Repair Procedures for the Exterior Mirror Mounting Bracket {0679, 7301, 7319} Caterpillar

Compact Wheel Loader

914G (S/N: PDF1-UP; 7ZM1-UP; 9WM1-UP)

914G2 (S/N: KNP1-UP)

IT14G2 (S/N: ERP1-UP)

Integrated Toolcarrier

IT14G (S/N: FWL1-UP; 8ZM1-UP; KZN1-UP; 1WN1-UP)

IT28G (S/N: WAC1-UP; EWF1-UP; 8CR1-UP; 9AR1-UP; DBT1-UP)

IT38G (S/N: 7BS1-UP; 1CW1-UP)

IT38G Series II (S/N: JAN1-UP; CSX1-UP)

IT38H (S/N: JNJ1-UP)

Wheel Loader

910G Series II (S/N: B9X1-UP)

924G (S/N: DDA1-UP; EEB1-UP; RBB1-UP; WMB1-UP; AAN1-UP; 9SW1-UP; 3PZ1-UP)

924GZ (S/N: RTA1-UP; AAB1-UP; KTC1-UP; 6YW1-UP; WGX1-UP; DFZ1-UP; 3DZ1-UP)

924H (S/N: HXC1-UP; JTM1-UP; WEM1-UP; KLN1-UP; RRS1-UP; LKW1-UP)

924HZ (S/N: RCB1-UP; WLB1-UP; PED1-UP; JRL1-UP; JZZ1-UP)

928G (S/N: DJD1-UP; WLG1-UP; 6XR1-UP; 7SR1-UP)

928H (S/N: RSB1-UP)

928HZ (S/N: BYD1-UP; CXK1-UP)

930G (S/N: TWR1-UP; TFW1-UP)

930H (S/N: DHC1-UP; FTD1-UP)

938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)

938G Series II (S/N: RTB1-UP; MSC1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)

938H (S/N: MCC1-UP; MJC1-UP; LKM1-UP)

Introduction

This Special Instruction explains the repair procedure for the exterior mirror mounting bracket. Do not begin the rework procedure until you have read the information that is contained in this instruction.

Safety

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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.

Note: Modification, alteration, or improper repair can impair the rollover protection structure (ROPS) protection capability. Do not weld on or drill holes in the structure.

Required Parts

Right Side

Left Side

Other Parts

Right Side Disassembly

1. Remove the existing 111-0177 Front Glass from the cab.
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   Illustration 1	g02442459
   Location of the plates to be removed

2. Cut off and remove plates (A) and (B). Refer to Illustration 1.
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   Illustration 2	g02442497

3. Cut the upper part of the sheet (C) above the grab handle as needed (approximately 150 mm (5.9 inch) (D)). Refer to Illustration 2.

4. Cut off and remove the plate (E). Be careful not to damage the A post (F). Refer to Illustration 2.

Right Side Re assembly

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Illustration 3	g02442579
(1) 112-5223 Plate As (G) Position the top of plate assembly flush with the bottom of the angle (H) Butt up against sheet (J) Butt up against the A post (K) Angle

1. Locate the 112-5223 Plate As (1). Refer to Illustration 3.
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   Illustration 4	g02442596
   (1) 112-5223 Plate As (L) 4 mm (0.2 inch) fillet weld

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   Illustration 5	g02442601
   (1) 112-5223 Plate As (M) 7 mm (0.3 inch) J groove weld

2. Weld the 112-5223 Plate As (1) in place. Refer to Illustration 4 and Illustration 5.

3. Cut the 361-9132 Sheet (4) to fit where the previous sheet was trimmed.
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   Illustration 6	g02442618
   (4) 361-9132 Sheet (N) 3 mm (0.12 inch) fillet weld (P) 2 mm (0.08 inch) butt weld between (4) and the existing sheet

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   Illustration 7	g02442636
   (4) 361-9132 Sheet (R) 2 mm (0.08 inch) butt weld, ground flat

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   Illustration 8	g02442639
   (4) 361-9132 Sheet (S) 2 mm (0.08 inch) fillet weld from point (T) to point (U).

4. Weld this new part to the original one with a backup strip ( 1.5 mm (0.06 inch) thick) to reinforce the weld. Refer to Illustrations 6, 7, and 8.

   Note: Apply 119-0781 Adhesive (11), to both sides of 112-5223 Plate As (1).

