
      12 V power outlet 2
      Radio
      Front wiper switch
      Front wiper/washer
      Rear wiper switch
      Rear wiper/washer
      All four speeds of the blower switch
      Both condenser fans
      Engaging of the compressor for the air conditioner

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      ( 1 )

      Leave the seat in the raised position.

Removal Of The Cab

1. Fully raise the seat.

2. Completely discharge the air conditioner system for the machine before disconnecting the air conditioner lines. Record the amount of refrigerant and the amount of Polyalkylene Glycol oil that was removed during the discharging of the air conditioner.

   ReferenceRefer to Testing and Adjusting, SENR5664 for the procedure on properly discharging the air conditioner system.

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Illustration 3	g01592385
Front of the cab

3. Remove horn (2) and front grab handles (1) in order to have better access to the pins for the cab.

   Note: This will prevent damaging the grab handles and the horn. The grab handles and the horn will be installed on the new cab.

4. Remove the cab.

   Note: Make sure that the tilt cylinder for the cab has been disconnected from the cab before removing the cab.

   ReferenceRefer to Disassembly and Assembly, KENR5178, "Cab - Remove" for the procedure for removing the cab on a 953D.

   ReferenceRefer to Disassembly and Assembly, KENR6064, "Cab - Remove" for the procedure for removing the cab on a 963D.

   Note: Make sure that all electrical harnesses are disconnected from the cab before removing the cab. Discard the eight mounting bolts for the ROPS.

5. Place the cab on suitable stands. The bottom of the cab needs to be 254 ± 51 mm (10 ± 2 inch) from the floor.

Removal Of The Cab Enclosures

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Illustration 4	g01594435

1. Remove door (3) and cover (4) from both sides of the machine.

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Illustration 5	g01594433

2. Remove bolts (6) and bar (5). Door latch (8) and bracket (7) need to remain attached to bar (5). Bar (5) is located on the left-hand side of the cab.

   Note: This will make the removal of the air conditioner easier.

3. Remove door latch (8) and bracket (7) from the right-hand side of the cab.

Removal Of The Hand Rail, Pedal Controls, Front Console, Duct Assembly, Front Dash Display, Front Wiper Motor, Mirror, And Sun Visor

1. Remove the hand rail, the pedal controls, the front console, the duct assembly, the front dash display, and the front wiper motor.

   Note: The front dash display, the front wiper motor, and the front wiper arm will be reinstalled on the new cab.

   ReferenceRefer to Disassembly and Assembly, KENR5178, "Window Wiper and Wiper Motor (Front) - Remove" for the removal of the front console, duct assembly, hand rails, front dash display, and front wiper motor for the 953D.

   ReferenceRefer to Disassembly and Assembly, KENR6064, "Window Wiper and Wiper Motor (Front) - Remove" for the removal of the front console, duct assembly, hand rails, front dash display, and front wiper motor for the 963D.

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Illustration 6	g01626389

2. Remove sun visor (9) and mirror (10) .

Removal And Installation Of The Controls From The Headliner

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Illustration 7	g01595897

1. Remove switch panels (11) .

2. Remove radio (12) .

3. Remove air conditioner controls (13) .

4. Install switch panels (11) in the new cab.

5. Install radio (12) in the new cab.

6. Install air conditioner controls (13) in the new cab. Tighten the screw for the air conditioner controls to 6 ± 1 N·m (53 ± 9 lb in).

Removal Of The Seat And Controls

Note: Notice the routing of all of the wiring harness for the seat and the controls. This is needed for installing the seat and the controls into the new cab.

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Illustration 8	g01610353
Location of the bolts for the arm assemblies

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Illustration 9	g01592407

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Illustration 10	g01592454

1. Raise left arm assembly (14). Disconnect harness assembly (15). Remove bolts (16) and left arm assembly (14). Refer to Illustration 8 for the location of bolts (16) .

   Note: Ensure that bushings (17) for mounting the armrest are retained.

