Installing the 277-0654, 277-0655, 277-0656, 277-0657 Roading Conversion Kits (LIGHTS, MIRRORS){1408, 1429, 1430, 7000, 7000, 7319} Caterpillar

Multi Terrain Loader:

267B (S/N: CYC1-UP)

277B (S/N: MDH1-UP)

287B (S/N: ZSA1-UP)

Skid Steer Loader:

236B (S/N: HEN1-UP)

246B (S/N: PAT1-UP)

248B (S/N: SCL1-UP)

252B (S/N: SCP1-UP)

262B (S/N: PDT1-UP)

268B (S/N: LBA1-UP)

Introduction

This Special Instruction provides the information that is necessary for installing the 277-0654 277-0655 277-0656 277-0657 Roading Conversion Kits (LIGHTS, MIRRORS) on the listed machines. Refer to Table 1 in order to identify the correct kit for use with your machine.

Read the instructions that are applicable for your machine before you begin installation of the kit. Parts information is provided in the Appendix of this instruction.

The 277-0654 Roading Conversion Kit (LIGHTS, MIRRORS)

Illustration 1	g01248000
The 277-0654 Roading Conversion Kit (LIGHTS, MIRRORS) for 236B, 246B, 267B and 277B Machines (1) 3E-7584 Head and Signal Lamp Gp (2) 3S-2093 Cable Strap (3) 4B-4863 Washer (4) 4P-7581 Clip (6) 5C-9553 Bolt (7) 7D-5473 Bolt (9) 8T-1887 Clip (10) 8T-1888 Clip (11) 8T-4121 Hard Washer (12) 8T-4133 Nut (14) 8T-4201 Locking Bolt (15) 8T-4205 Hard Washer (19) 8T-6685 Bolt (20) 8W-8909 Sleeve (21) 9X-2042 Screw (22) 115-1615 Relay As (BRAKE LIGHT) (23) 132-5166 Mirror Gp (24) 142-8634 Stop and Tail Lamp Gp (25) 142-9329 Rocker Switch (ROADING LIGHTS) (26) 142-9331 Rocker Switch (HAZARD WARNING LIGHTS) (27) 147-1773 Circuit Breaker As (28) 166-2033 Tee As (29) 175-4239 Bracket As (30) 184-1564 Pressure Switch Gp (BRAKE LIGHT) (31) 195-0935 Threaded Insert (32) 206-1346 Cable Strap (33) 216-4711 Rear Lighting Harness As (BRAKE) (35) 216-4727 Rear Lighting Harness As (36) 225-7990 Front Lighting Harness As (37) 225-8013 Wire (38) 226-5900 Rocker Switch (TURN SIGNAL) (40) 238-7637 Plate (43) 242-9000 Flasher As

Illustration 2	g01248003
The 277-0655 Roading Conversion Kits (LIGHTS, MIRRORS) for 252B, 262B and 287B Machines (1) 3E-7584 Head and Signal Lamp Gp (2) 3S-2093 Cable Strap (3) 4B-4863 Washer (4) 4P-7581 Clip (6) 5C-9553 Bolt (7) 7D-5473 Bolt (8) 7X-2547 Bolt (9) 8T-1887 Clip (10) 8T-1888 Clip (13) 8T-4194 Bolt (14) 8T-4201 Locking Bolt (15) 8T-4205 Hard Washer (16) 8T-4223 Hard Washer (20) 8W-8909 Sleeve (21) 9X-2042 Screw (22) 115-1615 Relay As (BRAKE LIGHT) (23) 132-5166 Mirror Gp (24) 142-8634 Stop and Tail Lamp Gp (25) 142-9329 Rocker Switch (ROADING LIGHTS) (26) 142-9331 Rocker Switch (HAZARD WARNING LIGHTS) (27) 147-1773 Circuit Breaker As (28) 166-2033 Tee As (29) 175-4239 Bracket As (30) 184-1564 Pressure Switch Gp (BRAKE LIGHT) (31) 195-0935 Threaded Insert (32) 206-1346 Cable Strap (33) 216-4711 Rear Lighting Harness As (BRAKE) (34) 216-4726 Front Lighting Harness As (35) 216-4727 Rear Lighting Harness As (37) 225-8013 Wire (38) 226-5900 Rocker Switch (TURN SIGNAL) (40) 238-7637 Plate (42) 238-7641 Base As (43) 242-9000 Flasher As

