Installation Procedure for the 388-8276 Cab Door and Mounting Kit (GLASS) on All D Series Skid Steer Loaders, Multi Terrain Loaders, and Compact Track Loaders {7308} Caterpillar

Compact Track Loader

299D (S/N: GTC1-UP)

299D XHP (S/N: JST1-UP)

Multi Terrain Loader

297D (S/N: BE71-UP)

297D XHP (S/N: HP71-UP)

Skid Steer Loader

272D (S/N: B5W1-UP)

272D XHP (S/N: ETL1-UP)

Introduction

This Special Instruction describes the procedures for installation of the poly door kit for the above listed machines.

Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.

Required Parts

Mounting Procedure for the Basic Cab Door Group

The 345-6235 Cab Door Gp for the Glass Door is provided pre-assembled from the factory to facilitate installation.

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Illustration 1	g03402954

1. Remove the 345-6285 Handhold from the front of the cab on the left-hand side of the machine.

2. Remove the two 101-7398 Bolts and the two 8T-4121 Hard Washers in order to remove handhold. Discard all of these components.

   Note: A second person may be required to complete the following steps.

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   Illustration 2	g03402961

3. Mount the corresponding cab door group onto the front of the cab.
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   Illustration 3	g03402968

4. Align the holes on the hinges with the holes on the left-hand side post from the 345-6204 Plate in front of the canopy.
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   Illustration 4	g03402985

5. Attach the Door Group by using two 8T-4121 Hard Washers and two 101-7398 Bolts .

Adjustment Procedure of the Striker Assembly

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Illustration 5	g03403004

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Illustration 6	g03403007

1. With the door opened, install the 258-3764 Striker As on the right-hand side ROPS post.

2. Tighten the striker assembly with one 5P-1076 Hard Washer and one 8T-4244 Nut.

3. Shut the door once assembled.

4. Ensure that the striker assembly is centered vertically in the latch jaws, engages the latch jaws smoothly, and does not guide the door upward or downward. Verify that there is no interference between the head of the striker assembly and the latch jaws or the latch case.

   Note: If required, add or remove striker shims.

5. Verify that the door is in the primary latched position or in the secondary latched position. The primary latched position is achieved when the door is fully closed and fully latched, while the secondary latched position corresponds to a latched door but the jaws are not fully engaged.

   Note: If primary latched position is not achieved because of striker assembly position or because of high seal pressure, loosen striker assembly on door post and adjust striker assembly until primary latched position is achieved. Tighten the nut to the specified torque.

6. Adjust the position of the hinges to achieve the primary latched door position or correct seal pressure.

   Note: It is possible to adjust the door so that the door is fully closed against the Door Seal with the secondary latched position, but the primary latched position must be achieved.

   Note: Excessive seal pressure will result in high opening torque loads.

   Note: The latches are coated with a dry-type lubricant, so the use of a wet type lubricant is not recommended because of the dust build-up. When maintenance of the latches is necessary, use a dry-type lubricant for a smoother operation.

Installation of the Washer Fluid Bottle

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Illustration 7	g03403061

1. Slide the 418-5944 Window Washer Tank As onto the 345-6207 Plate, which is located on the lower left corner of the cab.
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   Illustration 8	g03403066

2. Ensure that the holes on the top flange of the washer tank assembly align with the holes on top of the plate.

   1. Verify that the hole on the bottom flange of the washer tank assembly aligns with the boss on the bottom of the plate.
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   Illustration 9	g03403182

3. Attach the washer tank assembly to the top location on the plate by inserting two 215-6406 Screws, and to the bottom location by inserting one 9X-6165 Washer and one 215-6406 Screw.

4. Route the 144-0195 Hose from the washer tank assembly upward and along the left ROPS post.

5. Locate the other 144-0195 Hose that enters the cab through the door window from the 379-6471 Window Wiper Arm Gp. Route the hose downward and along the left ROPS post, so that the hose meets the other hose at this location.
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   Illustration 10	g03403194

6. Use the 8G-1151 Connector to connect both of the hoses.

Installation of the Electrical Harness

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Illustration 11	g03403197

1. Install the 378-1007 Magnetic Switch As on the left-hand side of the door group.
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   Illustration 12	g03403199

   1. Use two 8C-4982 Bolts and two 178-9983 Locknuts to attach the switch assembly to the left ROPS post.
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   Illustration 13	g03403249

2. Remove the two 258-3727 Screws and the 109-2356 Plug from the 345-6026 Console As (Left-Hand).

3. Carefully pull away this section of the console, being cautious not to damage the instrument panel harness.

   1. Discard the plug only.
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   Illustration 14	g03403270

4. Push the 281-6390 Rocker Switch into the newly open slot on the front of the console assembly until the tabs of the rocker switch engage into place.
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   Illustration 15	g03403300

5. From behind the console, plug the 271-2837 Switch Connector from the 388-1436 Cab Harness As onto the rocker switch.

6. Use one 332-0194 Cable Strap to secure the harness onto the left ROPS post.

7. Reinstall the console into the original position using the 258-3727 Screws.
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   Illustration 16	g03403350

8. Connect the 155-2267 Connector Plug As (connection A-C4) from the 378-1028 Cab Harness As (Door) onto the receptacle from the 378-1007 Magnetic Switch As.
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   Illustration 17	g03403384

9. Connect the 155-2272 Connector Plug As (connection A-C1) onto the 3E-3376 Connector Receptacle As from the 388-1436 Cab Harness As.

