Installing The 523-4908 Work Tool Positioner Kit {5112, 5264, 5479} Caterpillar

Compact Track Loader

289D (S/N: WE51-UP; WCT1-UP; TAW1-UP; A9Z1-UP)

299D (S/N: GTC1-UP)

299D2 (S/N: FD21-UP; BY41-UP)

Multi Terrain Loader

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

297D (S/N: BE71-UP)

297D2 (S/N: BL71-UP)

Skid Steer Loader

262D (S/N: RE51-UP; DTB1-UP; KTS1-UP; LST1-UP)

272D (S/N: B5W1-UP)

272D2 (S/N: BL21-UP)

Introduction

This Special Instruction provides information that is necessary to install the 523-4908 Work Tool Positioner Kit on the listed machines. Do not begin installation of this kit until you have read and understand the instruction that is contained in this instruction.

Safety

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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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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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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.

Reference Material

Reference: Operation and Maintenance, SEBU9084, "D-Series and D2-Series Compact Track Loaders (CTL), Multi-Terrain Loaders (MTL), and Skid Steer Loaders (SSL)""

Reference: Disassembly and Assembly, UENR3731, "Cab - Tilt"

Reference: Testing and Adjusting, UENR3729, "System Pressure - Release"

Required Parts

Machine Preparation

1. Move the machine to a smooth horizontal location. Move the machine away from other machines and personnel. Lower the bucket to the ground. Stop the engine.

2. Permit only one operator on the machine.

3. Block the front tracks and the rear tracks of the machine.

4. Place a barrier around the machine to keep personnel away from rotating machinery.

5. Remove the bucket and/or any other work tool connected to the lift arms.

6. If equipped with an Electronic Coupler, remove the two bolts that hold the guard onto the coupler assembly. Slide the guard out of place. Set aside for reinstallation.

Drill and Tap (if required)

Some early machines will require holes to be drilled and tapped in the right lift arm and also the N-A link (the yellow link.) If all the holes outlined in the illustration below are not present drilling and tapping is required. Otherwise, skip this section, and proceed to the Installation Instructions.

Illustration 1	g03866743

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Illustration 2	g03866787
View of dimensions for holes to be drilled (A) reference holes

Note: Drill all three holes with a diameter of 9.3 ± 0.2 mm (0.37± 0.01inch)

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Illustration 3	g03866826
View of dimensions for holes to be drilled

1. Drill holes using the dimensions mentioned in Table 3 on the lift arm and NA Link.

   Note: Drill both of the holes with a 7 mm (0.28 inch) drill bit, up to a depth of 20 mm (0.79 inch). Tap both holes with a M8X1.25 (5/16-24 inch) threaded tap to a depth of 16 mm (0.63 inch).

Installing the Angle Sensor

Illustration 4	g03866839
View of area of installation

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Illustration 5	g06172699
(1) 458-1051 Position Sensor As (2) 515-8578 Bracket As (3) 7X-2537 Bolts (4) 8T-4224 Hard Washers

1. Mount angle sensor assembly (1) onto bracket assembly (2). Use two bolts (3) and two hard washers (4) to secure the sensor.
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   Illustration 6	g06172872
   View of harness assembly (2) 515-8578 Bracket As (5) 7K-1181 Cable Strap

2. Secure angle sensor harness to bracket assembly (2) using strap cable (5).
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   Illustration 7	g03867821
   View of bracket installation (6) 266-3316 Bolt

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   Illustration 8	g06172890
   View of bracket installation (6) 266-3316 Bolt

3. Secure the bracket and sensor assembly to the right side of the coupler assembly. Use two bolts (6). Torque bolts to 40 ± 4 N·m (30 ± 3 lb ft).
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   Illustration 9	g03867855
   View of harness connection (7) 356-6119 Position Sensor As (8) LE-C3 (9) 421-4206 Sensor Harness As

4. Connect sensor assembly (7) to the LE-C3 connector (8) on sensor harness assembly (9).
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   Illustration 10	g03867859
   View of harness routing (A) Clamp (B) Plate (C) Bolt (9) 421-4206 Sensor Harness As

5. Unbolt clamp (A) from arm and route sensor harness assembly (9) through the empty slot in the clamp. Reinstall the clamp (A), plate (B), and bolt (C).