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Illustration 11	g01592386

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Illustration 12	g01610154
Seat backrest with no cushion

2. Install M10 x 1.5 x 35 mm bolt (18) and M10 washer (19) on the left side of the seat. Refer to Illustration 11 for the location of bolt (18) and washer (19) .

   Note: Installing bolt (18) and washer (19) will ensure that the shaft in the seat backrest will not turn when you remove the other arm assembly. Refer to Illustration 12 for an illustration of this shaft.

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Illustration 13	g01592408

3. Disconnect harness assembly (20) for the right-hand armrest.

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Illustration 14	g01592410

4. Remove bolts (22) and raise arm assembly (21). Refer to Illustration 8 for the location of bolts (22) .

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Illustration 15	g01592411

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Illustration 16	g01592454

5. Remove bolts (23) and arm assembly (21). Refer to Illustration 8 for the location of bolts (23) .

   Note: Ensure that bushings (17) for mounting the armrest are retained.

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Illustration 17	g01592412

6. Disconnect harness assemblies (24) .

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Illustration 18	g01592486

7. Remove clip (25) from the back of the seat on the right-hand side.

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Illustration 19	g01592414

8. Remove bolt (27). Slide seat (26) forward in order to remove seat (26). Use two people in order to remove seat (26). The weight of seat (26) is approximately 34 kg (75 lb).

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Illustration 20	g01592484

9. Ensure that seat sliders (28) are retained.

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Illustration 21	g01592425

10. Remove bolts (30). Use two people in order to remove seat assembly (29). The weight of seat assembly (29) is approximately 32 kg (70 lb).

    Note: Discard bolts (30) .

Removal Of The Right Hand Controls And The Electronic Control Module (ECM)

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Illustration 22	g01596317

1. Remove plastic consoles (31) from the right-hand side of the machine.

   Note: Discard consoles (31). A new console (31) is provided with the new cab.

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Illustration 23	g01596318

2. Remove control panels (32) .

3. Remove alarm (33) .

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Illustration 24	g01596320

Note: Pay attention to the orientation of the harness clips and the ECM mounting bolts.

4. Disconnect harness connectors (35). Remove bolts (34) and ECM (36). Discard bolts (34) .

5. Disconnect harness connector (37). Remove bolts (38) and power converter (39) .

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Illustration 25	g01599113

Note: Perform this step if the machine is equipped with Product Link.

6. Disconnect harness connector (40). Remove bolts (42) and ECM (41) .

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Illustration 26	g01596324
ECM (45) is located behind the seat on the left-hand side of the machine.

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Illustration 27	g01623338
ECM (45) is located behind the seat on the left-hand side of the machine.

Note: Perform this step if the machine is equipped with a ripper and/or a multipurpose bucket.

7. Disconnect harness connector (43). Remove bolts (44) and implement ECM (45) .

Removal Of The Air Conditioner

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Illustration 28	g01610194

Note: Pay attention to the orientation and clipping of the drain tubes.

1. Remove the air conditioner and the drain tubes.

   Note: In order to remove the air conditioner, the air conditioner will need to be rotated. This will allow the flange to pass from behind the duct. Refer to Illustration 28 for an example.

   ReferenceRefer to Disassembly and Assembly, KENR5178, "Air Conditioner and Heater Components - Remove" for the procedure on removing the air conditioner on the 953D.

   ReferenceRefer to Disassembly and Assembly, KENR6064, "Air Conditioner and Heater Components - Remove" for the procedure on removing the air conditioner on the 963D.

Illustration 29	g01626245

Valve (46) (if equipped) is not needed on the new cab.

Removal Of The Floor Mat, The Front Dash, And The Covers From The New Cab

1. Remove the floor mat from the new cab.

Note: Use caution when you enter the new cab.

2. Remove the front dash, the duct assembly, and the covers from the new cab. This will make the installation of the components into the new cab easier.

Installation Of The Air Conditioner

1. Install new seals for every connection. Apply 1U-9763 Vacuum Pump Oil to all seals before installation.

2. Before, you install the air conditioner ensure that the following rework has been completed:
   • Service Magazine, SEPD0939 05 May, "Improvements To The HVAC System Air Quality In The Cab"

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Illustration 30	g01627394
The latch housings are located on the left-hand side of the cab.