Illustration 3	g01248005
The 277-0656 Roading Conversion Kits (LIGHTS, MIRRORS) for 248B Machines (1) 3E-7584 Head and Signal Lamp Gp (2) 3S-2093 Cable Strap (3) 4B-4863 Washer (4) 4P-7581 Clip (5) 5C-7261 Nut (6) 5C-9553 Bolt (7) 7D-5473 Bolt (9) 8T-1887 Clip (10) 8T-1888 Clip (11) 8T-4121 Hard Washer (12) 8T-4133 Nut (14) 8T-4201 Locking Bolt (15) 8T-4205 Hard Washer (17) 8T-4224 Hard Washer (18) 8T-4908 Bolt (19) 8T-6685 Bolt (20) 8W-8909 Sleeve (21) 9X-2042 Screw (22) 115-1615 Relay As (BRAKE LIGHT) (23) 132-5166 Mirror Gp (24) 142-8634 Stop and Tail Lamp Gp (25) 142-9329 Rocker Switch (ROADING LIGHTS) (26) 142-9331 Rocker Switch (HAZARD WARNING LIGHTS) (27) 147-1773 Circuit Breaker As (28) 166-2033 Tee As (29) 175-4239 Bracket As (30) 184-1564 Pressure Switch Gp (BRAKE LIGHT) (31) 195-0935 Threaded Insert (32) 206-1346 Cable Strap (33) 216-4711 Rear Lighting Harness As (BRAKE) (35) 216-4727 Rear Lighting Harness As (36) 225-7990 Front Lighting Harness As (37) 225-8013 Wire (38) 226-5900 Rocker Switch (TURN SIGNAL) (39) 238-7636 Plate (40) 238-7637 Plate (43) 242-9000 Flasher As

Illustration 4	g01248007
The 277-0657 Roading Conversion Kits (LIGHTS, MIRRORS) for 268B and 287B (High Flow) Machines (1) 3E-7584 Head and Signal Lamp Gp (2) 3S-2093 Cable Strap (3) 4B-4863 Washer (4) 4P-7581 Clip (6) 5C-9553 Bolt (7) 7D-5473 Bolt (9) 8T-1887 Clip (10) 8T-1888 Clip (13) 8T-4194 Bolt (14) 8T-4201 Locking Bolt (15) 8T-4205 Hard Washer (16) 8T-4223 Hard Washer (20) 8W-8909 Sleeve (21) 9X-2042 Screw (22) 115-1615 Relay As (BRAKE LIGHT) (23) 132-5166 Mirror Gp (24) 142-8634 Stop and Tail Lamp Gp (25) 142-9329 Rocker Switch (ROADING LIGHTS) (26) 142-9331 Rocker Switch (HAZARD WARNING LIGHTS) (27) 147-1773 Circuit Breaker As (28) 166-2033 Tee As (29) 175-4239 Bracket As (30) 184-1564 Pressure Switch Gp (BRAKE LIGHT) (31) 195-0935 Threaded Insert (32) 206-1346 Cable Strap (33) 216-4711 Rear Lighting Harness As (BRAKE) (34) 216-4726 Front Lighting Harness As (35) 216-4727 Rear Lighting Harness As (37) 225-8013 Wire (38) 226-5900 Rocker Switch (TURN SIGNAL) (41) 238-7638 Plate (42) 238-7641 Base As (43) 242-9000 Flasher As

Installation Instructions

1. Install the appropriate mounting plate for the right lift arm. Review Step 1.a, Step 1.b, and Step 1.c. Then, perform the step that is applicable for your machine.

