Installing the 258-3645 Water Tank and Mounting Kit {5613, 5613} Caterpillar

Multi Terrain Loader:

277C (S/N: JWF1-UP)

287C (S/N: MAS1-UP)

297C (S/N: GCP1-UP)

Skid Steer Loader:

246C (S/N: JAY1-UP)

256C (S/N: DWS1-UP)

262C (S/N: MST1-UP)

272C (S/N: RED1-UP)

Compact Track Loader:

279C (S/N: MBT1-UP)

289C (S/N: JMP1-UP)

299C (S/N: JSP1-UP)

Introduction

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

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

This Special Instruction contains the information that is needed for installing the 258-3645 Water Tank and Mounting Kit on the listed machines.

Read the information that is provided in this instruction before you begin installation of the components.

Note: The hose routing from the water tank to the lift arm differs between machine models. Use the hose routing that is specified for your machine.

Parts Information

The parts that are provided in this kit are listed in Table 1.

Illustration 1	g01290966
The 258-3645 Water Tank and Mounting Kit

Illustration 2	g01290901
View of Section A-A in Illustration 1

Installation Instructions

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Illustration 3	g01303817
(17) 258-4389 Mount

1. Install the four mounts (17) to the top of the canopy, as shown. See Illustration 3.

   Follow the instructions for installing the mounts that are detailed in Step 1.a through Step 1.j.

   Note: If the mounts are already installed on your machine, disregard this step and proceed to Step 2.

   1. Mark the locations on top of the canopy for installing the four mounts (17). Use the dimensions that are provided in Illustration 21 in the Appendix of this instruction.
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   Illustration 4	g01292311
   (16) 258-3644 Bracket As (17) 258-4389 Mount (30) 7X-2561 Bolt (36) 154-1580 Hard Washer

   2. Temporarily attach the four mounts (17) to bracket assembly (16) with bolts (30) and hard washers (36). Then, place the bracket assembly in position on top of the canopy. See Illustration 4.

   3. Verify the position of the mounts with the marked locations from Step 1.a. When you have verified that the four marked locations are correct, remove the bracket assembly from the top of the canopy and place the bracket assembly aside while you prepare the mounting locations for welding.

   4. Prepare the four mounting locations by using a sanding disc that is made of aluminum oxide to remove the paint from these areas. After you have removed the paint from the mounting surfaces, clean these areas thoroughly in order to remove any debris.

      Note: Use of other kinds of sanding materials may result in welding defects.

      Note: Remove the paint from all surfaces that will be covered by the welds and remove the paint from the entire surface under each mount.

   5. Again, place the bracket assembly in position on top of the canopy. Ensure that each of the four mounts are correctly positioned for installation on the canopy.
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   Illustration 5	g01292442
   (17) 258-4389 Mount (C) Channel (P) Drain port

   6. Tack weld each mount (17) to the canopy. Use the gas metal arc welding (GMAW process) or the flux cored arc welding (FCAW process) .

      Note: Do not weld in the channel on top of the canopy and do not weld in the drain ports that are provided in each mount (17). See Illustration 5.

   7. Remove bolts (30) and hard washers (36) so that the bracket assembly can be removed from the top of the canopy. Place the bracket assembly aside while you complete the welding process.

   8. Weld each mount (17) to the canopy. Use the gas metal arc welding (GMAW process) or the flux cored arc welding (FCAW process). Use the weld specifications that are provided in Illustration 22 and Illustration 23.

   9. Clean the welds and inspect the welds.

   10. Paint the welds and the weld areas in order to prevent corrosion.

2. Assemble components that are specified in Step 2.a through Step 2.l.
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   Illustration 6	g01291393
   (3) 7X-0495 Adapter (5) 116-2001 Water Strainer (10) 166-2552 Hose As (15) 233-5719 Pump Gp (16) 258-3644 Bracket As (19) 003-2143 Elbow (22) 111-4627 Screw (24) 129-3178 Locknut (31) 8T-4205 Hard Washer (38) 167-0608 Seal

   1. On pump (15), install adapter (3) in the pump's inlet port and install elbow (19) in the pump's outlet port. See Illustration 6.

      Note: Use sealant (29) on all pipe fittings and connections.

