Field Installation Procedure for the 386-9224 Window Guard Ar on Certain K Series Medium Wheel Loaders{7165, 7182, 7256, 7310} Caterpillar

Wheel Loader:

966K (S/N: PBG1-UP; TFS1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

980K (S/N: W7K1-UP; GTZ1-UP)

Introduction

The information in this special instruction lists the procedures that are required in order to field install the window guard kits.

A complete listing of the parts that are contained in this kit are also listed in the Parts Manual, SEBP5727

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

Parts List

Installation of the 386-9224 Window Guard Ar

Show/hide table



Illustration 1	g02718008
(A) 279-0231 Rear View Mirror Gp for left side of machine. (B) 279-0231 Rear View Mirror Gp for right side of machine. (C) 364-5869 Tube As for the front of the machine. (D) 219-6487 Flood Lamp Gp for the front of the machine.

1. Remove the 279-0231 Mirror Gp (A) and (B) and retain.

2. Remove the two 219-6487 Lamp Gp (D) from the 364-5869 Tube As. (C) on the front of the machine and retain.

3. Remove the 364-5869 Tube As (C) and set aside.

Show/hide table



Illustration 2	g02719888
(2-B) Handle portion of 2G-9524 Latch (5) 6C-3678 Rivet (20) 354-0351 Plate for top position (21) 354-0352 Plate for bottom position

4. Install handle portion of 2G-9524 Latch As (2-B) onto the 354-0351 Plate (20) with two 6C-3678 Rivets (5). Perform this procedure for the top location on both sides.

5. Install handle portion of 2G-9524 Latch As (2-B) onto the 354-0352 Plate (21) with two 6C-3678 Rivets (5). Perform this procedure for the bottom location on both sides.

Show/hide table



Illustration 3	g02791510
(2-B) Handle portion of 2G-9524 Latch (5) 6C-3678 Rivet (9) 8T-4224 Hard Washer (12) 8T-7547 Bolt (18) 300-6569 Channel As for bottom location. (19) 325-1926 Channel As for top location. (20) 354-0351 Plate for top location. (21) 354-0352 Plate for bottom location. (RH) Right-hand location for mounting latch/plate assembly.

6. Install the 2G-9524 Latch As (2-B) and 354-0351 Plate (20) assembly onto the 325-1926 Channel As - Top (19) using two 8T-7547 Bolts (12) and 8T-4224 Washers-Hard (9). Perform this operation for both sides of the machine.

7. Install the 2G-9524 Latch As (2-B) and the 354-0352 Plate (21) assembly onto the 300-6569 Channel (18) using two 8T-7547 Bolts (12) and 8T-4224 Washers-Hard (9). Perform this operation for both sides of the machine.

Show/hide table



Illustration 4	g02791542
(4) 5P-1076 Hard Washer . (7) 8T-4183 Bolt . (18) 300-6569 Channel As for bottom location.

8. Install the 300-6569 Channel (18) onto the 279-0209 Operator Ar - Std . Use two 8T-6868 Bolts (11) and two 8T-4223 Washers-Hard (8) for each side.

Show/hide table



Illustration 5	g02718032
(4) 5P-1076 Hard Washer . (7) 8T-4183 Bolt . (19) 325-1926 Channel As for top location.

9. Install the 325-1926 Channel As - Top (19) onto the 279-0209 Operator Ar - Std . Use two 8T-6868 Bolts (11) and two 5P-1076 Washers-Hard (4) for each side.

Show/hide table



Illustration 6	g02719962
(8) 8T-4223 Hard Washer (11) 8T-6868 Bolt (15) 300-6557 Grill As (18) 300-6569 Channel As (19) 325-1926 Channel As

10. Install the 300-6557 Grill As Front (15) onto the 300-6569 Channel (18) and 325-1926 Channel As - Top (19). Secure the lower section with four 8T-6868 Bolts (11) and four 8T-4223 Washers-Hard (8) .

    Note: Install the bolts into the lower channel and snug finger tight. Do not install the bolts into the top channel at this time.