3. Remove the latch housings by depressing the tabs. The latch housings are for the recirculating air filter cover mounting. Refer to Illustration 30 for the location of the tabs.

4. Install the latch housings for the recirculating air filter cover mountings on the new cab.

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Illustration 31	g01713353
Location of 8T-8737 Seal Plug

5. Verify that the 8T-8737 Seal Plug is installed. 8T-8737 Seal Plug should be installed into the electrical plug on the actuator of the air conditioner. The actuator is located toward the rear of the machine on the air conditioner. See Illustration 31 for the location of 8T-8737 Seal Plug .

Note: The dryer may need to be loosened in order to properly align the tube for the air conditioner.

6. Install the air conditioner.

   ReferenceRefer to Disassembly and Assembly, KENR5178, "Air Conditioner and Heater Components - Install" for the procedure on installing the air conditioner on the 953D.

   ReferenceRefer to Disassembly and Assembly, KENR6064, "Air Conditioner and Heater Components - Install" for the procedure on installing the air conditioner on the 963D.

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Illustration 32	g01627838
Bolt (B) is located on the front side of the air conditioner.

Note: The air duct may need to be pressed downward in order to align bolt (B) .

7. Ensure proper alignment of bolt (B) .

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Illustration 33	g01627403
Routing of the drain tubes for the air conditioner on a 953D

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Illustration 34	g01627404
Routing of the drain tubes for the air conditioner on a 963D

8. Install the drain tubes for the air conditioner. Refer to Illustration 33 or Illustration 34 for orienting the drain tubes on your machine.

Installation Of The Right Hand Controls And The Electronic Control Module (ECM)

Note: Make sure that all harness connectors are fully seated before tightening the harness connectors.

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Illustration 35	g01596324

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Illustration 36	g01623338
ECM (45) is located behind the seat on the left-hand side of the machine.

Note: If, the machine is not equipped with a ripper and/or a multipurpose bucket proceed to Step 2.

1. Position implement ECM (45) and install bolts (44). Connect harness connector (43) .

   ReferenceIf your machine is equipped with joystick steering and the implement ECM that is shown in Illustration 35, perform the steps in Service Magazine, SEPD0980 23 February, "Improved Orientation Of Implement Attachment Electronic Control Module (ECM)" for installing the implement ECM.

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Illustration 37	g01626268
Bolts (47) are located behind the seat on the left-hand side of the machine.

2. Remove bolts (47) from the old cab. Install bolts (47) in the new cab.

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Illustration 38	g01599733

Note: Harness connector (40) may not be connected.

3. Perform Step 3.a through Step 3.c if the machine is equipped with Product Link. Proceed to Step 10 if the machine is not equipped with Product Link.

   1. Disconnect harness connector (40) .

   2. Remove bolts (48) and bracket (49). Bolts (48) and bracket (49) should be discarded.
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   Illustration 39	g01599113

   3. Position ECM (41) and install bolts (42). Connect harness connector (40). Tighten harness connector (40) to 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 40	g01596320

Note: When you install ECM (36) pay attention to the orientation of the clips. Before you install the ECM remove the bolts, the washers, and the mounts from the new cab. Do not cut the straps from the clips.

Note: When, you install harness connectors (35) the harness may need to be adjusted. Ensure that the harness connector matches the plugs for the ECM. If the harness connectors do not match the ECM, perform the following steps. Proceed to Step 10 if the harness connector matches the plugs for the ECM.

4. Remove the cover from the back of the connector.

5. Start at the top row with the longest wires and insert tooling (B) into the housing around the wire.

6. Firmly push tooling (B) inward until the terminal locking fingers are disengaged.

7. Pull the terminal wire and tool (B) straight out from the connector in order to remove.

8. Insert the removed wire into the same location in the new 147-1445 Connector Plug As .

Note: More than one tooling (B) will be required.