   Note: Use the components that are specified in the illustrations.

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   Illustration 5	g01258646
   (6) 5C-9553 Bolt (15) 8T-4205 Hard Washer (19) 8T-6685 Bolt (29) 175-4239 Bracket As (40) 238-7637 Plate (W) 8T-4121 Hard Washer (X) 8T-4133 Nut

   Note: The 8T-4121 Hard Washers (W) and the 8T-4133 Nuts (X) are reused from mounting the support plate to the left lift arm.

   1. For 236B, 246B, 267B, and 277B machines, install plate (40) on the right lift arm. Then, install bracket assembly (29) to plate (40), as shown. See Illustration 5.
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   Illustration 6	g01258604
   (6) 5C-9553 Bolt (13) 8T-4194 Bolt (15) 8T-4205 Hard Washer (16) 8T-4223 Hard Washer (29) 175-4239 Bracket As (42) 238-7641 Base As

   2. For 252B, 262B, 268B, 287B, and 287B (HF) machines, install plate (42) on the right lift arm. Then, install bracket assembly (29) to plate (42), as shown. See Illustration 6.
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   Illustration 7	g01250498
   (6) 5C-9553 Bolt (11) 8T-4121 Hard Washer (12) 8T-4133 Nut (15) 8T-4205 Hard Washer (19) 8T-6685 Bolt (29) 175-4239 Bracket As (40) 238-7637 Plate

   3. For 248B, install plate (40) on the right lift arm. Then, install bracket assembly (29) to plate (40), as shown. See Illustration 7.

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Illustration 8	g01250514
(1) 3E-7584 Head and Signal Lamp Gp (9) 8T-1887 Clip (10) 8T-1888 Clip (20) 8W-8909 Sleeve (23) 132-5166 Mirror Gp (29) 175-4239 Bracket As (A) 8T-0389 Locknut (B) 100-3255 Washer (C) 100-3254 Spacer

2. Install sleeve (20) on bracket assembly (29) by sliding the sleeve onto the bracket. See Illustration 8.

   Position the sleeve so that the sleeve is located in the middle of the bracket. Then, mate clip (9) with clip (10) and position the legs of the clips around sleeve (20). Draw the legs of the clips together and align the bolt holes.

   Note: Position the clips so that clip (10) is forward of clip (9) .

3. Remove nut (A), washer (B), and spacer (C) from the stud on the back of lamp (1) .

4. Mount lamp (1) on bracket assembly (29). Insert the stud on the back of the lamp through the bolt holes in clips (9) and (10). Replace spacer (C), washer (B), and nut (A) on the stud on the back of lamp. Tighten the nut to a torque of 25 ± 7 N·m (18.44 ± 5.16 lb ft) in order to secure the lamp.

5. Loosen the two screws for the clamp on the back of mirror (23). Install the mirror by sliding the clamp onto the end of bracket assembly (29). See Illustration 8.

   Position the mirror so that the end of the bracket assembly protrudes beyond the clamp. Then, tighten the screws to a torque of 2.25 ± 0.25 N·m (1.66 ± 0.18 lb ft) in order to secure the mirror.

6. Install the appropriate mounting plate for the left lift arm. Review Step 6.a, Step 6.b, Step 6.c, and Step 6.d. Perform the step that is applicable for your machine.

   Note: Use the components that are specified in the illustrations.

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   Illustration 9	g01250578
   (6) 5C-9553 Bolt (15) 8T-4205 Hard Washer (19) 8T-6685 Bolt (29) 175-4239 Bracket As (40) 238-7637 Plate (W) 8T-4121 Hard Washer

   Note: The 8T-4121 Hard Washer (W) is reused from securing the support plate to the left lift arm.

   1. For 236B, 246B, 267B, and 277B machines, install plate (40) on the right lift arm. Then, install bracket assembly (29) to plate (40), as shown. See Illustration 9.

