Service Manual User Manual

Section 4
4-8
4.2.2 Cab Installation
IMPORTANT: Transfer and install cab panels and other
components as needed
after
the cab is securely
mounted on the vehicle.
1. Cap or safely cover any fuel-tank or fuel-fitting
openings. Inspect vehicle parts that are exposed with
the cab removed. Repair or replace as required.
2. Block all four wheels
to help prevent the vehicle
from moving. Assure that there is sufficient overhead
and side clearance for cab installation.
3. Disconnect the cable at the battery negative (-)
terminal (Fig. 4–2) as required.
4. Install cab isolators (item 20 in the
General Overview
illustration on page three) into the mounting holes on
the cab mount.
5. Use a hoist or overhead crane and sling attached to
the cab (1). Carefully begin to lower the cab onto the
cab mount. Stop and check that wiring, fuel tank
components, hydraulic hoses, etc., will not be
pinched or damaged as the cab is lowered.
6. Route the throttle cable (Fig. 4–4) from beneath the
cab to the engine compartment by simply positioning
the cable under the frame, then up between the
transmission and engine. Bring the cable across the
side of engine to the throttle cable bracket. DO NOT
attach the cable to the throttle lever extension on the
engine at this time.
7. Carefully and slowly lower the cab (item 1 in the
General Overview
illustration) onto the cab mount.
Align the cab with the cab isolators (20) as the cab is
lowered. Readjust the position of the sling as needed
to help balance the cab during installation.
8. Install the cab-to-cab-mount attaching hardware
(items 12, 21, 22 and 23). At the rear of the cab,
install but DO NOT tighten the two 3/4-10 hex-lock
elastic nuts (12), two rebound washers (21) and two
3/4-10 x 3-3/4" Grade 8 hex-head capscrews (22)
that secure the cab (1) to the cab mount (ref.). Tap
the capscrews into the cab isolators (20) from below,
as required, but DO NOT distort or damage the cab
isolators.
Note: ALWAYS replace elastic-lined nuts with new
elastic-lined nuts to help ensure proper fastening.
9. At the front of the cab (1), install but DO NOT tighten
the two 3/4-10 hex-lock elastic nuts, two 3/4" lock
washers (23), two rebound washers (21) and two 3/4-
10 x 3-1/2" Grade 8 hex-head capscrews (22). Tap
the capscrews into the cab isolators (20) from below,
as required, but DO NOT distort or damage the cab
isolators.
Note: ALWAYS replace elastic-lined nuts with new
elastic-lined nuts to help ensure proper fastening.
10. From behind the cab, position the lower clamp (Fig.
4–3) on the fuel hose. Remove any cap or safety
cover from the fuel tank opening. If needed, secure
the fuel filler to the cab and the top end of the fuel
hose to the fuel filler.
11. Slip the lower end of the fuel hose onto the fuel hose
neck on the fuel tank and tighten the lower clamp.
12. Position a clamp on the fuel breather hose (Fig. 4–3).
Remove any cap or safety cover from the beaded
hose tee. If needed, secure the top end of the fuel
breather hose to the fuel filler with another clamp.
13. Secure the bottom end of the fuel breather hose to
the beaded hose tee.
14. From beneath the cab, route and connect the cab
wiring harness (Fig. 4–6). Install plastic conduit as
required to protect the wiring as it passes through
metal openings. Secure wiring with plastic wire ties
as needed.
15. Route the joystick, power steering and service brake
hydraulic hoses from the frame into the cab. Using
the hose labels made and attached earlier, connect
the hoses at the joystick, power steering valve and
brake control valve. Wipe up any spilled hydraulic
fluid.
16. Check that the cab is not distorting, pinching,
crushing or damaging the throttle cable, wiring or
hydraulic hoses. Make adjustments as necessary.
17. Tighten the cab-to-cab-mount hardware (refer to the
General Overview
illustration). Torque the 3/4-10
hex-lock elastic nuts (12) and 3/4-10 x 3-1/2" Grade 8
hex-head capscrews (22) to 280 lb/ft (380 Nm).
18. After the cab is securely mounted to the vehicle,
install all parts in the cab as required.
19. Connect the throttle cable at the engine (Fig. 4–4)
and, if necessary, to the throttle pedal.
WARNING: Explosion and fire hazard. Cap or
safely cover the fuel tank and beaded hose tee
openings.
WARNING: Wear protective footwear with
reinforced toe caps and slip-resistant soles.
Failure to comply can result in foot injury from
falling objects or other bodily injury from slip-
ping or falling.
WARNING: NEVER lift a heavy object without
the help of at least one assistant or a suitable
sling and hoist. Failure to comply can result in
serious personal injury.
Model 3606
•
Origin 10/99