Installing the 258-3915, 294-5580 Work Tool Positioner Kit (SELF-LEVELING HYDRAULICS){1435, 5057, 5112, 5264, 5479} Caterpillar

Compact Track Loader:

279C (S/N: MBT1-UP)

289C (S/N: JMP1-UP)

299C (S/N: JSP1-UP)

Multi Terrain Loader:

287C (S/N: MAS1-UP)

277C (S/N: JWF1-UP)

277C2 (S/N: MET1-UP)

287C2 (S/N: SSB1-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)

Introduction

ReferenceOperation and Maintenance, SEBU8407, "279C, 289C, and 299C Compact Track Loader"

ReferenceOperation and Maintenance, SEBU8019, "246C. 256C. 262C and 272C Skid Steer Loaders"

ReferenceOperation and Maintenance, SEBU8020, "277C, 287C, and 297C Multi Terrain Loaders"

ReferenceDisassembly and Assembly, KENR8832, "279C, 289C, and 299C Compact Track Loader Machine Systems"

ReferenceDisassembly and Assembly, KENR5116, "246C. 256C. 262C and 272C Skid Steer Loaders Machine Systems"

ReferenceDisassembly and Assembly, KENR5198, "277C, 287C, and 297C Multi Terrain Loaders Machine Systems"

This Special Instruction provides the information that is necessary to install the 258-3915 294-5580 Work Tool Positioner Kit (SELF-LEVELING HYDRAULICS) on the listed machines. The two kits have identical parts except for the control manifolds. Refer to Table 1 in order to identify the correct kit for use with your machine.

Do not begin installation of this kit until you have read the information that is contained in this instruction.

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 should also have the necessary training, skills, and tools in order to perform these functions properly.

Required Parts

The 258-3915 Work Tool Positioner Kit (SELF-LEVELING HYDRAULICS)

Illustration 1	g01417245
The 258-3915 Work Tool Positioner Kit (SELF-LEVELING HYDRAULICS) (1) 146-9439 Relay As (2) 258-2801 Control Manifold and Solenoid Gp (3) 318-0008 Tube As (4) 258-2884 Tube As (5) 258-2885 Tube As (6) 258-2886 Tube As (7) 263-5417 Rocker Switch (8) 148-8315 Connector (9) 148-8388 Elbow Gp (10) 148-8393 Elbow As (11) 205-3692 Elbow As (12) 6V-8398 O-Ring Seal (13) 6V-9830 Cap As (14) 7X-2535 Bolt (15) 8T-4205 Hard Washer (16) 4P-8134 Clip (17) 3S-2093 Cable Strap (18) 148-8327 Connector As

The 294-5580 Work Tool Positioner Kit (SELF-LEVELING HYDRAULICS)

Illustration 2	g01417259
The 294-5580 Work Tool Positioner Kit (SELF-LEVELING HYDRAULICS) (1) 146-9439 Relay As (2) 258-2802 Control Manifold and Solenoid Gp (3) 318-0008 Tube As (4) 258-2884 Tube As (5) 258-2885 Tube As (6) 258-2886 Tube As (7) 263-5417 Rocker Switch (8) 148-8315 Connector (9) 148-8388 Elbow Gp (10) 148-8393 Elbow As (11) 205-3692 Elbow As (12) 6V-8398 O-Ring Seal (13) 6V-9830 Cap As (14) 7X-2535 Bolt (15) 8T-4205 Hard Washer (16) 4P-8134 Clip (17) 3S-2093 Cable Strap (18) 148-8327 Connector As

Installation Instructions

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At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns. To prevent possible personal injury, release the pressure in the work tool hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed. Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch.

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Illustration 3	g01365530
(A) 258-3399 Plate

1. Remove plate (A) from the right side of the machine. See Illustration 3.

   Retain the plate and the four 266-3316 Bolts for the reinstallation.

