Tilt Rotator Control Group Installation Procedure for Certain Mini Hydraulic Excavators {1408, 5705} Caterpillar

Mini Hydraulic Excavator

307.5 (S/N: GW71-UP)

308 (S/N: GG81-UP; GW81-UP)

308.5 (S/N: GZ81-UP)

309 (S/N: GG91-UP; GW91-UP)

310 (S/N: GWT1-UP)

Introduction

This Special Instruction contains the procedure for installing the Tilt Rotator Control Group on certain Mini Hydraulic Excavators.

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

Reference Section

Reference: Disassembly and Assembly, M0095130 , Joystick Control - Remove and Install - Left-Hand side

Reference: Disassembly and Assembly, M0095130 , Joystick Control - Remove and Install - Right

Safety Section

Show/hide table

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

Show/hide table

Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

Show/hide table

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

Show/hide table

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

Show/hide table

Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Show/hide table

Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

Show/hide table

Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Show/hide table

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

Show/hide table

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Required Parts

Installation Procedure

For Fixed Boom Installation

1. Remove and discard the 577-6926 Work Tool Harness As.
   Show/hide table

   Illustration 1	g06426532
   (1) 577-6925 Work Tool Harness As (2) 577-6924 Work Tool Harness As (3) 577-6926 Work Tool Harness As

   Show/hide table

   Illustration 2	g06423500
   (1) 577-6925 Work Tool Harness As (2) 577-6924 Work Tool Harness As

2. Connect the 12-pin connectors of work tool harness assembly (1) and work tool harness assembly (2) together.
   Show/hide table

   Illustration 3	g06419884
   Parts removed for clarity (1) 577-6925 Work Tool Harness As

   Show/hide table

   Illustration 4	g06426619
   Detailed view of area A (1) 577-6925 Work Tool Harness As (4) 577-1570 Connector As (5) 577-1569 Bracket

3. Install the bracket (5) as shown in Illustration 4. Mount the 8-pin connector on work tool harness assembly (1) to the bracket (5). Route the work tool harness assembly (1) and work tool harness assembly (2) from the bracket (5) to the bottom of the boom. Secure with the supplied cable straps. Refer to Illustration 2, Illustration 3 and Illustration 4.
   Show/hide table

   Illustration 5	g06424301
   (2) 577-6924 Work Tool Harness As (B) 4-pin connector (FH-C15)

   Show/hide table

   Illustration 6	g06424320
   Electrical diagram

4. Connect the 4-pin receptacle connector on work tool harness assembly (2) labeled work tool expansion to the 4-pin work tools expansion plug connector (FH-C15) (B) on the machine harness near the swivel. Refer to Illustration 5 and Illustration 6.
   Show/hide table

   Illustration 7	g06424305
   (2) 577-6924 Work Tool Harness As (C) 2-pin plug connector SV2 (FH-C6)

5. Connect the 2-pin receptacle connector on work tool harness assembly (2) labeled SV2 to the 2-pin plug connector SV2 (FH-C6) (C) on the machine harness near the swivel. Refer to Illustration 7 and Illustration 6.

   Note: If the machine is equipped with a quick coupler valve, the 2-pin plug connector SV2 (FH-C6) will be plugged into a solenoid.

   Show/hide table

   Illustration 8	g06424309
   (2) 577-6924 Work Tool Harness As (D) 2-pin plug connector SV2 (FH-C6)

6. Connect the 2-pin plug connector on work tool harness assembly (2) labeled SV2 into the solenoid that the 2-pin plug connector SV2 (FH-C6) (D) on the machine harness was previously plugged into (if equipped). Refer to Illustration 8 and Illustration 6.
   Show/hide table

   Illustration 9	g06424350
   (2) 577-6924 Work Tool Harness As

7. Insert the socket pin on work tool harness assembly (2) labeled J2-80 into pin J2-80 of the machine (ECM J2) electrical connector. To insert this pin, the J2 connector must first be removed using a 4mm Allen wrench and the gray J2 connector cap on the reverse side of the connector (facing the machine ECM) must be carefully removed. After fully inserting the socket into J2-80, carefully reinstall the gray connector cap, reassemble to the machine ECM and tighten the J2 connector to the machine ECM using a 4mm Allen wrench. Refer to Illustration 9 .
   Show/hide table

   Illustration 10	g06424372
   (E) Connector FH-C14 (F) Resistor (CAN B 2)

8. Remove the resistor (CAN B 2) (F) from the connector FH-C14 (E) on the machine harness near the swivel and plug with a blank 3-pin connector. Refer to Illustration 6 and Illustration 10.
   Show/hide table

   Illustration 11	g06424418
   (6) 570-7211 Joystick Control Gp (LH) (7) 570-7212 Joystick Control Gp (RH)

9. Replace the standard joystick assemblies on the machine with the new joystick control group (6) and joystick control group (7).

   Note: Refer to Disassembly and Assembly , M0095130 for the installation of joystick control groups.

10. Set TRS8 to be install in ET: Connect to Machine ECM with ET2019A and select configurations. Change the tilt rotator system installation status to installed.

    Note: This configuration requires a factory password. Cycle the key OFF then back ON.

11. Calibrate the TRS8 feeder flow: Connect to Machine ECM with ET2019A and select calibrations.  If hydraulic oil is below the required temperature you can warm up the oil with the automatic warm-up within the valve calibrations by selecting “Valve Calibrations” then hit Start, deselect everything except hydraulic warm-up then hit start.  Follow instructions on screen to warm hydraulic oil. When hydraulic oil warm-up is complete, select “Tilt rotator System Calibration” then hit Start. Follow instructions on screen to calibrate feeder flow.

