A New Handle Assembly is Used on Certain D Series Skid Steer Loaders, Compact Track Loaders, and Multi-Terrain Loaders {7308} Caterpillar

Compact Track Loader

239D (S/N: CD41-UP; BL91-UP)

249D (S/N: AH91-UP; GWR1-UP)

259D (S/N: G351-UP; FTK1-UP; GTK1-UP; FTL1-UP)

279D (S/N: WEF1-UP; GTL1-UP; RCX1-UP)

289D (S/N: TAW1-UP; A9Z1-UP)

299D (S/N: GTC1-UP; HCL1-UP)

299D XHP (S/N: NLC1-UP; JST1-UP)

299D2 (S/N: FD21-UP)

Multi Terrain Loader

257D (S/N: FMR1-UP; EZW1-UP)

277D (S/N: NTL1-UP; FMT1-UP)

287D (S/N: STK1-UP; TLK1-UP; HMT1-UP)

297D (S/N: BE71-UP)

297D2 XHP (S/N: HP21-UP)

Skid Steer Loader

226D (S/N: HRD1-UP)

232D (S/N: KXC1-UP; DPR1-UP)

236D (S/N: SEN1-UP; MPW1-UP; BGZ1-UP)

242D (S/N: DML1-UP; DZT1-UP; A9W1-UP)

246D (S/N: BYF1-UP; JSL1-UP; HMR1-UP)

262D (S/N: DTB1-UP; KTS1-UP; LST1-UP)

272D (S/N: GSL1-UP; B5W1-UP)

272D XHP (S/N: ETL1-UP; SHY1-UP)

272D2 (S/N: BL21-UP)

272D2 XHP (S/N: MD21-UP)

Description Of Change: The new Handle Assembly and mounting hardware have an improved design that will improve service life of the Handle Assembly.

Mounting hardware is to be installed with liquid Loctite 243. Mounting torque on the bolts is reduced from 5.5 N·m (4.1 lb ft) to 3.5 N·m (2.6 lb ft). A washer is added as a spacer to the cab door handle at each of the side inserts at the top where the bolts are assembled.

Adaptable To: The new Handle As and mounting hardware are adaptable to the following machines:

• 236D (S/N: BGZ1-1145)

• 236D (S/N: MPW1-698)

• 236D (S/N: SEN1-499)

• 242D (S/N: A9W1-371)

• 242D (S/N: DML1-268)

• 242D (S/N: DZT1-20963)

• 246D (S/N: BYF1-1477)

• 246D (S/N: HMR1-997)

• 246D (S/N: JSL1-376)

• 257D (S/N: EML1-1)

• 257D (S/N: EZW1-849)

• 257D (S/N: FMR1-261)

• 259D (S/N: FTK1-591)

• 259D (S/N: FTL1-52992)

• 259D (S/N: G351-1)

• 259D (S/N: GTK1-137)

• 262D (S/N: DTB1-2675)

• 262D (S/N: KTS1-342)

• 262D (S/N: LST1-443)

• 272D (S/N: B5W1-959)

• 272D (S/N: GSL1-7376)

• 272D 2 (S/N: BL21-101)

• 272D 2 XHP (S/N: MD21-131)

• 272D XHP (S/N: ETL1-467)

• 272D XHP (S/N: SHY1-159)

• 277D (S/N: FMT1-484)

• 277D (S/N: MLT1-1)

• 277D (S/N: NTL1-3110)

• 279D (S/N: GTL1-1769)

• 279D (S/N: PPT1-275)

• 279D (S/N: RCX1-447)

• 279D (S/N: WEF1-24)

• 287D (S/N: HMT1-521)

• 287D (S/N: STK1-183)

• 287D (S/N: TLK1-228)

• 289D (S/N: A9Z1-490)

• 289D (S/N: TAW1-24439)

• 289D (S/N: WCT1-1)

• 297D (S/N: BE71-240)

• 297D 2 XHP (S/N: HP21-111)

• 297D XHP (S/N: HP71-228)

• 299D (S/N: GTC1-16265)

• 299D (S/N: HCL1-1008)

• 299D 2 (S/N: FD21-121)

• 299D 2 XHP (S/N: DX21-1)

• 299D XHP (S/N: JST1-1087)

• 299D XHP (S/N: NLC1-751)

• 226D (S/N: HRD1-UP)

• 232D (S/N: DPR1-UP)

• 232D (S/N: KXC1-UP)

• 236D (S/N: BGZ1146-UP)

• 236D (S/N: MPW699-UP)

• 236D (S/N: SEN500-UP)

• 239D (S/N: CD41-UP)

• 239D (S/N: BL91-UP)

• 242D (S/N: A9W372-UP)

• 242D (S/N: DML269-UP)

• 242D (S/N: DZT20964-UP)

• 246D (S/N: BYF1478-UP)

• 246D (S/N: HMR998-UP)

• 246D (S/N: JSL377-UP)

• 249D (S/N: GWR1-UP)

• 249D (S/N: AH91-UP)

• 257D (S/N: EML2-UP)

• 257D (S/N: EZW850-UP)

• 257D (S/N: FMR262-UP)

• 259D (S/N: FTK592-UP)

• 259D (S/N: FTL52993-UP)

• 259D (S/N: G352-UP)

• 259D (S/N: GTK138-UP)

• 262D (S/N: DTB2676-UP)

• 262D (S/N: KTS343-UP)

• 262D (S/N: LST444-UP)

• 272D (S/N: B5W960-UP)