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Illustration 4	g01199014
(B) Work Tool Control Valve (C) 258-2880 Tube As (D) 6V-9829 Cap As (E) 6V-9829 Cap As

2. Locate the work tool control valve (B) which is located on the right side of the machine. See Illustration 4.

   Remove the components that are specified in Step 2.a and Step 2.b.

   Note: If additional clearance to the valve is desired, the hydraulic tank can be removed. Refer to Operations and Maintenance Manual, "Hydraulic Oil System - Change" for instructions on draining the hydraulic tank. Refer to Disassembly and Assembly Manual, "Hydraulic Tank - Remove" for instructions on removing the hydraulic tank.

   1. Remove the 258-2880 Tube As (C). The tube assembly is connected between Port 1A on the work tool control valve and the center port on the 258-2965 Tube As . Discard the tube assembly. Then remove the 148-8341 Connector As from the main control valve. Discard the connector.

      Note: The 258-2880 Tube As (C) is part of the 258-2876 Work Tool Lines Gp .

      Note: Loosen adjacent connectors in order to facilitate the removal of the tube.

   2. Remove cap (D) from the center port of the 258-2933 Tube As and remove cap (E) from the center port of the 258-2934 Tube As . Discard the two caps.

      Note: The 258-2933 Tube As and the 258-2934 Tube As are part of the 258-2412 Tilt Cylinder Lines Gp .

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Illustration 5	g01198335
(2) Control manifold (8) 148-8315 Connector (9) 148-8388 Elbow Gp (10) 148-8393 Elbow As (11) 205-3692 Elbow As

3. Prepare control manifold (2) for installation per Step 3.a through Step 3.d. See Illustration 5.

   Use the control manifold that is specified for your machine:

   • The 258-2801 Control Manifold and Solenoid Gp is for installation on 246C, 256C, 277C and 279C machines.

   • The 258-2802 Control Manifold and Solenoid Gp is for installation on 262C, 272C, 287C, 289C, 297C and 299C machines.

   1. Install connector (8) in Port A on the control manifold and torque.

      Then, install elbow (10) into connector (8). Orient the elbow loosely, as shown. See Illustration 5.

      Note: Do not torque the elbow, yet.

   2. Install elbow (9) in Port B on the control manifold. Orient the elbow, as shown. See Illustration 5.

      Note: Do not torque the elbow, yet.

   3. Install one elbow (11) in Port C on the control manifold. Orient the elbow, as shown. See Illustration 5.

      Note: Do not torque the elbow, yet.

   4. Install one elbow (11) in Port D on the control manifold. Orient the elbow, as shown. See Illustration 5.

      Note: Do not torque the elbow, yet.

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Illustration 6	g01198500
(2) Control manifold (14) 7X-2535 Bolt (15) 8T-4205 Hard Washer (16) 4P-8134 Clip

4. Mount control manifold (2) with the installed fittings on the existing 258-2569 Bracket As . Use two bolts (14), hard washer (15), and clip (16), as shown. See Illustration 6.

   Note: Only hand tighten the bolt.

   Note: The 258-2569 Bracket As is part of the 258-2569 Mounting and Valve Group (Work Tool) .

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Illustration 7	g01417260
(2) Control manifold (3) 318-0008 Tube As (4) 258-2884 Tube As (5) 258-2885 Tube As (6) 258-2886 Tube As (8) 148-8315 Connector (9) 148-8388 Elbow Gp (10) 148-8393 Elbow As (11) 205-3692 Elbow As (12) 6V-8398 O-Ring Seal (13) 6V-9830 Cap As (16) 4P-8134 Clip (18) 148-8327 Connector As

5. Install the four new tubes per Step 5.a through Step 5.e. See Illustration 7.

   Note: Loosen adjacent tubes in order to facilitate the installation of the new tubes.

   1. Install tube (4). First, connect tube (4) to elbow (10) in Port A on control manifold (2). Then, connect the other end of tube (4) to the center port on the existing 258-2965 Tube As .

