Installing New Components for a Kickout and Positioner on a Track Loader{5109, 5112, 5132} Caterpillar

Track-Type Loader:

931 (PIN: 08N; 10N; 78U; 81U)

931B (PIN: 4SC; 6EC; 25Y; 26Y; 29Y; 30Y)

931C (PIN: 6RF; 7HF; 8AF; 5LG; 9AG; 2BJ; 6AJ; 2AK)

933 (PIN: 8FL; 9EL)

935B (PIN: 3DF)

935C (PIN: 8CF; 5DJ)

939 (PIN: 9GL)

Introduction

This special instruction outlines the basic steps in order to modify an older kickout and positioner on track loaders. The modifications are necessary due to the change in the serviceability of the older 6S-7255 Switch . The 6S-7255 Switch is no longer serviced.

Caterpillar recommends replacing the 6S-7255 Switch with the newer 117-9364 Control Group . The 117-9364 Control Group is not a direct replacement for the 6S-7255 Switch . Modifications to the older kickout and positioners are needed in order for the new switch to function correctly.

The 117-9364 Control Group is part of the newer 107-5594 Kickout and Positioner . The new kickout and positioner is used on many of the newer track loaders.

For more information concerning the modifications for your machine, refer to the sections in this publication which correspond to your machine .

Also refer to the Operation and Maintenance Manual, Disassembly and Assembly Manual, and the Parts Manual for your machine.

Do not perform any of the procedures until you have read the information in this publication.

Required Parts

The parts needed to modify the 931 and 935 track loaders are listed in Table 1. The parts needed to modify the 933 and 939 Track Loaders are listed in Table 2.

Installation of the New Components on a 933 and 939 Track Loader

Early models of the 933 and 939 used two 6S-7255 Switches . Conversion to the single 117-9364 Control Group requires rewiring the kickout circuit. This is accomplished by removing both 6S-7255 Switches and replacing the switches with a single 117-9364 Control Group . The two switch harnesses must be replaced with one switch harness.

Follow the instructions in this section in order to rework the old kickout and positioner.

1. Disconnect the battery from the electrical system.

2. Remove the cab's floorplate on the right side of the cab and remove the cab's center floorplate. Remove the right hand console cover. Remove the engine side panel on the right hand side of the machine.

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Illustration 1	g00636343
(A) Former 108-5592 Harness (B) Floorplates (F) Connection for the chassis harness (G) Lift kickout switch (H) Switch for the tilt kickout

3. Disconnect the 108-5592 Harness (A) from the lift kickout switch (G) and the switch for the tilt kickout (H). The switches are located on the right side of the tower assembly and on the right hand tilt cylinder. Disconnect the harness (A) from the chassis harness. The connection to the chassis harness is located near the flywheel housing (F). Refer to Illustration 1.

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Illustration 2	g00636428
View E (B) Former 108-5592 Harness (J) Former 113-0784 Harness (K) Former 6S-7255 Switches (L) Former 108-5595 Harness (M) Connection for the hydraulic solenoid valves (N) Fuse

4. Remove the 108-5592 Harness (B) from the 6S-7255 Switches (K). The 6S-7255 Switches are located on the right hand console. Refer to Illustration 2.

5. Remove the harnesses (J) and (L) from the 6S-7255 Switches (K). Refer to Illustration 2.

6. Remove the 6S-7255 Switches from the right hand console. Refer to Illustration 2.

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Illustration 3	g00636431
(1) 123-2860 Harness (P) Connection to the 117-9364 Relay Control (Q) Connection to the fuse (N) (R) Connection for power from the chassis harness (S) Connections for the switch on the lift arm (T) Connections for the switch on the tilt cylinder (U) Connection to the valve solenoids (V) Operating power (W) Chassis ground

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Illustration 4	g00636434
(2) 3E-3362 Plug Lock Wedge (3) 3E-3361 Connector Plug (4) 8T-8730 Connector Socket (5) 6K-1827 Bullet Connector (X) Number 16 black (Y) Number 16 pink

7. Fabricate a harness in order to provide power for the kickout circuit. The harness also provides the system ground. Use number 16 wire for both the power and ground connections. Refer to Illustration 3 and 4.