   Repeat this process for the second clamp on the lift arm torque tube.

   Note: The sensor harness assembly (9) should fit into the clamps as follows. The thicker portion of the harness starts just before entering the first clamp and just after the second clamp. This step ensures that the proper amount of slack is created. The slack is needed to accommodate the rotation of the bucket and/or work tool.

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   Illustration 11	g03867903
   View of harness routing (10) 178-3620 Strap

6. Use dual strap (10) to hold electric coupler harness along with self-level harness.
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   Illustration 12	g03867904
   View of harness routing (5) 7K-1181 Cable Strap (9) 421-4206 Sensor Harness As (10) 178-3620 Strap

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   Illustration 13	g03869345
   View of harness routing (10) 178-3620 Strap

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   Illustration 14	g03869347
   View of harness routing (10) 178-3620 Strap

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   Illustration 15	g03869348
   View of harness routing (10) 178-3620 Strap

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   Illustration 16	g03869350
   View of harness routing (5) 7K-1181 Cable Strap (10) 178-3620 Strap

7. Continue installing sensor harness assembly (9) and route along tilt cylinder lines group. Use six strap cable (5) and eight dual straps (10) to secure the harness to the machine.

Installing The Pressure Sensor

Note: Start machine, raise the lift arms, and secure the arms with the service brace. Refer to the proper Disassembly and Assembly manual for your machine. See Section "Reference Material" for more details.

Note: Lift the cab and secure. Refer to the proper Disassembly and Assembly manual for your machine. See Section "Reference Material" for more details.

Note: Release the system pressure before continuing the installation. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release" for the proper procedure.

Note: Refer to the table above to determine if 422-5585 Sensor Harness is required. This Harness is not included with the 523-4908 Work Tool Positioner Kit and must be purchased separately if needed. Install 422-5585 Sensor Harness As as indicated in Illustration 16 through 20, otherwise proceed to Note A.

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Illustration 17	g03868164
View of installation

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Illustration 18	g03868165
View of harness routing

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Illustration 19	g03868166
View of cover to be removed

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Illustration 20	g03868168
View of wire installation

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Illustration 21	g03868169
View of harness installation (11) 422-5585 Sensor Harness As (12) 441-4814 Sensor Harness As

1. Route harness (11) by following the cab harness towards the top connector on the ECM Module. Remove the top cover on the ECM Module and connect the two wires with the connecting sockets from harness (11) as indicated in table above.

2. Connect the wire with the terminal to the power relay module located to the right of the ECM Module as indicated in table above. Refer to illustrations above for details. Connect the wire with 3-pin connector to harness (12) under the cab.

   Note: The Pin Connector (DRCP Connector) on the ECM Module needs to be disassembled in order for the connections from harness (11) to be securely tight and properly connected. For troubleshooting or to prevent any issues after connecting the wires on harness (11) refer to Special Instructions, REHS7852, "DRCP Connector (D-Series Machine ECM) Repair Service Instruction".

   Note: Note A: If your machine is attached with 106-8715 Elbow As proceed to Illustration 18 or Step 5.

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   Illustration 22	g03868181
   View of adapter removal (D) Existing adapter

3. Remove adapter assembly (D) from the tilt group and scrap.
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   Illustration 23	g03868182
   View of adapter installation (13) 451-0482 Adapter As

4. Assemble adapter assembly (13) onto the tilt group and secure adapter assembly (13) with the Implement Valve.

5. If your machine has adapter assembly (13) move on to Step 6.
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   Illustration 24	g03868183
   View of plug removal (E) Existing plug (13) 451-0482 Adapter As

6. Remove plug (E) from adapter assembly (13) and scrap.
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   Illustration 25	g03868196
   View of sensor port (F) Sensor Port

7. If your machine has port (F) as shown in Illustration 24 and Illustration 25 all the following steps will remain the same.
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   Illustration 26	g03868220
   View of pressure sensor installation (F) Existing port (14) 3J-1907 O-Ring Seal (15) 344-7391 Pressure Sensor Gp