      Note: Remove the two bolts and the two washers that are used to secure the 218-6006 Bracket As to the lift arm. Discard the two bolts. Retain the two 8T-4121 Hard Washers for the reinstallation. Bolts (19) are installed into the weld nuts on the 218-6006 Bracket As .

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   Illustration 10	g01258611
   (6) 5C-9553 Bolt (8) 7X-2547 Bolt (12) 8T-4133 Nut (15) 8T-4205 Hard Washer (29) 175-4239 Bracket As (40) 238-7637 Plate (W) 8T-4121 Hard Washer

   2. For 252B, 262B, and 287B machines, install plate (40) on the right lift arm. Then, install bracket assembly (29) to plate (40), as shown. See Illustration 10.

      Note: Remove the two bolts and the two washers that are used to secure the 218-6006 Bracket As to the lift arm. Discard the two bolts. Retain the two 8T-4121 Hard Washers (W) for the reinstallation. Bolts (8) are installed into the weld nuts on the 218-6006 Bracket As .

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   Illustration 11	g01258613
   (5) 5C-7261 Nut (6) 5C-9553 Bolt (15) 8T-4205 Hard Washer (17) 8T-4224 Hard Washer (18) 8T-4908 Bolt (29) 175-4239 Bracket As (39) 238-7636 Plate

   3. For 248B machines, install plate (39) on the 218-6001 Cover As . The 218-6001 Cover As is part of the 218-5725 Work Tool Lines Gp . Then, install bracket assembly (29) to plate (39), as shown. See Illustration 11.
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   Illustration 12	g01259049
   (6) 5C-9553 Bolt (15) 8T-4205 Hard Washer (29) 175-4239 Bracket As (41) 238-7638 Plate (V) 8T-4136 Bolt part of the auxiliary hydraulic lines group (W) 8T-4121 Hard Washer part of the auxiliary hydraulic lines group

   4. For 268B and 287B (HF) machines, install plate (41) on the 218-5923 Cover Plate . The 218-5923 Cover Plate is part of the 218-5830 Work Tool Lines Gp . Then, install bracket assembly (29) to plate (41), as shown. See Illustration 12.

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Illustration 13	g01250800
(1) 3E-7584 Head and Signal Lamp Gp (9) 8T-1887 Clip (10) 8T-1888 Clip (20) 8W-8909 Sleeve (23) 132-5166 Mirror Gp (29) 175-4239 Bracket As (A) 8T-0389 Locknut (B) 100-3255 Washer (C) 100-3254 Spacer

7. Install sleeve (20) on bracket assembly (29) by sliding the sleeve onto the bracket. See Illustration 13.

   Position the sleeve so that the sleeve is located in the middle of the bracket. Then, mate clip (9) with clip (10) and position the legs of the clips around sleeve (20). Draw the legs of the clips together and align the bolt holes.

   Note: Position the clips so that clip (10) is forward of clip (9) .

8. Remove nut (A), washer (B), and spacer (C) from the stud on the back of lamp (1) .

9. Mount lamp (1) on bracket assembly (29). Insert the stud on the back of the lamp through the bolt holes in clips (9) and (10). Replace spacer (C), washer (B), and nut (A) on the stud on the back of lamp. Tighten the nut to a torque of 25 ± 7 N·m (18.44 ± 5.16 lb ft) in order to secure the lamp.

10. Loosen the two screws for the clamp on the back of mirror (23). Install the mirror by sliding the clamp onto the end of bracket assembly (29). See Illustration 13.

    Position the mirror so that the end of the bracket assembly protrudes beyond the clamp. Then, tighten the screws to a torque of 2.25 ± 0.25 N·m (1.66 ± 0.18 lb ft) in order to secure the mirror.

11. Disconnect the electrical connectors for the two stop/tail lamps from the 216-4703 Rear Lighting Harness As . Remove the two stop/tail lamps from the rear door. Discard the two stop/tail lamps and the fasteners.