   2. Connect strainer (5) and pump (15) by connecting the outlet of the strainer to adapter (3) in the pump's inlet port.

      Note: The point of the arrow indicates the strainer's outlet port.

   3. Place pump (15) with strainer (5) in position against the inside rear wall of bracket assembly (16). Align the two sets of mounting holes.

      Note: The bowl for the strainer, the elbow, and the pump's harness connector will extend through the two holes that are provided in the bottom plate of bracket assembly (16) .

   4. Mount pump (15) to the inside of the rear wall of bracket assembly (16) with four screws (22), four hard washers (31), and four locknuts (24) .

      Tighten the screws until the nuts and the washers are seated against the rubber mount. Then, tighten each screw for an additional four turns.

   5. Install hose (10) by connecting the end of the hose with the 1/2 inch hose coupling to the strainer's inlet port.

   6. Install the 85.5 cm (34 inch) length of seal (38) to the inside lip of bracket assembly (16) .
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   Illustration 7	g01291409
   (1) 3B-7255 Reducing Bushing (4) 8T-0737 Shutoff Valve (9) 166-2551 Water Tank Gp (11) 166-2557 Plate (23) 119-3859 Screw (40) 7R-0476 Strainer

   7. On tank (9), install bushing (1) in the tank's outlet port. See Illustration 7.

      Then, install valve (4) in bushing (1) .

   8. Install plate (11) on the top of tank (10). Use the six self-tapping screws (23) .

      Note: Install plate (11) on the centerline of the tank and to the rear of the tank cap lid. Plate (11) is provided in order to accommodate a beacon light with a magnetic holding base.

   9. Unscrew the tank filler cap from the top of the tank. Place strainer (40) into the tank filler opening. Then, replace the tank filler cap.
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   Illustration 8	g01291416
   (4) 8T-0737 Shutoff Valve (9) 166-2551 Water Tank Gp (13) 166-2559 Bracket (16) 258-3644 Bracket As (29) 8T-4122 Hard Washer (33) 8T-4779 Bolt (38) 167-0608 Seal

   10. Place tank (9) on bracket assembly (16). See Illustration 8.

       Connect the end of hose (10) with the 3/8 inch hose coupling to valve (4) .

   11. Slide tank (9) tightly against seal (38) which is installed on the inside lip of bracket assembly (16). Ensure that the stem of valve (4) extends through the hole in the rear plate of bracket assembly (16) .

   12. Install the two brackets (13) in order to secure tank (9) to bracket assembly (16). Use four bolts (33) and four hard washers (29) .

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Illustration 9	g01292504
(16) 258-3644 Bracket As (30) 7X-2561 Bolt (36) 154-1580 Hard Washer

Note: The weight of the tank assembly is approximately 50 kg (110 lb). Use the proper slings and the appropriate lifting device to place the tank assembly on top of the canopy.

3. Position bracket assembly (16) on the four mounts on top of the canopy. Align the mounting holes in the plate assembly with the bolt holes in the mounts, as shown. See Illustration 9.

   Install bolts (30) and hard washers (36) in order to secure the plate assembly on top of the canopy.

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Illustration 10	g01352380
(6) 124-1916 Permanent Coupling (7) 124-1917 Permanent Coupling (37) 122-6879 Hydraulic Hose

4. The hose assembly that will connect from the outlet of the pump to the quick connect coupler on the left lift arm needs to be fabricated. Use coupling (7), coupling (8), and the length of hose (37) that is specified below.
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   Table 3

   Machine	Hose Length
   272C, 297C, 299C	410 cm (161.42 inch)
   262C, 287C, 289C	383 cm (151 inch)
   246C, 256C, 277C, 279C	369 cm (145 inch)

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Illustration 11	g01303694
(14) 218-5847 Plate (26) 5C-7261 Nut (32) 8T-4224 Hard Washer (34) 8T-4908 Bolt (BB) 286-4863 Bracket As

5. Mount plate (14) to the top of the 286-4863 Bracket As (BB). Use two bolts (34), four hard washers (32), and two nuts (26), as shown. See Illustration 11.