Show/hide table



Illustration 7	g02718042
(2-A) Striker portion of 2G-9524 Latch (5) 6C-3678 Rivet (17) 300-6559 Grill As

11. Install striker portion of 2G-9524 Latch As (2-A) onto the 300-6559 Grill As LH (17) at the two locations shown in Illustration 7 with two 6C-3678 Rivets (5) .

Show/hide table



Illustration 8	g02719876
(2-A) Striker portion of 2G-9524 Latch (5) 6C-3678 Rivet (16) 300-6558 Grill As

12. Install striker portion of 2G-9524 Latch As (2-A) onto the 300-6558 Grill As RH (16) at the two locations shown in Illustration 8 with two 6C-3678 Rivets (5) .

Show/hide table



Illustration 9	g02792218
(3) 5C-7261 Nut (14) 178-2593 Bumper (17) 300-6559 Grill As

13. Install four 178-2593 Bumpers (14) and four 5C-7261 Nuts (3) onto 300-6559 Grill As (17). Refer to Illustration 9 for locations.

Show/hide table



Illustration 10	g02792220
(3) 5C-7261 Nut (14) 178-2593 Bumper (16) 300-6558 Grill As

14. Install four 178-2593 Bumpers (14) and four 5C-7261 Nuts (3) onto 300-6558 Grill As (16). Refer to Illustration 10 for locations.

Show/hide table



Illustration 11	g02729841
(8) 8T-4223 Hard Washer (11) 8T-6868 Bolt (15) 300-6557 Grill As (16) 300-6558 Grill As (17) 300-6559 Grill As

15. Install the 300-6558 Grill As (16) and the 300-6559 Grill As (17) as follows.

    1. Position the 300-7479 Plate (part of 300-6558 Grill As (16) ) and the 300-7479 Plate (part of 300-6559 Grill As (17) ) between the 325-1926 Channel As (19) and the 300-6557 Grill As (15). Install the 8T-6868 Bolts (11) and the 8T-4223 Washer-Hard (8) into the top channel through the 300-7479 Plate , the 300-7479 Plate , and the 300-6557 Grill As Front (15). Tighten all eight of the mounting bolts for the 300-6557 Grill As installed to this point.
    Show/hide table
    
    

    Illustration 12	g02726677
    (6) 6S-6646 Cotter Pin (13) 132-0338 Plastic Washer (15) 300-6557 Grill As (16) 300-6558 Grill As (1) 0S-0175 Clevis Pin

    2. Secure the 300-6558 Grill As RH (16) onto the right side of the 300-6557 Grill As (15). Use one 0S-0175 Pin (1) and two 132-0338 Plastic Washers (13) for upper location. Install the 6S-6646 Pin (6) into the hole located in the 0S-0175 Pin (1). Repeat for the lower location.
    Show/hide table
    
    

    Illustration 13	g02720007
    (1) 0S-0175 Clevis Pin (6) 6S-6646 Cotter Pin (13) 132-0338 Plastic Washer (15) 300-6557 Grill As (17) 300-6559 Grill As

    3. Secure the 300-6559 Grill As LH (17) onto the left side of the 300-6557 Grill As (15). Use one 0S-0175 Pin (1) and two 132-0338 Plastic Washers (13) for upper location. Install the 6S-6646 Pin (6) into the hole located in the 0S-0175 Pin (1). Repeat for the lower location.

       Note: The two 132-0338 Plastic Washers (13) fit between the 300-6557 Grill As (15) and the 300-6558 Grill As (16) on the right-hand side and the 300-6559 Grill As (17) on the left-hand side. Refer to Illustrations 13 and 12 for washer location.

Show/hide table



Illustration 14	g02794027
(F) Upper bumper location, adjust here first. (3) 5C-7261 Nut (14) 178-2593 Bumper

16. Adjust the 178-2593 Bumper (14). Start with the upper position (F).

Show/hide table



Illustration 15	g02794053
(3) 5C-7261 Nut (14) 178-2593 Bumper (G) Second location for adjustment.

17. Continue adjustments with the lower position, upper bumper (G). Then, move to the lower bumpers. Repeat adjustments for the other side.

