- 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)
- 416F (S/N: KSF1-UP; LWT1-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.
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     |
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
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. |
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. |
- Park the machine on a level surface.
- Apply the service brake in order to stop the machine. Move the transmission control lever to the NEUTRAL position.
- Move the speed control lever to the LOW IDLE position.
- Engage the parking brake.
- Engage the transmission neutral lock.
- Lower all the work tools to the ground.
- Stop the engine.
- Turn the engine start switch key to the ON position but do not start the engine.
- Move the hydraulic control levers back and forth in order to relieve hydraulic pressure.
- Move the hydraulic control levers to the HOLD position.
- Turn the engine start switch key to the OFF position and remove the key.
- 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.
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 1 | g01322351 |
(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
- Remove the weldment that secures the bottom rail (A) to the ROPS. Refer to Illustration 2.
Illustration 2 | g01286985 |
(A) Bottom rail |
- Remove the bottom rail (A) from the ROPS.
Illustration 3 | g01287067 |
(A) Bottom rail |
- Clean the area of any slag or dirt.
- 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 4 | g01315363 |
(B) ROPS plate (3) 205-9600 Frame As |
- Apply a 3 mm (0.12 inch) fillet weld along the bottom of the 205-9600 Frame As (3). Refer to Illustration 5.
Illustration 5 | g01315984 |
(3) 205-9600 Frame As (C) 3 mm (0.12 inch) |
- Apply a 3 mm (0.12 inch) fillet weld along the top of the 205-9600 Frame As (3). Refer to Illustration 6.
Illustration 6 | g01315365 |
(B) ROPS plate (C) 3 mm (0.12 inch) (3) 205-9600 Frame As |
Installation of the Cab Glass
- 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 7 | g01318372 |
(3) 205-9600 Frame As (9) 164-1314 Bulk Seal |
Illustration 8 | g01318373 |
(3) 205-9600 Frame As (9) 164-1314 Bulk Seal |
- Install the 218-4856 Plate As (RH) (36) onto the top right-hand side of frame assembly (3). Refer to Illustration 9.
Illustration 9 | g01320551 |
(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 |
- 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.
- Install the 229-0298 Linkage Assembly onto plate assembly (35) and plate assembly (36). Refer to Illustration 10.
Illustration 10 | g01320552 |
(24) 164-1342 Special Bolt (25) 164-1343 Thrust Washer (26) 164-1344 Thrust Washer (27) 164-1345 Bearing (37) 229-0298 Linkage Assembly |
- 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.
Illustration 11 | g01320555 |
(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 |
- 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.
- 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.
- 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 12 | g01318374 |
(B) ROPS plate (3) 205-9600 Frame As (11) 5P-0798 Seal |
Illustration 13 | g01318375 |
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 |
- 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 14 | g01320458 |
(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 15 | g01320459 |
Cutaway of the 229-0310 Window As (39) (10) 164-1354 Window Channel (39) 229-0310 Window As |
- Assemble the components for the upper window assembly (39). Refer to Illustration 16.
Note: Apply sealant to the channel (17) during installation.
Illustration 16 | g01318377 |
(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 |
- 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 17 | g01320435 |
(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 |
- Use screw (13) and washer (12) in order to install the lower window into the frame (3). Refer to Illustration 18.
Illustration 18 | g01322276 |
(3) 205-9600 Frame As (12) 5P-4115 Hard Washer (13) 9X-2044 Screw |
- 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.
Illustration 19 | g01322352 |
(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 20 | g01322279 |
(24) 164-1342 Special Bolt (25) 164-1343 Thrust Washer (26) 164-1344 Thrust Washer (27) 164-1345 Bearing (37) 229-0298 Linkage Assembly |
Installing the Side Glass Panels
- 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.
Illustration 21 | g01322489 |
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 22 | g01322354 |
(1) 205-9586 Channel (F) Grab handle on the left-hand side |
- 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.
- 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 23 | g01315361 |
(H) 8 ± 1 mm (0.32 ± 0.04 inch) |
- 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.
Illustration 24 | g01322278 |
(1) 205-9586 Channel (F) Grab handle on the left-hand side (J) 2 mm (0.08 inch) |
- 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.
- 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.
- 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.
- 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 25 | g01322808 |
(5) 205-9609 Glass (6) 223-2030 Latch As |
- 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 26 | g01828454 |
- Insert window (5) into the left-hand side of the ROPS. Refer to Illustration 27 for the left-hand side example.
Illustration 27 | g01322807 |
- 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.