6. Drill a 9.0 mm (0.35 inch) hole in the existing 250-2574 Bracket . For the locating dimensions, see Illustration 24.

   Note: This hole is used for installing bracket (18) on 246C, 256C, 277C and 279C machines. See Illustration 12. This hole is also used for installing a clip (20) on 262C, 272C, 287C, 289C, 297C and 299C machines. See Illustration 13 and Illustration 14.

7. For 262C, 272C, 287C, 289C, 297C and 299C machines, drill a 9.0 mm (0.35 inch) hole in the inside wall of the left tower. For locating dimensions, see Illustration 25 for 262C, 287C and 289C machines and see Illustration 26 for 272C, 297C and 299C machines.

   Note: This hole is used for installing a clip (20) that will secure hose (37) to the left tower.

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Illustration 12	g01312717
Hose routing and harness routing for 246C, 256C, 277C and 279C machines (2) 3S-2093 Cable Strap (8) 165-4894 Work Tool Harness As (18) 292-5476 Bracket (20) 067-2551 Clip (26) 5C-7261 Nut (27) 5P-4116 Hard Washer (34) 8T-4908 Bolt (37) 122-6879 Hydraulic Hose

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Illustration 13	g01298494
Hose routing and harness routing for 262C, 287C and 289C machines (2) 3S-2093 Cable Strap (8) 165-4894 Work Tool Harness As (20) 067-2551 Clip (26) 5C-7261 Nut (27) 5P-4116 Hard Washer (34) 8T-4908 Bolt (37) 122-6879 Hydraulic Hose

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Illustration 14	g01298496
Hose routing and harness routing for 272C, 297C and 299C machines (2) 3S-2093 Cable Strap (8) 165-4894 Work Tool Harness As (20) 067-2551 Clip (26) 5C-7261 Nut (27) 5P-4116 Hard Washer (34) 8T-4908 Bolt (37) 122-6879 Hydraulic Hose

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Illustration 15	g01303778
View of Area (A) in Illustrations 12, 13, and 15 (2) 3S-2093 Cable Strap (7) 124-1917 Permanent Coupling (8) 165-4894 Work Tool Harness As (25) 1L-2279 Elbow (37) 122-6879 Hydraulic Hose

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Illustration 16	g01883033
Hose routings from the left tower to the lift arm (20) 067-2551 Clip (21) 101-9759 Spacer (26) 5C-7261 Nut (27) 5P-4116 Hard Washer (35) 8T-6870 Bolt (37) 122-6879 Hydraulic Hose (39) 178-3620 Strap

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Illustration 17	g01312955
Hose routing along the lift arm for all machines (20) 067-2551 Clip (37) 122-6879 Hydraulic Hose

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Illustration 18	g01303746
View of Area (B) in Illustration 17 (6) 124-1916 Permanent Coupling (12) 166-2558 Coupling (14) 218-5847 Plate (28) 5P-8246 Hard Washer (37) 122-6879 Hydraulic Hose

8. Install the hose assembly that was fabricated in Step 4. Refer to Illustrations 12, 13, 14, 16, and 17, as needed. Use the routings and the components that are shown in the illustrations for your machine in order to install the hose assembly.

   Note: The fabricated hose assembly is installed between the outlet of pump (15) and coupling (12), which is mounted on plate (14) on the end of the lift arm. See Illustration 15 for details for connecting the hose assembly to the outlet of the pump. See Illustration 18 for details for connecting the hose assembly to plate (14) .

   Note: When you secure the hose assembly on the top of the tower and on the lift arm, provide sufficient slack in order to prevent stretching the hose when the lift arms are raised fully.

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Illustration 19	g01298530

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Illustration 20	g01312882

9. Install harness (8). Refer to Illustration 19 and Illustration 20.

   Note: Harness connector W-C3 is connected to the pump's electrical connector. The harness is routed along hose (37) into the left tower. The harness exits the left tower through the opening that is provided into the engine compartment. Harness connector W-C2 connects to connector P-C19 on the platform harness inside the engine compartment. Disconnect connector (T-C1) for the work tool harness from connector P-C19, if equipped. Then, connect connector T-C1 to connector W-C1.

   Note: Ensure that the configuration of the harness connectors match the configurations that are provided in the tables below.