9. Work across the top row and then move to the next row down until the entire connector has been changed over.

10. Position ECM (36) and install new bolts (34). Connect harness connectors (35). Tighten harness connectors (35) to 6 ± 1 N·m (53 ± 9 lb in). Tighten bolts (34) to 25 ± 5 N·m (18 ± 4 lb ft).

11. Position power converter (39) and install bolts (38). Connect harness connector (37) .

Note: Perform the following steps for 953D (S/N: LBP155-165) and 963D (S/N: LCS210-221) if the existing mounting brackets for the console do not match the mounting location. Proceed to Step 17 for all other machines.

12. Remove the engine start switch and Messenger (if equipped) from the front right-hand bracket.

13. Install the 218-0651 Film , the removed engine start switch, and the Messenger (if equipped) into the 289-1133 Bracket .

14. Remove the engine speed control, the parking brake switch, the hydraulic lockout switch, the kickout and positioner control, and the reversible fan switch (if equipped) from the right hand mounting bracket. Also, remove the ripper control from the mounting bracket.

15. Install the 283-9265 Film , the removed rocker switches, and the ripper control into the 289-1074 Panel .

16. Attach the bracket that was assembled in Step 13 and the panel that was assembled in Step 15 with two 8T-4224 Hard Washers and two 8T-4200 Bolts . Torque the bolts to 12 ± 3 N·m (106 ± 27 lb in).

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Illustration 41	g01596318

17. Install control panels (32) .

18. Install alarm (33) .

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Illustration 42	g01596317

19. Install new plastic console (31) for the right-hand side of the machine. Apply 4C-4030 Thread Lock Compound , 9S-3263 Thread Lock Compound , or 185-3996 Thread Lock Compound to all fasteners.

Installation Of The Seat And Controls

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Illustration 43	g01592425

1. Use two people in order to install seat assembly (29). The weight of seat assembly (29) is approximately 32 kg (70 lb). Install new bolts (30) .

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Illustration 44	g01592484

2. Verify the retention of seat sliders (28) .

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Illustration 45	g01592414

3. Use two people in order to install seat (26). The weight of seat (26) is approximately 34 kg (75 lb). Install bolt (27).

   Note: Ensure that the Operation and Maintenance Manual for the machine is transferred to the new cab.

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Illustration 46	g01592486

4. Install clip (25) on the back of the seat on the right-hand side.

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Illustration 47	g01592412

5. Connect harness assemblies (24) .

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Illustration 48	g01592411

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Illustration 49	g01592454

6. Position arm assembly (21) and install bolts (23) .

   Note: Verify the retention of bushings (17) for mounting the armrest.

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Illustration 50	g01592410

7. Lower arm assembly (21) and install bolts (22) .

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Illustration 51	g01592408

8. Connect harness assembly (20) .

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Illustration 52	g01592386

9. Remove M10 bolt (18) and M10 washer (19) on the left side of the seat. Refer to Illustration 52 for the location of bolt (18) and washer (19) .

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Illustration 53	g01592407

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Illustration 54	g01592454

Note: Before, you perform this step ensure that Service Magazine, SEPD0941 19 May, "Improved Routing Of Wiring Harness For Hydrostatic Controls" has been completed.

10. Position left arm assembly (14) and install bolts (16). Connect harness assembly (15). Lower left arm assembly (14) .

    Note: Verify the retention of bushings (17) for mounting the armrest.

11. After the seat is installed, the sliders require adjustment. The sliders are adjusted from the side of the seat that faces the access door of the machine. Use the following procedures in order to adjust the sliders.
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    Illustration 55	g01621689

    1. The two sliders (28) are located on each side of the suspension (50). The sliders that are located near the access door for the cab have adjustment screws (51) .

    2. Access holes are provided in the sides of the seat assembly. Move the seat until the access holes are in line with the sliders.

    3. Tighten the adjustment screws in the sliders. Move the seat. A resistance of approximately 9 kg (20 lb) should be felt.