• 272D (S/N: GSL737-UP)

• 272D 2 (S/N: BL2102-UP)

• 272D 2 XHP (S/N: MD2132-UP)

• 272D XHP (S/N: ETL468-UP)

• 272D XHP (S/N: SHY160-UP)

• 277D (S/N: FMT485-UP)

• 277D (S/N: MLT2-UP)

• 277D (S/N: NTL311-UP)

• 279D (S/N: GTL1770-UP)

• 279D (S/N: PPT276-UP)

• 279D (S/N: RCX448-UP)

• 279D (S/N: WEF25-UP)

• 287D (S/N: HMT522-UP)

• 287D (S/N: STK184-UP)

• 287D (S/N: TLK229-UP)

• 289D (S/N: A9Z491-UP)

• 289D (S/N: TAW2440-UP)

• 289D (S/N: WCT2-UP)

• 297D (S/N: BE7241-UP)

• 297D 2 XHP (S/N: HP2112-UP)

• 297D XHP (S/N: HP7229-UP)

• 299D (S/N: GTC1626-UP)

• 299D (S/N: HCL1009-UP)

• 299D 2 (S/N: FD2122-UP)

• 299D 2 XHP (S/N: DX22-UP)

• 299D XHP (S/N: JST1088-UP)

• 299D XHP (S/N: NLC752-UP)

Rework Procedure

Disassembly Procedure

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Illustration 1	g06028422
(A) Bolt (B) Washer

1. Park the machine on level ground. Remove bolt (A) and washer (B) from the door assembly from inside the cab. Discard bolt (A). Refer to Illustration 1.
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   Illustration 2	g06028486
   (C) Latch cover screws

2. Remove the two latch cover screws (C). Refer to Illustration 2.
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   Illustration 3	g06028497
   (D) Latch cover

3. Remove the latch cover (D) from the assembly. Refer to Illustration 3.
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   Illustration 4	g06028515
   (E) Nut (F) Bolt (G) Spacer (H) Washer

4. Loosen nut (E). Remove bolt (F), spacer (G), and washer (H) from the latch assembly. Refer to Illustration 4.
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   Illustration 5	g06028522
   (J) Bolts

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   Illustration 6	g06028528
   (K) Latch assembly

5. Remove four bolts (J) to detach the latch assembly (K). Refer to Illustrations 5 and 6.
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   Illustration 7	g06028830
   (L) Bolts (M) Washers

6. Remove the two remaining bolts (L) and washers (M) holding the latch assembly together. Discard bolts (L). Retain washers (M). Refer to Illustration 7.
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   Illustration 8	g06031006
   (N) Bracket (P) Gasket (R) Pull handle (S) Gasket

7. Disassemble the latch assembly. Discard Pull handle (R). Refer to Illustration 8.

Assembly Procedure

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Illustration 9	g06028582
Exterior view of the door (S) 345-6284 Gasket

1. Place the 345-6284 Gasket (S) in the hole in the door from the inside. Refer to Illustration 9.
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   Illustration 10	g06028591
   Exterior view of the door (P) Gasket

2. Locate the retained Gasket (P) to the door. Refer to Illustration 10.
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   Illustration 11	g06028534
   (M) Washers (N) Bracket (3) 9X-2480 Bolt

3. Place the retained metal bracket (N) on the inner side of the door. Secure using retained washers (M) and new bolts (3) in the upper two holes. Refer to Illustration 11.
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   Illustration 12	g06031011
   (S) Gasket (2) 5P-4115 Hard Washer (3) 9X-2480 Bolt

4. Place 5P-4115 Hard Washers (2) over the 9X-2480 Bolts (3) on the other side of the door. Refer to Illustration 12.

   Note: Ensure the Hard Washers (2) are between Gasket (S) and Handle As (1) when fully assembled in Steps 5 and 6.

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   Illustration 13	g06028871
   (1) 252-1862 Handle As (3) 9X-2480 Bolt

5. Apply Loctite to bolts (3) and locate the bolts into the inserts on the new Handle As (1). Refer to Illustration 13.
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   Illustration 14	g06028890
   (3) 9X-2480 Bolt

6. Tighten the top two bolts (3) to 3.5 ± 0.5 N·m (2.6 ± 0.4 lb ft). Refer to Illustration 14.
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   Illustration 15	g06028898
   (J) Bolts (K) Latch assembly

7. Assemble the latch assembly (K) using four bolts (J). Torque the bolts to 12 + 2/-0 N·m (8.9 + 1.5/-0 lb ft). Refer to Illustration 15.
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   Illustration 16	g06028902
   (E) Nut (F) Bolt (G) Spacer (H) Washer (K) Latch assembly

8. Assemble bolt (F) through the spacer (G), washer (H), latch assembly (K), and nut (E). The nut is used to adjust the screw length on the other side to get the optimum setting in the pull handle. Torque to 3.5 ± 0.5 N·m (2.6 ± 0.4 lb ft). Refer to Illustration 16.
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   Illustration 17	g06028912
   (B) Washer (C) Latch cover screws (D) Latch cover (3) 9X-2480 Bolt

9. Place the latch cover (D) over the latch assembly. Secure using washer (B) and new bolt (3) and screws (C). Torque the two screws to 6 ± 1 N·m (4.4 ± 0.7 lb ft). Torque the bolt to 3.5 ± 0.5 N·m (2.6 ± 0.4 lb ft) (bottom bolt (3)). Refer to Illustration 17.