   Note: Ensure that the pin connections correspond to the ones shown on the tables below:

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   Table 2

   Connection "AC-4"
   Pin	Wire Number	Wire Color
   A	200-A9	BK(Black)
   B	G943-A4	BU(Blue)
   C	G944-A5	YL(Yellow)

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   Table 3

   Connection "AC-1"
   Pin	Wire Number	Wire Color
   1	118-A2	GY(Grey)
   2	200-A1	BK(Black)
   3	506-A6	PU(Purple)
   4	614-A11	PU(Purple)

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   Illustration 18	g03403489

10. Secure the door harness assembly onto the right ROPS post by using three 332-0194 Cable Straps.
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    Illustration 19	g03403520

11. Strap the 388-1436 Cab Harness As and the 378-1007 Magnetic Switch As together by using one 3S-2093 Cable Strap.

12. Connect the 155-2272 Connector Plug As from the 388-1436 Cab Harness As to the connector on the 379-1084 Window Wiper Motor Gp.

13. Use the other Strap provided to secure this connection onto the 388-1436 Cab Harness As.
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    Illustration 20	g03403532

14. Connect the 123-7615 Connector (connection A-C2) onto the washer fluid bottle.
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    Illustration 21	g03403549

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    Illustration 22	g03403550

15. Install the three 258-4141 Clip on the locations where texture was removed.

    Note: Before installing the clips, ensure that the opening of the Clips faces the left side of the machine. Clean the bonding surfaces with a 1:1 mixture of IDA/Water. To apply the Clips, remove backing and hold firmly onto surface for two full seconds. Do not apply a full load to the clip for 24 hours.

16. Connect the 3E-3382 Connector Receptacle As (connection A-C3) from the door harness onto the 155-2273 Connector Plug As (connection CH-C10) from the 361-6397 Cab Harness As (Seat).

    Note: Before making this connection, remove the 3E-3382 Connector Receptacle As (Jumper) (connection CH-C18) from the 155-2273 Connector Plug As.

    Note: If necessary, strap the Jumper Connector to the Plug for service repair purposes.

    Note: Ensure that the connections correspond to the ones shown on the table below:

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    Table 4

    Connection "AC-3"
    Pin	Wire Number	Wire Color
    1	118-CH65	GY(Grey)
    2	200-CH66	BK(Black)
    3	614-CH33	PU(Purple)
    4	G943-CH69	BU(Blue)
    5	G944-CH70	YL(Yellow)
    6	N/A	N/A

17. Secure the door harness with the previously installed Clips.

    Note: The cab door is provided with a switch that prevents the operation of worktools while the door is open. If the operator chooses to remove the door, plug the 3E-3382 Connector Receptacle As (Jumper) back onto the 155-2273 Connector Plug As.

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    Illustration 23	g03403577

18. Install the 345-6024 Cover (Left-Hand Side A-Post) onto the left-hand side post located in the interior of the Cab, in order to protect the newly installed Harness and the 144-0195 Hose for the Wiper Blade Jet.
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    Illustration 24	g03403578

19. Attach the cover by inserting one of the provided 8Y-5947 Fastener.

20. Repeat Steps 18 and 19 for the right-hand side post by using the 345-6025 Cover (Right-Hand Side A-Post) Cover.

Installation of the Gas Springs

Note: Refer to the Operation Maintenance Manual for information on how to disassemble and assemble the Gas Springs.

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Illustration 25	g03403619

1. Remove the 153-2683 Gas Spring As installed on the left-hand side of the cab.

2. Install the provided 418-5945 Gas Spring As on the right-hand side of the machine.
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   Illustration 26	g03660744

   1. Use one 6L-3966 Pin, one 388-8019 Washer between the hinge and the Gas Spring As., one 388-8018 Spacer between the Gas Spring As. and the cab frame and one 5P-0372 Lock Pin for the upper connection.
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      Illustration 27	g03660746

   2. For the lower connection, use one 6L-3966 Pin, one 388-8019 Washer between the hinge and the Gas Spring As., one 388-8028 Spacer between the Gas Spring As. and the cab frame and one 5P-0372 Lock Pin.

3. For the left-hand side of the machine, use the same 418-5945 Gas Spring As in place of the previously installed 153-2683 Gas Spring As.

   1. For the upper connection, use one 418-5845 Pin, and place two 388-8028 Spacers in between the hinge and the Gas Spring As. and one 388-8018 Spacer between the Gas Spring As. and the cab frame. Use one 345-6168 Washer and one 164-1344 Thrust Washer on the other side of the Pin and lock this connection with one 5P-0372 Lock Pin.

   2. For the lower connection, use one 437-9853 Pin, two 388-8019 Washers between the hinge and the Gas Spring As., one 388-8019 Washer between the Gas Spring As. and the cab frame and one 5P-0372 Lock Pin.