2021/03/04 Installation Procedure for the Position Sensor Kit (Gate Position) on Certain 3500 Engines {1087, 1439} (M0088137) ‘SMCS - 1087,1439 josso1644 Engine 35088 (SIN: $2A123-198; $28254-857; $20268-269; S2E551-824; 3DM511-543; 30W189-191) 35128 (SIN: ED21-126; ED31-124; NSC1-27; ESD1-101; $2G111.426; S2H195-711; $2/298-765; $2K303-372; $2L702-968; S2M151-198; BEMS54-561; S2N120-121; 1PW447-455) 3512C (SIN: ED41; TTC431-432; ELG1-101; MKH224.292; MXN208-216)MXP213-236; E3Y201-454; T3Y1) 35168 (SIN: EDH1-101; CBN381-498; 9AN397-411; S2P108.265; S2R187-865; S2S227-475; S2T111; S2W106-150; 2FW391-423; S2X364- 1873; $2Y109-116; $22106-440) 3516C (SIN: PAG198-429; TTH783-890; TTJ266-361; EDK1-106; JTS116-561; MXT212-216; TTY102-115) Petroleum Engine 3512C PETROLEUM (SIN: LLB1-164) 3516C PETROLEUM (SIN: PES1-1312) Introduction This special instruction contains the procedure to install the position sensar kt (gate position). Do not perform any procedure inthis Special Instruction unt you have read the information and you understand the information Safety Section Work safely. Most accidents that involve produét operation, maintenance, and repair are caused by fallure to observe basic safety rules or precautions. An accident can often be avoided by recognizing poteiially hazardous situations before an accident occurs. A person must be alert to potential hazards, This person must also Rave the necessary training! skis, and fools to perform these functions properly Safety precautions and warnings are provided in this instruction and en the:product. If these hazard wamings are notfhegted, 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 inthis publication and the wamings that are on the product are not all inclusive, Avoid using a tool, a procedure, a work ‘method, or operating technique that isnot recommended by Caterpillar. If used, ensure the safety ofthe operating personnel and others. Eneure that the product wil not be damaged or the product wll be made unsafe by the operation, lubriaiion, maintenance, or the repair procedures. Operation ofthe machine and the maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and the instructions and the wamings are understood 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. ‘Accidental engine starting can cause injury or death to Personnel working on the equipment. ‘To avold accidental engine starting and to bring the equipment to a zero energy state, disconnect all positive (+) and negative (-) battery cables. install an appropriate battery cable lockout device and protect the battery posts to prevent accidental contact and shorting. Place a Do Not Operate tag at the StartiStop switch location to inform personnel that the equipment is being worked on.Do not operato 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 hheed the warnings could result in injury or death. Contact your ‘Cat dealer for replacement manuals. Proper care is your responsibilty. Required Parts Required Part List tem |Qty [Part Number | Description 1 | 2 | 261-6824 Pug 2 | 1 | 518-6000 Bracket 3 | 1 | 518-6008 Bracket 4 | 4 | oTosrs Bolt 3 | 4 | 1984766 | Hard Washer 6 | 1 | 5186002" Target 7 | 4 | evotes ‘Setscrew @ | 2 | 526-0318 | Position Sensor Gp 2 | 1 | ste6001 Target Table 1 o, (2The 518-6002 Targets used forthe left-hand aiuto The S18:001 Targets used forthe righthand a shutoff Rework Procedure Perform the folowing rework procedures 1 intall new positon sensor group. 1. Use emergency stop button, or supply 24V DC power té the solenoid t close air shutoft Iustaton + osasres7 (asian 2, Remove switch (A) from Alr Shut-Off (ASO) and unplug from engine.stration 2 900459175 (ey Bats 3, Remove four bolts (8) from the engine. Imustraton 3 ps2sre60 (7) 261-8624 Pig 4, Install plug (1) on left and right side of engineIustraton 4 psasress (2) 516.6000 Sracket (3) 816-0008 Bracket (a) 070673 Bot (5) 10641766 Hard Washer 6. Install bracket (2) using two bolts (4) and two hard washers (5) on left side of engine. 