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   Illustration 9	g02442644
   (2) 134-5591 Plate (V) 3 mm (0.12 inch) V-groove weld ground flat

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   Illustration 10	g02442648
   (2) 134-5591 Plate (W) 3 mm (0.12 inch) fillet weld

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   Illustration 11	g02442649
   (3) 185-2424 Angle (X) 2 mm (0.08 inch) butt weld, ground flat (Y) 2 mm (0.08 inch) fillet weld (Z) 2 mm (0.08 inch) fillet weld from (DD) to (EE) ( AA) 2 mm (0.08 inch) butt weld (BB) 2 mm (0.08 inch) V weld

5. Locate and weld the plates 134-5591 Plate (2) and 185-2424 Angle (3). Refer to Illustrations 9, 10, and 11.
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   Illustration 12	g02442561
   Apply 119-0781 Adhesive from point (CC) to (DD) and to point (EE)

6. Apply 119-0781 Adhesive (11) to the areas shown in Illustration 12.

7. Grind the weld and polish all the butt welds.

8. Prepare the affected area for painting.

9. Paint the repaired area using primer and top coat.

10. Install and bond a new 111-0177 Front Glass (9).

Left Side Disassembly

1. Remove the existing 107-6144 Front Glass from the cab.
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   Illustration 13	g02442700

2. Cut off and remove plates (EE) and (FF). Refer to Illustration 13.
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   Illustration 14	g02442702

3. Cut the upper part of the sheet (HH) above the grab handle as needed (approximately 150 mm (5.9 inch) (JJ)). Refer to Illustration 14.

4. Cut off and remove the plate (KK). Be careful not to damage the A post (LL). Refer to Illustration 14.

Left Side Re assembly

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Illustration 15	g02442718
(5) 112-5222 Plate As (MM) Butt up against sheet (NN) Angle (PP) Position the top of plate assembly flush with the bottom of the angle (QQ) Butt up against the A post

1. Locate the 112-5222 Plate As (5). Refer to Illustration 15.
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   Illustration 16	g02442719
   (5) 112-5222 Plate As (RR) 4 mm (0.2 inch) fillet weld

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   Illustration 17	g02442720
   (5) 112-5222 Plate As (NN) Angle (SS) 7 mm (0.3 inch) J groove weld

2. Weld the 112-5222 Plate As (5) in place. Refer to Illustration 16 and Illustration 17

3. Cut the 361-9131 Sheet (4) to fit where the previous sheet was trimmed.
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   Illustration 18	g02442723
   (8) 361-9131 Sheet (TT) 3 mm (0.12 inch) fillet weld (UU) 2 mm (0.08 inch) butt weld between (8) and the existing sheet

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   Illustration 19	g02442736
   (8) 361-9131 Sheet (NN) Angle (VV) 2 mm (0.08 inch) butt weld ground flat

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   Illustration 20	g02442737
   (8) 361-9131 Sheet (WW) 2 mm (0.08 inch) fillet weld from point (XX) to point (YY).

4. Weld this new part to the original one with a backup strip ( 1.5 mm (0.06 inch) thick) to reinforce the weld. Refer to Illustrations 18, 19, and 20.

   Note: Apply 119-0781 Adhesive (11), to both sides of 112-5222 Plate As (5).

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   Illustration 21	g02442738
   (6) 134-5591 Plate (ZZ) 3 mm (0.12 inch) V-groove weld ground flat

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   Illustration 22	g02442739
   (6) 134-5591 Plate (AAA) 3 mm (0.12 inch) fillet weld

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   Illustration 23	g02442756
   (7) 185-2423 Angle (BBB) 2 mm (0.08 inch) butt weld (CCC) 2 mm (0.08 inch) butt weld, ground flat (DDD) 2 mm (0.08 inch) fillet weld from (EEE) to (FFF) ( GGG) 2 mm (0.08 inch) fillet weld (HHH) 2 mm (0.08 inch) V weld

5. Locate and weld the 134-5591 Plate (6) and 185-2423 Angle (7). Refer to Illustrations 21, 22, and 23.
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   Illustration 24	g02442758
   Apply 119-0781 Adhesive from point (JJJ) to (KKK) and to point (LLL)

6. Apply 119-0781 Adhesive (11) to the areas shown in Illustration 24

7. Grind the weld and polish all the butt welds

8. Prepare the affected area for painting

9. Paint the repaired area using primer and top coat

10. Install and bond a new 107-6144 Front Glass (9).