- Compact Track Loader
- 239D (S/N: CD41-UP; BL91-UP; T9S1-UP)
- 249D (S/N: AH91-UP; D9E1-UP; GWR1-UP)
- Skid Steer Loader
- 226D (S/N: HR61-UP; HRD1-UP)
- 232D (S/N: EH21-UP; KXC1-UP; DPR1-UP)
Introduction
| Revision History | |
|---|---|
| Revision | Summary of Changes |
| 01 | Added prefixes HR6, EH2, T9S, D9E |
The procedures in this Special Instruction are for the installation of 421-0261 Work Tool Kit. Read and understand the information in this Special Instruction before performing any of the steps listed below.
References
Reference: Operation and Maintenance Manual, SEBU9084, "259D, 279D, 289D, 299D, and 299D XHP Compact Track Loaders, 257D, 277D, 287D, 297D, and 297D XHP Multi Terrain Loaders and 236D, 242D, 246D, 262D, 272D, and 272D XHP Skid Steer Loaders"
Reference: Disassembly and Assembly, UENR2332, "299D and 299D XHP Compact Track Loaders and 272D and 272D XHP Skid Steer Loaders Power Train"
Reference: Disassembly and Assembly, UENR2333, "299D and 299D XHP Compact Track Loaders and 272D and 272D XHP Skid Steer Loaders Machine Systems"
Safety
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 must also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, 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 in this publication and the warnings that are on the product are not all inclusive.
Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.
Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
Operation of the 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. Do not perform maintenance until the instructions and the warnings are understood.
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To avoid personal injury, always wear eye and face protection when using pressurized air. |
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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal 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. |
Required Parts
| 421-0261 Work Tool Kit | |||
|---|---|---|---|
| Item | Qty | Part
Number |
Part Name |
| 1 | 1 | Cable Strap | |
| 2 | 5 | Relay As | |
| 3 | 1 | Nut | |
| 4 | 1 | Rocker Switch | |
| 5 | 1 | Plate | |
| 6 | 1 | Work Tool Harness As | |
| 6a | 1 | Receptacle As | |
| 6b | 1 | Cover | |
| 6c | 1 | Connector Receptacle As | |
| 6d | 1 | Terminal As | |
| 7 | 1 | Lockwasher | |
| 8 | 5 | Strap | |
| 9 | 1 | Washer | |
| 10 | 1 | Nut | |
Installation Procedure
Note: The following Steps apply for both Extended Arm machines and Radial Lift machines.
Routing the Harness on the Machines
- Route work tool harness assembly (6) inside the left lift arm. Start from the rear of the machine and feed work tool harness assembly (6) with receptacle (6a) in first. Insert the harness until the receptacle reaches the slot near the end of the lift arm.
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Illustration 2 g03870002 (A) Existing hardware
(3)159-9495 Nut
(5)421-0030 Plate
(6)422-5526 Work Tool Harness As
(6a)344-6145 Receptacle As
(6b)156-1458 Cover
(7)159-9496 Lock washer - Attach plate (5) to the coupler assembly, from the auxiliary lines on the lift arm in the orientation shown.
- Insert receptacle (6a) through the hole in plate (5). Secure using lock washer (7) and nut (3). Tighten nut (3) to a torque between
29 to 31.5 N·m (21 to 23 lb ft) . Install cover (6b) on to receptacle (6a) to protect against debris while not in use.
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| Illustration 1 | g03869938 |
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Showing Extended Arm machine, but same procedure applies to Radial Lift machines (6) | |
Connecting the Harness
- Return to the rear of the machine. Locate connector (B) from the left platform harness assembly inside the left rear tower. Cut the cable strap that secures connector (B) to the left platform harness assembly. Remove the cap seal from connector (B) and discard the cap seal.
- Connect receptacle (6c) on harness assembly (6) to connector (B).
- Secure ground terminal (6d) from harness assembly (6) to the ground stud located in the left rear tower. Use washer (9) and nut (10) to secure ground terminal (6d). Tighten nut (10) to a torque of
30 ± 7 N·m (22 ± 5 lb ft) . Secure the connection to the auxiliary lines using strap (8).
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| Illustration 3 | g03870089 |
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(B) RL-C19 Connector
(6c) (6d) (9) (10) | |
Securing the Work Tool Harness
- Use strap (1) to secure harness assembly (6) to the weld link on the lift arm.
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| Illustration 4 | g03870197 |
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(1) (6) | |
For Extended Arm Machines
- Use four straps (8) to secure harness assembly (6) to the auxiliary lines in the locations shown.
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| Illustration 5 | g03870208 |
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(6) (8) | |
For Radial Lift Machines
- Use three straps (8) to secure harness assembly (6) to the auxiliary lines on the locations shown. Coil and secure any excess of harness assembly (6) inside the left rear tower using one strap (8).
Note: Ensure that there is sufficient slack to allow for free movement at the pivot point of the lift arms for both types of machines.
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| Illustration 6 | g03870217 |
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(6) (8) | |
Installing the Work Tool Rocker Switch
- Enter the cab and locate switch cover (C), which is part of the left instrument panel. Remove the switch cover from the instrument panel.
Note: Movement of the switch cover will be hindered by the connections behind it. Exercise caution when removing the switch cover.
Note: Use a thin blade screwdriver in order to release the locking tab on the sides of the switch cover. Then, withdraw the switch cover from the panel.
- Switch cover (C) has provisions for four rocker switches. Remove plug (D) from the location on the switch cover.
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Illustration 8 g03876232 (C) Switch cover
(4)263-5418 Rocker Switch - Carefully pull out the L-C8 Connector from the panel harness assembly by pushing the connector from the back of switch cover (C). Install rocker switch (4) onto the L-C8 Connector and push the rocker switch into the new opening from the front of switch cover (C). Push the rocker switch until the locking tabs on the rocker switch are engaged. Ensure that the connection corresponds to the one in the following Table.
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Table 3 263-5418 Rocker Switch Connection to Instrument Panel Harness Assembly Connection L-C8 Position Wire Name Color - Gage 1 N/A N/A 2 190-L108 PINK-14-GXL 3 A572-L119 PINK-14-GXL 4 N/A N/A 5 N/A N/A 6 N/A N/A 7 200-L91 BLACK-18-GXL 8 614-L114 9 N/A N/A 10 N/A N/A - Reinstall switch cover (C) into the control panel.
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| Illustration 7 | g03876117 |
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View of left instrument panel (C) Switch cover (D) Plug | |
Installing the Relays
- Locate the fuse panel in the rear liner of the cab at the right-hand side. Remove cover assembly (E) to expose the panel.
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Illustration 10 g03876327 (F) Upper fuse block
(2)146-9439 Relay As - Install the five relays (2) into positions "R1" through "R5" onto the upper fuse block.
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| Illustration 9 | g03876316 |
| (E) Cover assembly | |