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   Table 4

   Connector W-C1 165-4894 Work Tool Harness As
   Position	Color	Wire Name
   1	Black	200-W1
   2	Brown	A752-W2
   3	Blue	M906-W3
   4	Gray	M907-W4
   5	Black	200-W5
   6	Pink	M733-W11
   7	Blue	C460-W10
   8	Purple	A571-W12

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   Table 5

   Connector W-C2 165-4894 Work Tool Harness As
   Position	Color	Wire Name
   1	Black	200-W7
   2	Brown	A752-W8
   3	Blue	M906-W3
   4	Gray	M907-W4
   5	Black	200-W5
   6	Pink	M733-W11
   7	Blue	C460-W10
   8	Purple	A571-W12

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   Table 6

   Connector W-C3 165-4894 Work Tool Harness As
   Position	Color	Wire Name
   1	Black	200-W6
   2	Brown	A752-W9

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   Table 7

   Connector P-C19 258-4108 Chassis Harness As
   Position	Color	Wire Name
   1	Black	200-P48
   2	Pink	A572-P55
   3	Blue	M906-P50
   4	Gray	M907-P51
   5	Black	200-P52
   6	Black	200-P53
   7	Blue	C460-P54
   8	Purple	A571-P49

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   Table 8

   Connector T-C1 258-4126 Work Tool Harness As
   Position	Color	Wire Name
   1	Black	200-T1
   2	Pink	A572-T8
   3	Blue	M906-T3
   4	Gray	M907-T4
   5	Black	200-T5
   6	Black	200-T6
   7	Blue	C460-T7
   8	Purple	A571-T2

Appendix

Installation of the 258-4389 Mounts

Note: Ensure that the mounts are flush with the FOPS plate and with the posts.

Illustration 21	g01303821
Dimensions for locating the four mounts (17) (A) 711.7 ± 2 mm (28.02 ± 0.08 inch) (B) 159.6 ± 2 mm (6.28 ± 0.08 inch) (C) 59.4 mm (2.34 inch)

Illustration 22	g01368114
Top view of the 258-4389 Mount (17) that shows the welding instructions that apply for each mount (L1) Continuous weld from "XX" to "WW" (L2) Continuous weld from "XX" to "YY" and from "WW" to "ZZ" (S) 3 mm (0.12 inch) V-Groove weld with 1.5 mm (0.06 inch) penetration (T) 3 mm (0.12 inch) Fillet weld with 1.5 mm (0.06 inch) penetration

Note: Do not weld in the channel on top of the canopy and do not weld in the drain ports that are provided in each mount. See Illustration 5.

Illustration 23	g01368117
Side view of the 258-4389 Mount (17) that shows the welding instructions that apply for each mount (L3) Continuous weld from "AA" to "BB" and from "EE" to "FF" (L4) Continuous weld from "CC" to "DD" (W) 3 mm (0.12 inch) Fillet weld with 1.5 mm (0.06 inch) penetration (X) 3 mm (0.12 inch) V-Groove weld with 1.5 mm (0.06 inch) penetration

Note: Do not weld in the channel on top of the canopy and do not weld in the drain ports that are provided in each mount. See Illustration 5.

Installation Details

Illustration 24	g01311159
Drilling location for the bolt hole in the 258-2574 Bracket As for 246C, 256C, 277C and 279C machines (A) 12.1 mm (0.48 inch) (B) 16.3 mm (0.64 inch) (C) 9.0 mm (0.35 inch) Diameter

Illustration 25	g01311155
Drilling location for the bolt hole in the 258-2658 Plate for 262C, 287C and 289C machines (A) 188.4 mm (7.42 inch) (B) 13.0 mm (0.51 inch) (C) 9.0 mm (0.35 inch) Diameter

Illustration 26	g01311157
Drilling location for the bolt hole in the 258-2667 Plate for 272C, 297C and 299C machines (A) 187.7 mm (7.4 inch) (B) 13.0 mm (0.51 inch) (C) 9.0 mm (0.35 inch) Diameter

Illustration 27	g01311158
Drilling location for the bolt hole in the 258-3514 Plate for 246C, 256C, 277C and 279C machines (A) 85 mm (3.3 inch) (B) 20 mm (0.80 inch) (C) 9.0 mm (0.35 inch) Diameter