    4. Adjust screws (51), as needed.

Installation Of The Front Wiper Motor, Duct Assembly, Front Dash Display, Front Console, Pedal Controls, Hand Rail, Mirror, And Sun Visor

Use the following specifications for installing the front wiper motor and front wiper arm assembly:

Installation of the wiper motor assembly

Torque for motor assembly ... 19 ± 1 N·m (14 ± 1 lb ft)

Torque for wiper arm ... 23 ± 1 N·m (17 ± 1 lb ft)

After a minimum of 0.5 hours to a maximum of 4 hours, tighten again. ... 23 ± 1 N·m (17 ± 1 lb ft)

Minimum torque check for the field ... 12 N·m (106 lb in)

Installation torque for the harness connector for the front dash display ... 2.25 ± 0.25 N·m (20 ± 2 lb in)

1. Install the front wiper motor, the duct assembly, the front dash display, the front console, the pedal controls, and the hand rail.

   ReferenceRefer to Disassembly and Assembly, KENR5178, "Window Wiper and Wiper Motor (Front) - Install" for the installation of the front wiper motor, duct assembly, front dash display, hand rail, and front console for the 953D.

   ReferenceRefer to Disassembly and Assembly, KENR6064, "Window Wiper and Wiper Motor (Front) - Install" for the installation of the front wiper motor, duct assembly, front dash display, hand rail, and front console for the 963D.

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Illustration 56	g01626389

2. Install sun visor (9) and mirror (10) .

Removal And Installation Of The Refrigerant Condenser, The Refrigerant Condenser Fan And Fan Motor, The Rear Light, Product Link (If Equipped), The Side Flood Lights (If Equipped), And The Rear Wiper Arm Assembly

Note: Cleanliness is an important factor. Before you begin the removal procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: Install new seals for every connection to the refrigerant condenser. Apply 1U-9763 Vacuum Pump Oil to all seals before installation.

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Illustration 57	g01603933

1. Remove bolts (52) and guard assembly (53) .

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Illustration 58	g01604193

2. Attach Tooling (A) and a suitable lifting device to guard assembly (54). Remove bolts (55) and guard assembly (54) .

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Illustration 59	g01603993

3. Disconnect hose assembly (56) and hose assembly (57) .

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Illustration 60	g01604814

4. Disconnect harness assembly (58) .

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Illustration 61	g01604773

5. Disconnect harnesses (60) and remove lights (59) and lights (61) (if equipped).

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Illustration 62	g01604196

6. Remove bolts (63) and refrigerant condenser (62) .

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Illustration 63	g01604793

Note: Perform Step 7 and Step 8 if the machine is equipped with Product Link.

7. Disconnect harness (65) from receiver (64). Remove bolts (67), receiver (64), and antenna (66) .

8. Position receiver (64) on the new cab and install bolts (67). Mount antenna (66). Connect harness (65) to receiver (64) .

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Illustration 64	g01606313

9. Disconnect hose (70). Remove nut (69) and remove arm assembly (68) .

10. Connect hose (70) on the new cab. Install arm assembly (68) and nut (69) .

    Use the following specification for tightening nut (69) :

    Installation of the rear wiper arm assembly

    Torque for wiper arm ... 21 ± 1 N·m (15 ± 1 lb ft)

    After a minimum of 0.5 hours to a maximum of 4 hours, tighten again. ... 21 ± 1 N·m (15 ± 1 lb ft)

    Minimum torque check for the field ... 12 N·m (106 lb in)

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Illustration 65	g01604196

11. Position refrigerant condenser (62) and install bolts (63) .

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Illustration 66	g01604773

12. Install lights (59) and lights (61) (if equipped) and connect harnesses (60). Tighten the nuts for lights (59) and lights (61) (if equipped) to 25 ± 7 N·m (18 ± 5 lb ft).

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Illustration 67	g01604814

13. Connect harness assembly (58) .

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Illustration 68	g01603993

14. Install new seals in hose assembly (56) and hose assembly (57). Connect hose assembly (56) and hose assembly (57) .

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Illustration 69	g01604193

15. Attach Tooling (A) and a suitable lifting device to guard assembly (54). Position guard assembly (54) and install bolts (55) .

