- 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 |
| 02 | Added prefixes HR6, EH2, T9S, D9E |
The procedures in this Special Instruction are for the installation of the 421-0261 Work Tool Kit. Read and understand the information in this Special Instruction before performing any of the steps listed below.
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"
Important Safety Information
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 and the instructions and the warnings are understood.
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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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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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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. |
Parts List
| Parts List | ||
|---|---|---|
| Qty | Parts No. | Description |
| 2 | Cable Strap | |
| 1 | Cable Strap | |
| 5 | Relay As | |
| 1 | Nut | |
| 1 | Rocker Switch | |
| 1 | Joystick Control Gp | |
| 1 | Plate | |
| 1 | Work Tool Harness As | |
| 1 | Lockwasher | |
| 5 | