Field Installation for the 281-7219 Cab Window Kit {7310} Caterpillar


Field Installation for the 281-7219 Cab Window Kit {7310}

Usage:

416E BWC
Backhoe Loader:
416E (S/N: SHA116-UP; BWC1-UP; LMS1-UP)
416F (S/N: KSF1-UP; LWT1-UP)
420E (S/N: PRA1-UP; PHC1-UP; DJL1-UP; DAN1-UP; HLS210-UP; KMW150-UP)
420F (S/N: LTG1-UP; LKH1-UP; JWJ1-UP; SKR1-UP)
430E (S/N: MXB1-UP; SWC1-UP; SCD1-UP; RLN1-UP; DDT220-UP; EAT230-UP)
430F (S/N: RDF1-UP; LNH1-UP; RGS1-UP; LDY1-UP)
450E (S/N: EBL1-UP)

Introduction

This special instruction contains the information that is needed in order to install the 281-7219 Cab Window Kit . The kit is a guard that is available for the machines that were manufactured with open ROPS. The kit protects the operator platform from debris that is generated when work tools are used.

Note: All welding and fabrication on the rollover protective structure ROPS must be performed by a ROPS certified welder. All welds must be applied in the same manner as an enclosed rollover protective structure EROPS and in the same places as an EROPS. Special care must be taken in order to avoid creating a hole in the ROPS tube. Any hole that is created in the ROPS tube may void the ROPS/FOPS certification. Refer to Special Instruction, SEHS6929, "Inspection, Maintenance, and Repair of Rollover Protective Structures (ROPS) and Attachment Installation Guidelines" for additional information for welding on the ROPS.

References

ReferenceOperation and Maintenance Manual, SEBU7970, "416E, 422E, and 428E Backhoe Loaders".

ReferenceOperation and Maintenance Manual, SEBU7687, "420E, 430E, 432E, 434E, 442E, and 444E Backhoe Loaders".

ReferenceDisassembly and Assembly, RENR6485, "414E, 416E, 420E, 422E, 428E, 430E, 432E, 434E, 442E, and 444E Backhoe Loaders Machine Systems ".

ReferenceDisassembly and Assembly, UENR2321, "416F, 420F and 430F Backhoe Loaders Machine Systems".

ReferenceDisassembly and Assembly, KENR5491, "450E Backhoe Loader Machine Systems ".

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceSpecial Instruction, SEHS6929, "Inspection, Maintenance, and Repair of Rollover Protective Structures (ROPS) and Attachment Installation Guidelines"

Required Parts

The required parts for the field installation of the 281-7219 Cab Window Kit are identified in Table 1.

Table 1
Required Parts    
Item     Qty     Part Number     Description    
1     1     205-9586     Channel    
2     1     205-9596     Channel    
3     1     205-9600     Frame As    
4     1     205-9608     Glass    
5     1     205-9609     Glass    
6     2     223-2030     Latch As    
7     1     229-0300     Cab Window Gp    

Table 2
229-0300 Cab Window Gp    
Item     Qty     Part Number     Description    
8     880 mm (35 inch)     9X-6383     Seal    
9    
3070 mm (121 inch)    
164-1314     Bulk Seal    
10    
3890 mm (153 inch)    
164-1354     Window Channel    
11    
1000 mm (39 inch)    
5P-0798     Seal    
12     6     5P-4115     Hard Washer    
13     4     9X-2044     Screw    
14     4     9X-2132     Retainer    
15     2     110-5602     Knob    
16     2     119-8349     Cap    
17     1     121-9743     Seal    
18     4     129-3180     Locknut    
19     1     146-7744     Latch Kit    
20     1     146-7745     Latch Kit    
21     2     150-8015     Gasket    
22     2     164-1308     Roller    
23     2     164-1328     Gas Spring As    
24     4     164-1342     Special Bolt    
25     4     164-1343     Thrust Washer    
26     4     164-1344     Thrust Washer    
27     4     164-1345     Bearing    
28     4     164-1346     Striker    
29     2     164-1351     Pin    
30     1     164-1352     Latch As    
31     1     164-1353     Latch As    
32     2     167-8182     Bumper    
33     2     171-2870     Spacer    
34     4     201-9465     Shim    
35     1     218-4854     Plate As    
36     1     218-4856     Plate As    
37     1     229-0298     Linkage Assembly    
38     1     229-0308     Glass    
39     1     229-0310     Window As    
40     1     290-1273     Frame As    
41     4     179-7262     Flat Head Screw    
42     2     5C-2890     Nut    
43     4     5P-4116     Hard Washer    
44     4     8T-4200     Bolt    
45     4     8T-4223     Hard Washer    

Preparing the Machine for Servicing

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

Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component.

Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly.

Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

----------------------

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

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

----------------------


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.


  1. Park the machine on a level surface.

  1. Apply the service brake in order to stop the machine. Move the transmission control lever to the NEUTRAL position.

  1. Move the speed control lever to the LOW IDLE position.

  1. Engage the parking brake.

  1. Engage the transmission neutral lock.

  1. Lower all the work tools to the ground.

  1. Stop the engine.

  1. Turn the engine start switch key to the ON position but do not start the engine.

  1. Move the hydraulic control levers back and forth in order to relieve hydraulic pressure.

  1. Move the hydraulic control levers to the HOLD position.

  1. Turn the engine start switch key to the OFF position and remove the key.

  1. Disconnect the battery.

Weld Specifications and Qualifications

Refer to Special Instruction, REHS1841, "General Welding Procedures" and Special Instruction, SEHS6929, "Inspection, Maintenance, and Repair of Rollover Protective Structures (ROPS) and Attachment Installation Guidelines" for general welding procedures and information for welding on ROPS.

Note: All welding and fabrication on the rollover protective structure ROPS must be performed by a ROPS certified welder. All welds must be applied in the same manner as an enclosed rollover protective structure EROPS and in the same places as an EROPS. Special care must be taken in order to avoid creating a hole in the ROPS tube. Any hole that is created in the ROPS tube may void the ROPS/FOPS certification. Refer to Special Instruction, SEHS6929, "Inspection, Maintenance, and Repair of Rollover Protective Structures (ROPS) and Attachment Installation Guidelines" for additional information for welding on the ROPS.

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

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 kill.

Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts.

Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

----------------------

Welders must be qualified for fillet welding and groove welding. The welder must be qualified in different welding angles. The angles are vertical, horizontal, etc. The welders should be qualified in the use of the welding processes that follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to ISO 9606 or "American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards the qualifications for the processes that follow: SMAW process, FCAW process and GMAW process. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Installation of the 281-7219 Cab Window Kit

Note: All welding and fabrication on the rollover protective structure ROPS must be performed by a ROPS certified welder. All welds must be applied in the same manner as an enclosed rollover protective structure EROPS and in the same places as an EROPS. Special care must be taken in order to avoid creating a hole in the ROPS tube. Any hole that is created in the ROPS tube may void the ROPS/FOPS certification. Refer to Special Instruction, SEHS6929, "Inspection, Maintenance, and Repair of Rollover Protective Structures (ROPS) and Attachment Installation Guidelines" for additional information for welding on the ROPS.




Illustration 1g01322351

(1) 205-9586 Channel

(2) 205-9596 Channel

(3) 205-9600 Frame As

(4) 205-9608 Glass

(5) 205-9609 Glass

(6) 223-2030 Latch As

(7) 229-0300 Cab Window Gp

Installation of the Rear Window Frame Assembly




    Illustration 2g01286985

    (A) Bottom rail

  1. Remove the weldment that secures the bottom rail (A) to the ROPS. Refer to Illustration 2.



    Illustration 3g01287067

    (A) Bottom rail

  1. Remove the bottom rail (A) from the ROPS.

  1. Clean the area of any slag or dirt.



    Illustration 4g01315363

    (B) ROPS plate

    (3) 205-9600 Frame As

  1. Insert the 205-9600 Frame As (3) behind the ROPS plate (B) and into the rear of the ROPS assembly. Refer to Illustration 4, Illustration 5, and Illustration 6.



    Illustration 5g01315984

    (3) 205-9600 Frame As

    (C) 3 mm (0.12 inch)

  1. Apply a 3 mm (0.12 inch) fillet weld along the bottom of the 205-9600 Frame As (3). Refer to Illustration 5.



    Illustration 6g01315365

    (B) ROPS plate

    (C) 3 mm (0.12 inch)

    (3) 205-9600 Frame As

  1. Apply a 3 mm (0.12 inch) fillet weld along the top of the 205-9600 Frame As (3). Refer to Illustration 6.

Installation of the Cab Glass




    Illustration 7g01318372

    (3) 205-9600 Frame As

    (9) 164-1314 Bulk Seal




    Illustration 8g01318373

    (3) 205-9600 Frame As

    (9) 164-1314 Bulk Seal

  1. Cut the 164-1314 Bulk Seal (9) into two 1531 ± 1 mm (60.3 ± 0.04 inch) lengths. Insert one seal (9) into the 205-9600 Frame As (3) on the left-hand side. Insert one seal (9) into the 205-9600 Frame As (3) on the right-hand side. Refer to Illustration 7 and Illustration 8.



    Illustration 9g01320551

    (B) ROPS plate

    (3) 205-9600 Frame As

    (34) 201-9465 Shim

    (35) 218-4854 Plate As

    (36) 218-4856 Plate As

    (43) 5P-4116 Hard Washer

    (44) 8T-4200 Bolt

  1. Install the 218-4856 Plate As (RH) (36) onto the top right-hand side of frame assembly (3). Refer to Illustration 9.

  1. Install the 218-4854 Plate As (LH) (35) onto the top left-hand side of frame assembly (3). Refer to Illustration 9 for the right-hand side example.



    Illustration 10g01320552

    (24) 164-1342 Special Bolt

    (25) 164-1343 Thrust Washer

    (26) 164-1344 Thrust Washer

    (27) 164-1345 Bearing

    (37) 229-0298 Linkage Assembly

  1. Install the 229-0298 Linkage Assembly onto plate assembly (35) and plate assembly (36). Refer to Illustration 10.



    Illustration 11g01320555

    (B) ROPS plate

    (3) 205-9600 Frame As

    (12) 5P-4115 Hard Washer

    (14) 9X-2132 Retainer

    (18) 129-3180 Locknut

    (23) 164-1328 Gas Spring As

    (28) 164-1346 Striker

    (29) 164-1351 Pin

    (32) 167-8182 Bumper

    (33) 171-2870 Spacer

    (42) 5C-2890 Nut

    (45) 8T-4223 Hard Washer

  1. Install one 167-8182 Bumper (32) on the left-hand side and one 167-8182 Bumper (32) on the right-hand side of frame assembly (3). Refer to Illustration 11.

  1. Install one 164-1328 Gas Spring As (23) on the left-hand side and one 164-1328 Gas Spring As (23) on the right-hand side of frame assembly (3). Refer to Illustration 11.

  1. Install one 164-1346 Striker (28) on the left-hand side and one 164-1346 Striker (28) on the right-hand side of frame assembly (3). Refer to Illustration 11.



    Illustration 12g01318374

    (B) ROPS plate

    (3) 205-9600 Frame As

    (11) 5P-0798 Seal




    Illustration 13g01318375

    Part of frame assembly (3) has been removed for clarity.

    (B) ROPS plate

    (3) 205-9600 Frame As

    (11) 5P-0798 Seal

    (40) 290-1273 Frame As

  1. Cut the 5P-0798 Seal (11) to a length of 945 ± 3 mm (37.2047 ± 0.1181 inch). Peel off the adhesive backing of the seal (11) and attach the seal to the inside face of the ROPS plate (B). Attach the seal so that the frame of the window contacts only the seal. Refer to Illustration 12 and Illustration 13.



    Illustration 14g01320458

    (10) 164-1354 Window Channel

    (10A) 164-1354 Window Channel cut to a length of 895 ± 1 mm (35.24 ± 0.04 inch).

    (10B) 164-1354 Window Channel cut to a length of 748 ± 1 mm (29.45 ± 0.04 inch).

    (39) 229-0310 Window As




    Illustration 15g01320459

    Cutaway of the 229-0310 Window As (39)

    (10) 164-1354 Window Channel

    (39) 229-0310 Window As

  1. Install the seals into the frame of the upper window assembly (39). Refer to Illustration 14 and Illustration 15.

    Note: Apply a 5 mm (0.2 inch) length of 5H-2471 Adhesive at both ends of the channel. Apply a 5 mm (0.2 inch) length of 5H-2471 Adhesive at the center of the channel. Cut a 45° chamfer at the open ends of channel.




    Illustration 16g01318377

    (15) 110-5602 Knob

    (16) 119-8349 Cap

    (17) 121-9743 Seal

    (22) 164-1308 Roller

    (30) 164-1352 Latch As

    (31) 164-1353 Latch As

    (39) 229-0310 Window As

    (41) 179-7262 Flat Head Screw

  1. Assemble the components for the upper window assembly (39). Refer to Illustration 16.

    Note: Apply sealant to the channel (17) during installation.




    Illustration 17g01320435

    (8) 9X-6383 Seal cut to a length of 875 ± 3 mm (34.45 ± 0.12 inch).

    (10C) 164-1354 Window Channel cut to a length of 739 ± 1 mm (29.10 ± 0.04 inch).

    (19) 146-7744 Latch Kit

    (20) 146-7745 Latch Kit

    (21) 150-8015 Gasket

    (38) 229-0308 Glass

    (40) 290-1273 Frame As

  1. Assemble the components for the lower window frame assembly (40). Refer to Illustration 17.

    Note: Apply a 5 mm (0.2 inch) length of 5H-2471 Adhesive at both ends of the channel. Apply a 5 mm (0.2 inch) length of 5H-2471 Adhesive at the center of the channel. Cut a 45° chamfer at the open ends of channel.




    Illustration 18g01322276

    (3) 205-9600 Frame As

    (12) 5P-4115 Hard Washer

    (13) 9X-2044 Screw

  1. Use screw (13) and washer (12) in order to install the lower window into the frame (3). Refer to Illustration 18.



    Illustration 19g01322352

    (24) 164-1342 Special Bolt

    (25) 164-1343 Thrust Washer

    (26) 164-1344 Thrust Washer

    (27) 164-1345 Bearing

    (37) 229-0298 Linkage Assembly




    Illustration 20g01322279

    (24) 164-1342 Special Bolt

    (25) 164-1343 Thrust Washer

    (26) 164-1344 Thrust Washer

    (27) 164-1345 Bearing

    (37) 229-0298 Linkage Assembly

  1. Install the upper window assembly (39) into the window frame (3). Use bolt (24), washer (25), washer (26), and bearing (27) in order to fasten the window assembly (39) onto the linkage assembly (37). Refer to Illustration 19 and Illustration 20.

Installing the Side Glass Panels




    Illustration 21g01322489

    Window and channel on the left-hand side

    (1) 205-9586 Channel

    (5) 205-9609 Glass

    (6) 223-2030 Latch As

    (D) 342 mm (13.5 inch)

    (E) 12.5 mm (0.50 inch)




    Illustration 22g01322354

    (1) 205-9586 Channel

    (F) Grab handle on the left-hand side

  1. Cut a notch in channel (1) for grab handle (F) on the left-hand side. Refer to Illustration 21 and Illustration 22 for the left-hand side example.

  1. Cut a notch in channel (2) for the grab handle on the right-hand side. Refer to Illustration 21 and Illustration 22 for the left-hand side example.



    Illustration 23g01315361

    (H) 8 ± 1 mm (0.32 ± 0.04 inch)

  1. Remove 8 ± 1 mm (0.32 ± 0.04 inch) from the bottom of channel (1) and the bottom of channel (2). Refer to Illustration 23.



    Illustration 24g01322278

    (1) 205-9586 Channel

    (F) Grab handle on the left-hand side

    (J) 2 mm (0.08 inch)

  1. Tack weld channel (1) into position on the left-hand side. Refer to Illustration 24 for the left-hand side example.

    Note: All welding and fabrication on the rollover protective structure ROPS must be performed by a ROPS certified welder. All welds must be applied in the same manner as an enclosed rollover protective structure EROPS and in the same places as an EROPS. Special care must be taken in order to avoid creating a hole in the ROPS tube. Any hole that is created in the ROPS tube may void the ROPS/FOPS certification. Refer to Special Instruction, SEHS6929, "Inspection, Maintenance, and Repair of Rollover Protective Structures (ROPS) and Attachment Installation Guidelines" for additional information for welding on the ROPS.

  1. Tack weld channel (2) into position on the right-hand side. Refer to Illustration 24 for the left-hand side example. The left-hand side example is typical of the right-hand side.

  1. Apply a 2 mm (0.08 inch) fillet weld on the top of channel (1) in order to secure the channel to the ROPS. Refer to Illustration 24 for the left-hand side example.

  1. Apply a 2 mm (0.08 inch) fillet weld on the top of channel (2) in order to secure the channel to the ROPS. Refer to Illustration 24 for the left-hand side example. The left-hand side example is typical of the right-hand side.



    Illustration 25g01322808

    (5) 205-9609 Glass

    (6) 223-2030 Latch As

  1. Assemble one 223-2030 Latch As (6) onto the left side window (5). Assemble one 223-2030 Latch As (6) onto the right side window (4). Refer to Illustration 25 for the left-hand side example.



    Illustration 26g01828454

  1. Apply adhesive to the window frame on the left-hand side. Refer to Illustration 26 for the left-hand side example. The left-hand side example is typical of the right-hand side.



    Illustration 27g01322807

  1. Insert window (5) into the left-hand side of the ROPS. Refer to Illustration 27 for the left-hand side example.

  1. Apply adhesive to the window frame on the right-hand side. Insert window (5) into the ROPS. Refer to Illustration 26 and Illustration 27 for the left-hand side example.

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