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Illustration 70	g01603933

16. Position guard assembly (53) and install bolts (52) .

Removal And Installation Of The Rear ROPS Covers And The Window Washer Tank

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Illustration 71	g01606574

1. Remove bolts (73), stopper (72), and cover (71) .

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Illustration 72	g01606714

2. Remove antenna (74) from the right-hand cover for the ROPS.

   Note: Discard antenna (74) from the old cab.

3. Connect antenna (74) from the new cab to the right-hand cover for the ROPS.

4. Position cover (71) on the new cab and install bolts (73) and stopper (72) .

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Illustration 73	g01606614

Note: Window washer tank (76) is located on the back of the cab on the right-hand side.

5. Disconnect harnesses (77) and hoses (79). Remove nuts (75), bolt (78), and window washer tank (76). Discard nuts (75) and bolt (78) .

Note: New nuts (75), spacers, and washers are provided on the new cab. Also, a new bolt (78) and a new tube is provided on the new cab.

6. Position window washer tank (76) on the new cab and install new nuts (75) and bolt (78). Connect hoses (79) and harnesses (77) .

   Note: The connector with the purple and black wires connect to the left pump. The connector with the white and black wires connect to the right pump.

Removal And Installation Of The Front Lights And Top ROPS Covers

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Illustration 74	g01606813

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Illustration 75	g01606833

1. Remove bolts (85) and cover (80) .

2. Remove bolt (83) (if equipped) and disconnect harnesses (84) from the back of lights (81). Remove lights (81) .

3. Install lights (81) on the new cab. Connect harnesses (84) on the new cab to the back of lights (81) .

4. Position cover (80) on the new cab. Install bolts (85) and bolt (83) (If equipped).

5. Repeat Step 1 through Step 4 for the other side of the machine.

   Note: There is only one cover (82) on the machine.

6. Remove bolts (85) and cover (82) .

7. Position cover (82) on the new cab. Install bolts (85) .

Removal And Installation Of The Main Circuit Breaker

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Illustration 76	g01607153
right-hand side of the cab

1. Disconnect cables (86) and harness (89). Remove bolts (87) and breaker (88) .

2. Position breaker (88) on the new cab and install bolts (87). Connect cables (86) and harness (89) .

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Illustration 77	g01626390

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Illustration 78	g01626391

3. Remove bolts (90), bolts (92), bolts (94), and harness (93) .

Note: Use spacers (91) if the old cab was not equipped with spacers (91) .

4. Position harness (93) on the new cab and install bolts (94), spacers (91), bolts (92), and bolts (90) .

Removal And Installation Of The Cab Doors And The Cab Door Hold Open Locks

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Illustration 79	g01607679

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Illustration 80	g01607680

1. Remove door (95) .

   Note: Spacer (96) must be discarded in order to avoid cab door water leaks on the replacement cab.

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Illustration 81	g01607693

2. Remove bolts (97), cover (98), and stop (99) .

3. Install cover (98), bolts (97), and stop (99) on the new cab.

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Illustration 82	g01607679

4. Install door (95) .

5. Repeat Step 1 through Step 4 for the other side of the machine.

Installation Of The Cab Enclosures

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Illustration 83	g01594433

1. Install bar (5) with bolts (6) onto the left-hand side of the cab.

2. Install bracket (7) and latch (8) on the right side of the cab.

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Illustration 84	g01594435

3. Install door (3) and cover (4) on both sides of the machine.

4. Adjust doors (3) and covers (4) in order to ensure a proper fit, as needed.

Test The Cab For Leaks

1. Test the cab for leaks in one of the following methods:

   1. Spray the cab with jets of high-pressure water. Check the window seals for water leaks.

   2. Use an air gun and follow the front window seal.

      Note: This method will require two people.

2. If, leaks are present then perform Step 3 through Step 8. If leaks are not present proceed to ""Installation Of The Cab" ".

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Illustration 85	g01721895
(C) Location of M10 screws

3. Remove the front window.

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Illustration 86	g01722098

4. Protect the interior of the cab from dust with a piece of cardboard. Apply an automotive body filler to the junctions of the top plate and the structure in order to fill the gap between the welds. See Illustration 86 for the general location for applying the automotive body filler.