8. Install o-ring seal (14) onto pressure sensor group (15). Install the pressure sensor (15) into port (F).
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   Illustration 27	g03868222
   View of harness installation (9) 421-4206 Sensor Harness As (15) 344-7391 Pressure Sensor Gp (16) LE-C4 connector

9. Connect LE-C4 (16) connector on harness assembly (9) to pressure sensor group (15).
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   Illustration 28	g03869359
   View of seal caps to be removed (H) Seal cap (I) Seal Cap

10. Remove seal cap (H) and seal cap (I) from the connector on harness (12) and discard.
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    Illustration 29	g03868239
    View of harness connections (5) 7K-1181 Cable Strap (9) 421-4206 Sensor Harness As (12) 441-4814 Sensor Harness As (17) LE-C2 (18) C-C25 (19) LE-C5

11. Connect the LE-C2 connector (17) on harness assembly (9) to C-C25 connector (18) on harness (12). Connect LE-C5 connector (19) to harness (12). Secure the connectors to the harness with one strap cable (5).
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    Table 6

    Connector C-C25 Configuration
    Position	Wire Name	Color - Gauge
    1	P769-C140	YL-18-GXL
    2	P770-C146	WH-18-GXL
    3	A426-C225	BU-18-GXL
    4	T867-C223	BU-18-GXL
    5	T868-C224	YL-18-GXL
    6	E416-C139	PU-18-GXL

    Note: Ensure that the configuration of the C-C25 harness connector matches the configuration that is provided in table above.

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    Illustration 30	g03868295
    View of harness routing (5) 7K-1181 Cable Strap

12. Secure the connectors to the harness with two cable straps (5).

Installing the Position Sensor

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Illustration 31	g03868566
View of link assembly sensor installation (4) 8T-4224 Hard Washer (20) 435-8737 Rod End (21) 435-9154 Bracket (22) 5C-7261 Nut

1. Secure link assembly sensor (20) with plate (21) using hard washer (4) and nut (22).
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   Illustration 32	g03868567
   View of link assembly sensor installation (4) 8T-4224 Hard Washer (20) 435-8737 Rod End (22) 5C-7261 Nut (23) 421-0128 Bracket As

2. Secure link assembly sensor (20) with bracket assembly (23) using hard washer (4) and nut (22).
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   Illustration 33	g03868569
   View of link assembly sensor installation (23) 421-0128 Bracket As (24) 266-2337 Position Sensor Gp (25) 5H-3182 Spring Pin

3. Assemble position sensor group (24) onto bracket assembly (23) using spring pin (25).
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   Illustration 34	g03868571

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   Illustration 35	g03868572
   View of link assembly sensor installation (4) 8T-4224 Hard Washer (24) 266-2337 Position Sensor Gp (26) 8T-4189 Bolt

4. Secure position sensor group (24) onto the right-hand side frame – lift arm linkage holes using two bolts (26) and two hard washers (4).
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   Illustration 36	g03868573

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   Illustration 37	g03868578

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   Illustration 38	g03868576
   View of bracket installation (4) 8T-4224 Hard Washer (21) 435-9154 Bracket (22) 5C-7261 Nut (23) 421-0128 Bracket As (24) 266-2337 Position Sensor Gp (26) 8T-4197 Bolt (27) 421-0130 Bracket

5. Secure bracket (27) onto position sensor group (24) using five bolts (26), ten washers (4), and five nuts (22)
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   Illustration 39	g06172875
   View of sensor group installation (23) 421-0128 Bracket As (27) 421-0130 Bracket

6. Secure bracket (27) onto the lift arm using three bolts (28).
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   Illustration 40	g06172879
   (27) 421-0130 Bracket (30) 224-8645 Film (31) 224-8646 Film

7. Install film (30) onto bracket (27) for ANSI configured machines. Install film (31) onto bracket (27) for ISO configured machines. Locate the film using the dimensions listed in Table 3.

Installing Self-Level Switch

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Illustration 41	g03869340

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Illustration 42	g03869341
View of rocker switch (G) Switch cover (F) Console assembly

1. Locate switch cover (G) which is part of console assembly (F). Remove switch cover (G) from the control panel .

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

2. install rocker switch (29) in the switch cover (G).
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   Table 7

   Connector L-C10 Configuration
   Position	Wire Name	Color - Gage
   1	F905-L18	YL-18-GXL
   2	117-L146	YL-14-GXL
   7	200-L19	BK-18-GXL
   8	614-L20	PU-18-GXL

   Locate harness connector L-C10 on the panel harness assembly that is behind console assembly. Connect the harness to the rocker switch.