Show/hide table



Illustration 16	g02729871
(28) 8T-4224 Hard Washer , use four for each side. (29) 8T-4908 Bolt , use four for each side. (31) 325-1943 Handhold As for right-hand side of machine. (32) 325-1944 Handhold As for left-hand side of machine. (33) 329-4344 Handle As for front of machine.

18. Assemble the 325-1943 Handle As - RH (31) and the 329-1944 Handle As - LH (32) onto the 329-4344 Handle As - Front (33). Use four 8T-4908 Bolts (29) and four 8T-4224 Hard Washers (28) per side.

Show/hide table



Illustration 17	g02791438
(15) 300-6557 Grill As (16) 300-6558 Grill As (17) 300-6559 Grill As (24) 8T-4221 Hard Washer (25) 8T-4136 Bolt (33) 329-4344 Handle As

19. Install the 300-6556 Handrail Gp (24) onto 300-6557 Grill As - Front (15) using four 8T-4136 Bolts (25) and four 8T-4121 Washers - Hard (24). Do not tighten at this time.

Show/hide table



Illustration 18	g02736927
(30) 9X-2040 Screw . (E) 364-5870 Tube As

20. Fasten the 300-6556 Handrail Gp onto the existing 364-5870 Tube As (E) with two 9X-2040 Screws (30). Perform this step for both sides. Do not tighten at this time.

Show/hide table



Illustration 19	g02737236
(17) 300-6559 Grill As (26) 8T-4139 Bolt (27) 8T-4223 Hard Washer (E) 300-6556 Handrail Gp assembled.

21. Fasten the 300-6556 Handrail Gp (E) to the 300-6559 Grill As (17) with two 8T-4139 Bolts (26) and two 8T-4223 Hard Washers (27). Perform this step for both sides.

22. Tighten all of the fasteners for the 300-6556 Handrail Gp (E) .

Show/hide table



Illustration 20	g02737376
(15) 300-6557 Grill As (D) 219-6487 Flood Lamp Gp

23. Invert and attach the two 219-6487 Lamp Gp (D) removed in step 2 to the 300-6557 Grill As - Front (15). Use the original hardware. Reroute the wiring to the lamps and reconnect.

Show/hide table



Illustration 21	g02738658
(9) 8T-4224 Hard Washer (10) 8T-4908 Bolt (22) 370-8151 Bracket As (23) 370-8152 Bracket As

24. Install the 370-8151 Bracket As (22). Use the original upper location for the right-hand portion of the 279-0231 Rear View Mirror Gp . Secure the Bracket As with two each of the 8T-4908 Bolt (10) and the 8T-4224 Hard Washer (9) .

Show/hide table



Illustration 22	g03044938
(22) 370-8151 Bracket As (23) 370-8152 Bracket As

25. Install the right-hand portion of the 279-0231 Rear View Mirror Gp onto the 370-8151 Bracket As (22) and the 370-8152 Bracket As (23) Use the original hardware to secure the mirrors to the machine.

Show/hide table



Illustration 23	g03044457
(9) 8T-4224 Hard Washer (10) 8T-4908 Bolt (22) 370-8151 Bracket As (23) 370-8152 Bracket As

26. Install the 370-8151 Bracket As (22). Use the original upper location for the right-hand portion of the 279-0231 Rear View Mirror Gp . Secure the Bracket As with two each of the 8T-4908 Bolt (10) and the 8T-4224 Hard Washer (9) .

    Install the 370-8152 Bracket As (23). Use the original lower location for the right-hand portion of the 279-0231 Rear View Mirror Gp . Secure the Bracket As with two each of the 8T-4908 Bolt (10) and the 8T-4224 Hard Washer (9) .

Show/hide table



Illustration 24	g03044638

27. Install the left-hand portion of the 279-0231 Rear View Mirror Gp onto the left-hand side of the Operator Ar. Use the 370-8151 Bracket As (22) and the 370-8152 Bracket As (23). Use the original hardware to secure the mirrors to the machine.

Show/hide table



Illustration 25	g02793900
(34) 363-4467 Mount

28. Replace both 363-4466 Mounts with 363-4467 Mounts (34) in the front locations only. Refer to Disassembly and Assembly, "Cab - Remove and Install" and Specifications, "Cab Mounting" for your machine.