6. Install bracket (3) using two bolts (4) and two hard washers (6) on right side of engine. Imustraton § ooeasteer Lehand ar shutoff (@)st68002 Target 7. Clean paintiburs from reset hex, so that the target slide easily nto reet hex. 8. Install target (6) and orient target, so that the indent on battom aligns with rallpin/arrow on the reset hex. Iustaton 6 05257668 Latnand ar shutoff (@)stes0oe Target (hevetes setscew 9. Apply adhesive to inside of target (6), and the shaft ofthe reset hex. Install target onto reset hex, so thatthe faces are flush, Install two set screws (7) on to target.Iustaton 7 sosasrres Lana a shat (6)52640318 Poston Sensor Gp 10. Install position sensor group (8) onto bracket as indicated. The serrations in the jam nuts should face the bracket. Iustration 8 00257745 (0)42 2mm (018 20091n=) 11, Set clearance between target afd sensor to 4 min (0.16 ii). Tighten jam huts fo 30N-m (266 ib in). 12, Tighten set screws on target. Verify that lBarance is stil 4 + 21mm (0.16 x 0.09 inch, 13, Repeat installation procedure for target and sensor on Fight side of engine: Wiring Rework Required Part List tem | Qty [Part Number Description 1 [4 | s46-680 Heat Insulation 2 | 4 | 108-9656 Cable Strap 3 | 6 | 126-4768 | Connector Socket 4 | 2 | 297-5488 | Connector Plug As 5 | 2 | a-ao7s Ring Terminal @ | - | 68.3961 | Electrical Wire (1 dm) 7_| = | 9x:2506 _ | Heat Shrink Tube (10 om) 8 | 4 | 283.0056 | Connector Adapter Table 2 1. Perform the following procedures to install wiring onto sensor group,Imustation 9 05257716 (¢) 346180 Heat nsutaton (2) 106-9656 Cable Sop 2 Install three inch heat shield tube (1) and slide over connector on sensor pgtal 3, Secure to kickstand bracket with cable strap (2). 4, Clearly mark which wire went to pins one and two on the current connector and cut the wires to remove connector. Istaon 10 06257675 (a) Heat Shvnk 5, Remove heat shrink (A) from engin¢ side connector and slide new 6V-2724 Heat Shrink Tube over wires and convolute Note: Convolute wil need to be trimmed back fo accommodate shortef wires, and new connector. Istraton 1 06257718 (6) 126-1768 Comector Socket 6. Using appropriate tool for crimping the deutsch terminals. Crimp socket connector (3) to both wires.stration 12 0627722 (4) 207.5484 Comector Pig As 7. Wire from pin one on old connector goes to pin one on new connector (4). 8. Wire from pin two on old connector goes to pin three on new connector (4). station 13 00287728 (5) 2807S Ring Terminal (6) 64-396 Elecal Wire 9. Crimp terminal (5) to supplied length of wire (6) Iustaton 14 06257681 (BY connect 10, Remove three clips from the "Y" connector (B) on the engine harness.Mustain 15 06257725 (7) 9.2506 Heat Srink Tue 11. Remove existing heat shrink from solenoid power wiring 12, Mark and remove both wires from solenoid and remove wire covers, Side new tube (7) over wires and convolute station 16 90257790 13, Reinstall wre covers, positive wire, and nut. Install loose wife and Terminal wth the negative Wire for solenoid, Thread free end through cover. stration 17 06287087 14, Thread free end of supplied wire through convolute as ici¢ated direction.stration 18 0627088 (8) comecte 15, Seat convolute in “Y" connector (8) and reinstall clips to secure. ° ip rT station 19 90257750 16. Use appropriate too for crimping deutsch terminals. Trim witg ta length and crimp on socket-connector (3) Insert pin 2 to new connector (4) engine harness, Imustaton 20 00257954 (6) 285.0055 Connector Adopter 117, Breakout plastic piece from one piece of adapter. connector (8)Imustraton 21 06257601 Iustraton 22 osasre02 18. Align opening withthe release tab on hamess connector. Snap the two cover pieces together around connector. Cover will not ft over Convolute, trim as necessary. Imustraton 23 05257780 19, Align heat shrink as indicated and apply heat o shrink tightly around conwvolute and wires.stration 24 os2sre9t 20. Plug connector into proximity sensor pictall Note: Re-secure any clipping that was removed, Repeat wiring rework on opposite side of engine, Imustaton 25 os2srer 21, Vetiy the operation of the sensor by the status ight onthe rear of sensor, 22. Light on, gate closure has not been detectedigate open. Iustaton 28 95257608 23, Light off, gate closure has been detectedigate closed, PIp-11185859 2o2tion9 06:24:31+10:00 lor204144 © 2021 Caterpillar Ino.Caterptiar: Confidential Green