Retrofitting Hydraulic Hose Clamping On D2 Series Loaders {5057} Caterpillar

Compact Track Loader

289D (S/N: WCT1-299; TAW1-8628; A9Z1-603)

Multi Terrain Loader

287D (S/N: STK1-198; TLK1-252; HMT1-1046)

Skid Steer Loader

262D (S/N: DTB1-7714; KTS1-655; LST1-607)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Operation and maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and are understood.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. 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 cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Required Parts

Note: Quantities in the following table are to replace one clamp only. Multiply the quantities by the number of clamps to be replaced.

AUX Clamps

Tilt Clamps

Required Tools

Installation Procedure

Illustration 1	g06251649
The rework only applies to these clamps (A) Tilt Hydraulic Lines (B) Auxiliary Hydraulic Lines

For this rework, ensure that you have general access to the clamps indicated in the above figure. The rework only applies to the indicated clamps and is not to be used for any other clamps in the hydraulic lines. If necessary to raise the arms for access, brace the lift cylinder with a short arm brace or support with an overhead hoist.

1. Remove hoses from the clamps. Even if not replacing all clamps, freeing all locations is still helpful.

   Note: If tape is not on the hoses to show alignment to the clamp, mark the hose to ensure that the hose is placed in the same location on the new clamp.

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   Illustration 2	g06251186
   Arm 471-1774 Weld Plate and block beneath

2. Cut or grind off 471-1774 Weld Plate that have the threaded boss.

   Note: Do not grind off the thick block beneath the arm weld plate.

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   Illustration 3	g06251199

3. Weld two 159-9541 Weld Nut onto each 7G-3834 Clip (3). Weld all around the nuts, filling the slots.
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   Illustration 4	g06251330

4. If machine has a hydraulic coupler, you will need to modify two parts to accommodate the hoses. The clips for the tilt tower clamp and the hose p-clip will need to have material removed with a hand grinder. Use the following procedure:
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   Illustration 5	g06251215

   1. Remove 5 mm (0.20) of material (5) a third of the length across the clip to clear the hose p-clip.

   2. Remove material (6) from around the bolt hole, leaving 3 mm (0.12) of material. Doing so for the top and bottom clips to push the clips rearward as far as possible to clear the hose p-clip.
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      Illustration 6	g06251221

   3. Remove material (7) from around p-clip bolt hole, leaving 3 mm (0.12) of material.

5. Weld clip with weld nuts onto the arm clamp block:
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   Illustration 7	g06251227

   1. Center clip with weld nuts onto the arm clamp block and clamp in place.
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      Illustration 8	g06251229

   2. Weld along top and bottom of clip.
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   Illustration 9	g06251242
   Tower clamp surface after grinding off bracket. Ensure that clamp is centered and holes are aligned.

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   Illustration 10	g06251245
   Tower clamp behind the cab

6. For the tower clamps, weld clip with weld nuts onto the frame. Center about the hole and slots under the weld plate just ground off, maintaining the same angle of rotation about the center.

   Note: For the tower clamp behind the cab, welding on the left and right sides may be easier.

7. Install grommet and route hoses through, aligning the tape or marks on the hose to the clip.

   Note: For the rear tower clamp, to bolt the clips together the following procedure may be necessary. Torque all bolts to 55 Nm (40.6 lb ft)

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   Illustration 11	g06251257

   1. Place a tie strap through the top hole and then compress the clips together.

   2. Install one washer and 8T-4186 Bolt into bottom hole.

      This longer bolt helps start the threads and bring the clips together.

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      Illustration 12	g06251258

   3. Install washer and 8T-4136 Bolt or 8T-4195 Bolt into the top hole. This shorter bolt is needed in the top hole because the angled rear tower sheet causes interference when trying to start the longer bolt.

8. Ensure that all harnesses are strapped and properly oriented before clamping:
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   Illustration 13	g06251262

   1. On the auxiliary arm clap with the arms raised, strap harness to drain hose (8) and auxiliary hose (9).
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      Illustration 14	g06251341

   2. Strap harness to top of new clamp before the hose enters the tower.
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      Illustration 15	g06251343

   3. Route harness inside the tilt tower clamp clip to avoid interference with the black rear arm linkage.
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      Illustration 16	g06251344

   4. Strap coupler hoses to lower auxiliary hose.
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      Illustration 17	g06251346

   5. Route harness behind clamp at the top and strap to upper auxiliary hose on both sides of clamp. Also route coupler hoses behind clamp at the bottom and strap to lower auxiliary hose as hoses enter under the cab.
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   Illustration 18	g06251265

9. Ensure that the harnesses are not rubbing on clamps or interfering with moving components. Have a second person actuate the arms while you check for clearance to harness and hoses. Ensure that the harnesses do not pull too tightly with motion.