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Illustration 14	g01250843
(24) 142-8634 Stop and Tail Lamp Gp (D) 5C-2890 Nut (E) 1H-3244 Lockwasher

12. Remove the two nuts (D) and the two lockwashers (E) from the back of each of the two stop/tail lamps (24). Place each stop/tail lamp (24) in position, as shown. See Illustration 14.

    Secure each stop/tail lamp to the support bracket with two nuts (D) and two lockwashers (E) .

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Illustration 15	g01251108
(21) 9X-2042 Screw (31) 195-0935 Threaded Insert (43) 242-9000 Flasher As

13. Find the mounting location on the right side of the rear wall of the cab. See Illustration 15.

    Install threaded insert (31) in the mounting hole that is provided in the rear wall of the cab.

    Connect the base of flasher assembly (43) into connector C-C20. Connector C-C20 is part of the 216-4752 Panel Harness As .

    Then, secure flasher assembly (43) to threaded insert (31) with screw (21) .

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Illustration 16	g01251054
(3) 4B-4863 Washer (7) 7D-5473 Bolt (27) 147-1773 Circuit Breaker As (37) 225-8013 Wire

14. Locate the 225-7981 Bracket As on the right inside wall of the engine compartment. The 225-7981 Bracket As is part of the 216-4700 Chassis Wiring Gp .

    Temporarily remove the three 5C-7261 Nuts and the three 8T-4224 Hard Washers that secure the 225-7981 Bracket As on the mounting studs.

    Install breaker assembly (27) to the bracket assembly. Use two bolts (7) and two hard washers (3), as shown. See Illustration 16.

    Note: The two bolts (7) and the two hard washers (3) are inserted from the back of the plate. The two bolts (7) thread into the bushings that are provided in the breaker assembly.

    Install wire jumper (37) between one of the terminals of the circuit breaker and the power stud, as shown.

    Locate wire P-T12 (102-RD). Install wire P-T12 (102-RD) to the unused terminal of the circuit breaker. Wire P-T12 (102-RD) is part of the 216-4701 Platform Harness As (UPPER) .

    Reinstall the 225-7981 Bracket As on the three mounting studs with three 5C-7261 Nuts and the three 8T-4224 Hard Washers that were previously removed.

15. Install pressure switch (PS1) into the hydraulic hose connection to port (X4) of the hydrostatic pump.
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    Illustration 17	g01259508
    View of the right side of the hydrostatic pump (28) 166-2033 Tee As (30) 184-1564 Pressure Switch Gp

    1. Install one swivel tee (28) in the hydraulic hose connection to port (X4) of the hydrostatic pump, as shown. See Illustration 17.

       Tighten the tee to a torque of 26.5 ± 1.5 N·m (19.5 ± 1.10 lb ft).

    2. Then, install one pressure switch (30) in the perpendicular port of swivel tee (28) .

       Tighten the pressure switch to a torque of 26.5 ± 1.5 N·m (19.5 ± 1.10 lb ft).

16. Install pressure switch (PS2) into the hydraulic hose connection to port (X3) of the hydrostatic pump.
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    Illustration 18	g01259510
    View of the left side of the hydrostatic pump (28) 166-2033 Tee As (30) 184-1564 Pressure Switch Gp

    1. Install one swivel tee (28) in the hydraulic hose connection to port (X3) of the hydrostatic pump, as shown. See Illustration 18.

       Tighten the tee to a torque of 26.5 ± 1.5 N·m (19.5 ± 1.10 lb ft).

    2. Then, install one pressure switch (30) in the perpendicular port of swivel tee (28) .

       Tighten the pressure switch to a torque of 26.5 ± 1.5 N·m (19.5 ± 1.10 lb ft).