   2. Install tube (3). First, connect tube (3) to elbow (9) in Port B on control manifold (2). Install connector (18) into the other end of tube (3). Then, connect tube (3) to Port 1A on the work tool control valve.

   3. Tighten all of the connections for tubes (3) and (4). Then, tighten bolts (14) in order to secure the control manifold to the bracket. See Illustration 6.

      Note: Tighten the connections for any tubes that were loosened during the installation of tubes (3) and (4) .

   4. Install tube (5). First, connect tube (5) to elbow (11) in Port C on control manifold (2). See Illustration 7.

      Then, connect the other end of tube (5) to the center port on the existing 258-2932 Tube As .

   5. Install tube (6). First, connect tube (6) to elbow (11) in Port D on control manifold (2). Then, connect the other end of tube (6) to the center port on the existing 258-2933 Tube As .

   6. Tighten all of connections for tubes (5) and (6) .

6. Install cap (13) on the center port of tube (4). Use O-ring (12) when you install cap assembly (13) .

7. Connect the solenoid on the control manifold to connector P-C11 on the 258-4108 Platform Harness . Secure the harness to clip (16) with cable strap (17) .

   Note: Ensure that the configuration of the harness connector matches the configuration that is provided in Table 3.

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   Table 3

   Position	Color	Wire Name
   1	Yellow	F905-P34
   2	NA	-
   3	Black	200-P35
   4	NA	-

8. If you removed the hydraulic tank for the installation of this kit, reinstall the hydraulic oil tank. Refer to Disassembly and Assembly Manual, "Hydraulic Tank - Install".

   Refill the hydraulic oil tank. Refer to Operations and Maintenance Manual, "Hydraulic Oil System - Change".

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Illustration 8	g01365530
(A) 258-3399 Plate

9. Reinstall plate (A) on the right side of the machine. Use the four 266-3316 Bolts that were retained for the reinstallation. See Illustration 8.

   Tighten the 266-3316 Bolts to a torque of 40 ± 8 N·m (30 ± 6 lb ft).

10. Install rocker switch (7) per Step 10.a through Step 10.d.
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    Illustration 9	g01198933
    (S) 258-4007 Switch Cover

    1. Locate switch cover (S) which is part of the 258-4001 Control Panel (LH). Remove switch cover (S) from the control panel. See Illustration 9.

       Note: Switch cover (S) has provisions for four rocker switches. Use a thin blade screwdriver in order to release the locking tab on one side of the switch cover. Then, withdraw the switch cover from the panel.

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    Illustration 10	g01273237
    (7) 263-5417 Rocker Switch (S) 258-4007 Switch Cover

    2. Remove the 109-2356 Plug at Location P in the switch cover, as shown. See Illustration 10.

       Then, install rocker switch (7) in the switch cover at Location P.

       Note: Remove the plug by pushing the plug from the back of the switch cover.

       Note: Install the rocker switch by pushing the rocker switch into the opening in the switch cover. Insert the rocker switch from the front of the switch cover. Push the rocker switch until the locking tabs on the rocker switch are engaged.

    3. Locate harness connector L-C10 on the 258-4101 Panel Harness As that is inside the 258-4001 Control Panel (LH). Connect the harness connector to the back of the rocker switch.

       Note: Ensure that the configuration of the harness connector matches the configuration that is provided in Table 4.

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       Table 4

       Position	Color	Wire Name
       1	Yellow	F905-L18
       2	Yellow	E741-L82
       7	Black	200-L19
       8	Purple	614-L20

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    Illustration 11	g01273440
    (7) 263-5417 Rocker Switch (S) 258-4007 Switch Cover

    4. Reinstall switch cover (P) into the 258-4001 Control Panel (LH). See Illustration 11.

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Illustration 12	g01198938
(1) 146-9439 Relay As

11. Install relay (1) in Position R4 in the lower fuse panel, as shown. See Illustration 12.

    The fuse panels are located in the rear wall of the cab.