Replacement of the Cab Roof on Certain Caterpillar Machines {7301} Caterpillar


Replacement of the Cab Roof on Certain Caterpillar Machines {7301}

Usage:

IT14G 1WN
Compact Wheel Loader
914G (S/N: 7ZM1-UP; 9WM1-UP)
Integrated Toolcarrier
IT14G (S/N: 8ZM1-UP; 1WN1-UP)
IT28G (S/N: WAC1-UP; EWF1-UP; 8CR1-UP; 9AR1-UP; DBT1-UP)
Vibratory Compactor
CP-433E (S/N: CYE1-UP; CFK1-UP)
CP-533D (S/N: AFC1-UP; 6AZ1-UP)
CP-563D (S/N: 9ZW1-UP)
CP-663E (S/N: AFL1-UP)
CS-433E (S/N: DAC1-UP; CFP1-UP)
CS-531D (S/N: AGH1-UP; 3AZ1-UP; 4MZ1-UP)
CS-533D (S/N: AET1-UP; 5CZ1-UP)
CS-563D (S/N: 9MW1-UP; 2RZ1-UP)
CS-573D (S/N: CMK1-UP; 2YZ1-UP)
CS-583D (S/N: 2CZ1-UP)
CS-663E (S/N: AEF1-UP)
CS-683E (S/N: AGR1-UP)
CS433E (S/N: ASH1-UP; DCL1-UP; CFX1-UP)
Wheel Loader
924G (S/N: DDA1-UP; RBB1-UP; WMB1-UP; AAN1-UP; 9SW1-UP; 3PZ1-UP)
924GZ (S/N: RTA1-UP; AAB1-UP; 6YW1-UP; WGX1-UP; DFZ1-UP; 3DZ1-UP)
924H (S/N: HXC1-UP; JTM1-UP; KLN1-UP)
924HZ (S/N: WLB1-UP; PED1-UP)
928G (S/N: DJD1-UP; WLG1-UP; 6XR1-UP; 7SR1-UP)
928HZ (S/N: BYD1-UP; CXK1-UP)
930G (S/N: TWR1-UP; TFW1-UP)
930H (S/N: DHC1-UP; FTD1-UP)
938G Series II (S/N: RTB1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)
938H (S/N: MJC1-UP; JKM1-UP; LKM1-UP)

Introduction

This Special Instruction outlines the basic procedure for modifying the 307-2634 Roof to service the 292-0509 Roof, the 180-5100 Roof, and the 111-0126 Roof.

Do not attempt any procedure in this Special Instruction until you have read the information and you understand the information.

------ WARNING! ------

Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.


------ WARNING! ------

Accidental engine starting can cause injury or death to personnel working on the equipment.

To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door.

Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.


Refer to the Operation and Maintenance Manual for your machine.

Refer to the Disassembly and Assembly Manual for your machine.

Note: Permit only one operator on the machine. Keep other personnel away from the machine or in sight of the operator.

Required Parts

Table 1
Required Parts 
Part Number  Description  Quantity 
307-2634  Roof 
8P-6364  Plugs  8(1) 
9C-0071  Plugs  4(2) 
(1) Install the plugs in eight 30 mm (1.18 in) holes with clear silicone to cover up the holes used for the 8T-4137 Bolts.
(2) Install the plugs in four 23 mm (0.90 in) holes with clear silicone to cover up the holes used for the 8T-4137 Bolts.

Remove the Former Roof

Note: Permit only one operator on the machine. Keep other personnel away from the machine or in sight of the operator.

  1. Park the machine on a smooth, level surface. Move away from other operating machines and away from personnel.

  2. Lower the work tools to the ground. Stop the engine.

  3. Engage the parking brake. Place blocks in front of the wheels and behind the wheels.

  4. Install the steering frame lock so that the machine cannot articulate.


    Illustration 1g01461535
    (1) Wire Harness
    (2) Antenna cable

  5. Disconnect harness (1) and antenna (2).


    Illustration 2g01461530
    (3) Bolts

  6. Machines with 292-0509 Roof or 180-5100 Roof As, remove 12 bolts (3). Retain the bolts for installation.

    Machines with 111-0126 Roof As, remove 24 screws and retainer plates. Retain for installation.

  7. Remove the lights, the antenna, and any accessories. Retain parts for installation in the new roof.

Modifications to the 307-2634 Roof in Order to Replace the 292-0509 Roof



    Illustration 3g01461167

  1. Enlarge the two holes (B) to a diameter of 8.6 mm (0.34 in).

  2. Leave the three holes (A) empty.


    Illustration 4g01461166

  3. Ignore the four holes (C).

Modifications to the 307-2634 Roof in Order to Replace the 180-5100 Roof



    Illustration 5g01461190

  1. Ignore two holes (E).

  2. Ignore three holes (D).


    Illustration 6g01461192

  3. Ignore the four holes (F).

Modifications to the 307-2634 Roof in Order to Replace the 111-0126 Roof As



    Illustration 7g01461227

  1. Ignore the two holes (H).

  2. Ignore the three holes (G).


    Illustration 8g01461230

  3. Ignore the four holes (J).


    Illustration 9g01461228
    (4) Supports
    (M) 15 mm (0.6 in)

  4. Trim 24 of the supports (4) in order to allow clearance for the mounting bracket. Cut out the amount of material in dimension (M).

    Note: At least 15 mm (0.6 in) clearance is required.



    Illustration 10g02803616
    (A) 1269.9 mm (50 in)
    (B) 1136.7 mm (44.75 in)
    (C) 776.7 mm (30.60 in)
    (D) 325 mm (12.80 in)
    (E) 1287.3 mm (50.70 in)
    (F) 1116 mm (44 in)
    (G) 756 mm (30 in)
    (H) 576 mm (22.70 in)
    (J) 216 mm (8.50 in)
    (K) 148 mm (5.83 in)
    (L) 776.7 mm (30.60 in)
    (M) 1136.7 mm (44.75 in)
    (N) 1269.9 mm (50 in)
    (P) 98 mm (3.86 in)
    (R) 1234 mm (48.60 in)

  5. Drill 11 13 ± 0.5 mm (0.50 ± 0.02 in) holes. Refer to Illustration 10.


    Illustration 11g01462229

  6. The three supports (L) in rear do not require removal.

Install the New Roof in place of 292-0509 Roof and 180-5100 Roof As

  1. Install the lights, the antenna, and any accessories.


    Illustration 12g01461530

  2. Install 12 bolts (3).


    Illustration 13g01461535
    (1) Harness
    (2) Antenna

  3. Connect harness (1) and antenna (2).

Install the New Roof in place of 111-0126 Roof As

  1. Install the lights, the antenna, and any accessories.

  2. Install 124-7363 Plate, 135-8658 Plate As, 151-8114 Plate As and 151-8112 Plate As into the roof. Install 2 118-7256 Studs into each retainer plate to align plates with roof holes.

  3. Clean areas of roof surface where adhesive sealant will be applied with alcohol.

  4. Apply adhesive sealant to cab sheet metal completely around the perimeter of roof mounting pattern.


Illustration 14g02814397
(3) bolts

  1. Install 24 screws, removing 118-7256 Studs as screws are installed in each plate.

  2. After torquing roof screws, remove excess sealant. Wipe in a horizontal direction along roof to cab sheet metal joint.


    Illustration 15g02804979
    (1) Harness
    (2) Antenna

  3. Use four 9C-0071 Plugs and eight 8P-6364 Plugs for the holes in the new roof.

  4. Connect harness (1) and antenna (2).

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