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Illustration 19	g01263820
View of the top of the hydrostatic pump (2) 3S-2093 Cable Strap (22) 115-1615 Relay As (BRAKE LIGHT) (30) 184-1564 Pressure Switch Gp (33) 216-4711 Rear Lighting Harness As (BRAKE) (U) 216-4701 Platform Harness As (UPPER)

17. Install harness (33). See Table 2 for installation details.

    Secure harness (33) with four cable straps (2), as shown. See Illustration 19.

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    Table 2

    Connector	Description	Connection
    G-C1	2-Pin Plug 1 110-GN 2 C457-BU	Pressure Switch (PS1)
    G-C2	2-Pin Plug 1 C576-BU 2 C457-BU	Pressure Switch (PS2)
    G-C3	3-Pin Receptacle 1 110-GN 2 200-BK 3 604-OR	216-4701 Platform Harness As (UPPER) Connector P-C21
    G-C4	5-Pin Plug 1 110-GN 2 200-BK 3 Blank 4 604-OR 5 C576-BU	Relay (22)

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Illustration 20	g01264206
(1) 3E-7584 Head and Signal Lamp Gp (2) 3S-2093 Cable Strap

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Illustration 21	g01264163
View under the lift arm cross-tube (2) 3S-2093 Cable Strap (4) 4P-7581 Clip (14) 8T-4201 Locking Bolt (32) 206-1346 Cable Strap

18. Install harness (36) or install harness (34). See Table 3 for installation details.

    Note: Harness (36) is used on 236B, 246B, 248B, 267B, and 277B, machines. Harness (34) is used on 252B, 262B, 268B (HF), 287B, and 287B (HF) machines.

    Secure the harness to each support plate with a cable strap (2), as shown. See Illustration 20.

    Secure the harness under the lift arm cross-tube with eight cable straps (2) and with two cable straps (32), as shown. See Illustration 21.

    Note: Harness (36) is routed inside the right lift arm and down the right tower. The harness exits the tower through the opening in the right wall of the engine compartment.

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    Table 3

    Connector	Description	Connection
    KR-C1	6-Pin Plug 1 200-BK 2 505-YL 3 506-GY 4 517-BR 5 618-YL 6 619-GN	Harness (35) Connector KJ-C1
    KR-C2	6-Pin Plug 1 606-GY 2 200-BK 3 618-YL Blank Blank 619-GN	Right Lamp (1)
    KR-C3	6-Pin Plug 1 605-YL 2 200-BK 3 617-BR Blank Blank 619-GN	Left Lamp (1)

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Illustration 22	g01264479
View of the inside of the engine compartment that shows the routing of harness (35) (2) 3S-2093 Cable Strap (35) 216-4727 Rear Lighting Harness As

19. Install harness (35). See Table 4 for installation details.

    Secure harness (35) with seven cable straps (2), as shown. See Illustration 22.

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    Table 4

    Connector	Description	Connection
    KJ-C1	6-Pin Receptacle 1 200-BK 2 605-YL 3 606-GY 4 617-BR 5 618-YL 6 619-GN	Harness (36) or Harness (34) Connector KR-C1
    KJ-C2	8-Pin Receptacle 1 200-BK 2 312-BR 3 604-OR 4 605-YL 5 606-GY 6 617-BR 7 618-YL 8 619-GN	216-4701 Platform Harness As (UPPER) Connector P-C17
    KJ-C3	8-Pin Plug 1 200-BK 2 321-BR 3 604-OR 4 605-YL 5 606-GY 6 617-BR 7 618-7L 8 Blank	216-4703 Rear Lighting Harness As Connector H-C1

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Illustration 23	g01250940
View of the right hand control panel (25) 142-9329 Rocker Switch (ROADING LIGHTS) (26) 142-9331 Rocker Switch (HAZARD WARNING LIGHTS) (38) 226-5900 Rocker Switch (TURN SIGNAL)

20. Remove the 109-2356 Plugs from the three switch positions that are identified in Illustration 23. Install switch (25) and switch (26) .

    Install switch (38) .

Appendix

Parts Information

Parts List

Service Parts