   Note: Ensure that the configuration of the harness connector matches the configuration that is provided in the table above.

   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. Reinstall switch cover (G) into the console assembly.

Machine Configuration

The 523-4908 Work Tool Positioner Kit is a premium feature that must be configured using the Cat^® Electronic Technician (Cat ET) Service Tool.

1. Connect the CAT ET to the machine. Turn the start key to the ON position. Do not start the engine.

2. Start CAT ET and select the machine ECM.
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   Illustration 43	g03868818
   View of configuration

3. From the menu select "Service", then "Configuration".
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   Illustration 44	g03868819
   View of "Work Tool Self-Level System Installation Status"

4. In the configuration screen, doubleclickon the "Work Tool Self-Level System Installation Status" link.

5. In the Pop-up window, click 'Yes'.
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   Illustration 45	g03868833

6. Access the CAT Factory Password System (FPS) at https://fps.cat.com.

7. Enter the required information.

8. Obtain the passwords and enter them into the appropriate input boxes labeled "Factory Password #1" and "Factory Password #2".

9. Turn the start key to theOFF position and wait at least 15 seconds. Turn the start key back to the ON position.

   Note: The new feature will be activated on the next power cycle.

10. In the configuration screen, doubleclickon the "Work Tool Self-Level System installation Status". Ensure that the feature is set to "Installed".
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    Illustration 46	g03868842

11. In the configuration screen, doubleclickon the "Lift Linkage Sensor Configuration" link.
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    Illustration 47	g03868844

12. In the Pop-up window, Select 'Rotary Position Sensor' and click 'Yes'.

RTD (Return to Dig) Machine Configuration (Optional)

The 388-8269 Work Tool Positioner (Self-Level) Kit can also be configured for the RTD (Return to Dig) feature by using Caterpillar Electronic Technician (Cat ET). This feature consists of two additional modes. "Work Tool Positioner Mode" enables the work tool to automatically return to an operator selectable preset angle. "Return to Dig" enables the work tool to automatically return to an operator selectable preset angle and automatically lowers the lift arms to the stops. Refer to the machine's Operation and Maintenance Manual for more information on using these modes.

1. Connect the CAT ET to the machine. Turn the start key to the ON position. Do not start the engine.

2. Start CAT ET and select the machine ECM.
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   Illustration 48	g03868818
   View of configuration

3. From the menu select "Service", then "Configuration".
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   Illustration 49	g03868918
   View of "Return to Dig Feature Installation Status"

4. In the configuration screen, doubleclickon the "Return to Dig Feature Installation Status" link.
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   Illustration 50	g03868922
   View of pop up window

5. In the Pop-up window, change the New Value field to "Installed". Click "OK".
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   Illustration 51	g03868833

6. Access the CAT Factory Password System (FPS) at https://fps.cat.com.

7. Enter the required information.

8. Obtain the passwords and enter them into the appropriate input boxes labeled "Factory Password #1" and "Factory Password #2".

9. Turn the start key to the OFF position and wait at least 15 seconds. Turn the start key back to the ON position.

   Note: The new feature will be activated on the next power cycle.

10. From the menu select "Service", then "Configuration".

11. In the configuration screen, doubleclickon the "Return to Dig Feature Installation Status". Ensure that the feature is set to "Installed".

Machine Calibration

1. Connect the CAT ET to the machine. Turn the start key to the ON position. Do not start the engine.

2. Start the CAT ET and select the machine ECM.
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   Illustration 52	g03868939

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   Illustration 53	g03868941

3. From the menu select "Service", then "Calibration".

   Note: Ensure no one will cross the path of the machine as the lift arms will move during the calibration. Follow the instructions to initiate the calibration, hitting "Next" as each condition is satisfied. As the last step suggests, move the lever to the raise position to begin the automated calibration. This calibration process takes approximately 5 to 10 minutes.

   Note: The new feature will be activated on the next power cycle.