12. Set the TRS8 quick coupler wedge position: Connect to Machine ECM with ET2019A and select service procedures. Select “Tilt rotator Quick Coupler Wedge Lock Position Adjustment” then hit Start. Follow instructions on screen to set the locked position of the quick coupler wedge.
    Show/hide table

    Illustration 12	g06426752
    (1) 577-6925 Work Tool Harness As (4) 577-1570 Connector As

13. Connector assembly (4) is required, only when we want to operate the quick coupler that is mounted directly to the stick above the TRS8 (if equipped). The cap should be connected to the 8-pin connector on the end of work tool harness assembly (1) to operate the stick-mounted quick coupler, as shown in Illustration 12. Otherwise the harness coming out of the tilt rotator head should be connected to the 8-pin connector on the end of work tool harness assembly (1).

For Swing Boom Installation

1. Remove and discard the 577-6924 Work Tool Harness As.
   Show/hide table

   Illustration 13	g06426768
   (1) 577-6925 Work Tool Harness As (4) 577-1570 Connector As (5) 577-1569 Bracket

   Show/hide table

   Illustration 14	g06424605
   (G) 12-pin work tools expansion plug connector (F-C4) (1) 577-6925 Harness

   Show/hide table

   Illustration 15	g06424725
   Electrical diagram

2. Install the bracket (5). Mount the 8-pin connector on work tool harness assembly (1) to the bracket (5). Refer to Illustration 13. Secure with cable straps. Connect the 12-pin receptacle connector on work tool harness assembly (1) labeled work tool expansion to the 12-pin work tools expansion plug connector (F-C4) (G) on the machine harness. Refer to Illustration 14 and Illustration 15.
   Show/hide table

   Illustration 16	g06424686
   (H) FG-C2 boom harness (J) F-C1 boom harness (3) 577-6926 Work Tool Harness As

   Show/hide table

   Illustration 17	g06424693
   Electrical diagram

3. Find the two 12-pin connectors for the boom harness (FG-C2) (H) and (F-C1) (J) on the machine harness near the swivel. Separate these connectors and insert the work tool harness assembly (3) between these connectors. Refer to Illustration 16 and Illustration 17.
   Show/hide table

   Illustration 18	g06424710
   (K) 2-pin plug connector SV2 (FG-C6) (3) 577-6926 Work Tool Harness As

   Show/hide table

   Illustration 19	g06424715
   Electrical diagram

4. Connect the 2-pin receptacle connector on the work tool harness assembly (3) labeled SV2 to the 2-pin plug connector SV2 (FG-C6) (K) on the machine harness near the swivel. Refer to Illustration 18 and Illustration 19.

   Note: If the machine is equipped with a quick coupler valve, the 2-pin plug connector SV2 (FG-C6) (K) will be plugged into a solenoid. It must be disconnected from this solenoid first.

5. Connect the 2-pin connector on the work tool harness assembly (3) labeled SV2 into the solenoid that the 2-pin plug connector SV2 (FG-C6) (K) on the machine harness was previously plugged into (if equipped). Refer to Illustration 18 and Illustration 19.
   Show/hide table

   Illustration 20	g06424735
   (3) 577-6926 Work Tool Harness As

6. Insert the socket pin on work tool harness assembly (3) labeled J2-80 into pin J2-80 of the machine (ECM J2) electrical connector. To insert this pin, the J2 connector must first be removed using a 4mm Allen wrench and the gray J2 connector cap on the reverse side of the connector (facing the machine ECM) must be carefully removed. After fully inserting the socket into J2-80, carefully reinstall the gray connector cap, reassemble to the machine ECM and tighten the J2 connector to the machine ECM using a 4mm Allen wrench. Refer to Illustration 20.
   Show/hide table

   Illustration 21	g06424747
   (L) Connector F-C5 (M) Resistor (CAN B2)

7. Remove the resistor (CAN B2) (M) from the connector (F-C5) (L) on the machine harness on the boom and plug with a blank 3-pin connector. Refer to Illustration 21.
   Show/hide table

   Illustration 22	g06424418
   (6) 570-7211 Joystick Control Gp (LH) (7) 570-7212 Joystick Control Gp (RH)

8. Replace the standard joystick assemblies on the machine with the new joystick control group (6) and joystick control group (7).

   Note: Refer to Disassembly and Assembly , M0095130 for the installation of joystick control groups.

9. Set TRS8 to be install in ET: Connect to Machine ECM with ET2019A and select configurations. Change the tilt rotator system installation status to installed.

   Note: This configuration requires a factory password. Cycle the key off then back on.

10. Calibrate the TRS8 feeder flow: Connect to Machine ECM with ET2019A and select calibrations.  If hydraulic oil is below the required temperature you can warm up the oil with the automatic warm-up within the valve calibrations by selecting “Valve Calibrations” then hit Start, deselect everything except hydraulic warm-up then hit start.  Follow instructions on screen to warm hydraulic oil. When hydraulic oil warm-up is complete, select “Tilt rotator System Calibration” then hit Start. Follow instructions on screen to calibrate feeder flow.

11. Set the TRS8 quick coupler wedge position: Connect to Machine ECM with ET2019A and select service procedures. Select “Tilt rotator Quick Coupler Wedge Lock Position Adjustment” then hit Start. Follow instructions on screen to set the locked position of the quick coupler wedge.
    Show/hide table

    Illustration 23	g06426752
    (1) 577-6925 Work Tool Harness As (4) 577-1570 Connector As

12. Connector assembly (4) is required, only when we want to operate the quick coupler that is mounted directly to the stick above the TRS8 (if equipped). The cap should be connected to the 8-pin connector on the end of work tool harness assembly (1) to operate the stick-mounted quick coupler, as shown in Illustration 23. Otherwise the harness coming out of the tilt rotator head should be connected to the 8-pin connector on the end of work tool harness assembly (1).