   Note: On newer models, the 123-2860 Harness (A) picks up power and ground for the kickout and positioner through a two-pin connector. The 123-2860 Harness plugs into the chassis harness above the flywheel housing (F). The former harness picks up power only from the same location through a one-pin connector. The adapter harness assembly will connect the new harness which has two connections to the chassis harness which has one connection. Power and ground will be provided through the adapter harness assembly. The adapter harness assembly is made by cutting the one-pin connector off of the 108-5592 Harness . Then install the one-pin connector and a ground wire to the 3E-3361 Connector Plug . Leave a substantial amount of wire connected to the one-pin connector. Also measure a length of ground wire which is long enough to reach a convenient chassis ground. The 108-5592 Harness (B) was originally plugged into the chassis harness.

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Illustration 5	g00636439
(7) 117-9364 Relay Control

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Illustration 6	g00636443
(1) 123-2860 Harness (7) 117-9364 Relay Control (8) 8T-9043 Bolt (9) 8T-4226 Plated Washer

8. Install the 117-9364 Relay Control (7) on the right hand console. Refer to Illustrations 5 and 6.

9. Install the 123-2860 Harness (1) to the 117-9364 Relay Control (7). Refer to Illustration 6.

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Illustration 7	g00636438
(1) 123-2860 Harness (G) Switch for lift kickout (H) Switch for tilt kickout (R) Power connection

10. Install the 123-2860 Harness (1) to the lift kickout switch (G) and tilt kickout switch (H), valve solenoids, and chassis harness (F). Refer to Illustration 7.

11. Connect the battery to the electrical system.

12. Test the system according to the Operation and Maintenance Manual.

    Note: If the system works in reverse tilt, you must exchange the wires which are connected to pins 3 and 6. The pins are located at the harness end of the 117-9364 Relay Control connector. The wires are numbered D719-OR and D718-PK.

Installation of the New Components for the Kickout and Positioner on 931 and 935 Track Loaders

On the 931 and 935 machines, the 117-9364 Control Group cannot handle the current demands of the 6S-7103 Coil . A relay must be added in order to limit the amount of current going to the 117-9364 Control Group .

The assembly instructions are outlined in the following procedures.

1. Disconnect the battery from the electrical system.

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Illustration 8	g00636457
(A) Floorplates (B) Right side console

2. Remove the right hand console cover. Refer to Illustration 8.

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Illustration 9	g00636466
(C) Harness (D) Former 6S-7255 Switch

3. Remove the harness (C) from the fuse and the 6S-7255 Switch (D). Refer to Illustration 9.

4. Remove the 6S-7255 Switch (D) from the right hand console. Refer to Illustration 9.

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Illustration 10	g00636468
(2) 151-1267 Bracket (3) 8T-0337 Screw (4) 4B-4274 Washer (5) 4M-6425 Bolt (6) 8T-4224 Hard Washer (7) 117-9364 Relay Control (8) 3E-9362 Relay

5. Attach the 117-9364 Control Group (7) and the 3E-9362 Relay to the 151-1267 Bracket (2). Refer to Illustration 10.

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Illustration 11	g00636469
(1) 151-1268 Harness (2) 151-1267 Bracket (5) 4M-6425 Bolt (6) 8T-4224 Hard Washer (7) 117-9364 Relay Control (8) 3E-9362 Relay (9) 106-8704 Arc Suppressor (10) 6K-0806 Cable Strap (E) Ground (F) Fuse

6. Attach the bracket (2) to the right side console. Refer to Illustration 11.

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Illustration 12	g00636470
(1) 151-1268 Harness (7) Connection for the 117-9364 Relay Control (8) Connection for the 3E-9362 Relay () Connection for the 106-8704 Arc Suppressor (E) Connection to ground (F) Connection for the fuse (G) Connection for the coil (H) Connection to the hydraulic solenoid valves

7. Attach the 151-1268 Harness (1) to the 117-9364 Control Group (7). Connect the harness to the other components on the right side console. Refer to Illustrations 11 and 12.

8. Connect the battery to the electrical system.

9. Test the system according to the Operation and Maintenance Manual.