5. Permit the automotive body filler to dry. Sand the automotive body filler to a flat surface.

6. Use 4C-4198 Black Paint to paint the surfaces that were sanded.

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Illustration 87	g01721895
(C) Location of M10 screws

Note: When, you install the window remember to put the 2 mm (0.08 inch) washers between the studs and the hold down plates. Failure to install these washers can cause the window to be clamped too hard. This may result in cracking the window.

7. Install the front window. Tighten screws (C) to 55 N·m (40 lb ft).

8. Repeat Step 1.

Installation Of The Cab

1. Install the cab with the new hardware that is provided.

   ReferenceRefer to Disassembly and Assembly, KENR5178, "Cab - Install" for the procedure for installing the cab on a 953D.

   ReferenceRefer to Disassembly and Assembly, KENR6064, "Cab - Install" for the procedure for installing the cab on a 963D.

   Note: Make sure that all electrical harnesses get connected after the cab has been installed.

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Illustration 88	g01592385
Front of the cab

2. Install horn (2) and front grab handles (1) .

3. Completely charge the air conditioner system in the cab and in the machine after connecting the air conditioner lines. Add 100 cc (3.4 oz) of 4C-2959 Air Conditioner Oil to the air conditioner system for the dryer, accumulator, and air conditioner lines.

   ReferenceRefer to Testing and Adjusting, SENR5664 for the procedure on properly charging the air conditioner system.

Adjust The Cab Doors

1. The fully closed position may not be achieved due to a high seal pressure or the position of the striker. The striker may require an adjustment in order to achieve the fully closed position.

   Note: In order to check for a suitable alignment, close the door gently against the latch. You should hear a click. Press the door firmly against the latch. You should hear a second click.

2. Close the cab door and locate the striker in the cab assembly so that the striker is centered vertically in the jaws of the door latch. Make sure that the door is not raised or lowered, when the striker engages the jaws.

3. Add or remove shims in order to make sure that there is no interference between the striker assembly and the door latch assembly.

   Note: The hinge may also need to be adjusted in order to achieve the primary latch position or the correct door seal pressure.

4. Adjust stop (98) and stop (72) in order to ensure that the door does not rattle when the door is in the latched open position.

Install New Labels

ReferenceRefer to Operation and Maintenance Manual for your machine for the correct location of the labels.

You should also use the old cab as a reference for the correct location of the labels.

Recheck The System

1. Perform a check of all the functional systems and the electrical systems. Check for any fault codes with Caterpillar Electronic Technician (ET).

   1. Record any problems with the functional systems.

   2. Record all fault code from Cat ET.

   3. Record all failed electrical components.
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      Table 5

      Check with the key in the OFF position
      Item	Switch Position	Operational
      		Yes	No
      Horn switch
      Dome light
      Beacon switch-on headliner
      Light switch	1 (1)
      	2 (2)
      Optional attachment flood lights (if equipped)
      Are the decals installed
      Operation and Maintenance Manual in the new cab
      Cab leaks

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      ( 1 )	Backlight on switches and backlight on cluster
      ( 2 )	The front and rear flood lights, the backlight on the switches, and the backlight on the instrument cluster.

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      Table 6

      Check with the key in the ON position
      Item	Operational
      	Yes	No
      Check Messenger
      Instrument cluster
      Seat (raise and lower)
      Check the clearance of the electrical harness by moving the seat through a full range of motion.
      12 V power outlet 1
      12 V power outlet 2
      Radio
      The left speaker and the right speaker
      Front wiper switch
      Front wiper/washer
      Rear wiper switch
      Rear wiper/washer
      All four speeds of the blower switch
      Both condenser fans
      Engaging of the compressor for the air conditioner

2. Compare the results from the above test with the results from the ""System Checks" ".

Cab Decommissioning

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Illustration 89	g01608834

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Illustration 90	g01608857

1. Cut the serial number of the cab and a section of the ROPS tube out of the old cab.

   Note: The serial number of the cab is located on the right-hand side of the cab.

   Note: The serial number of the cab is also the serial number of the machine.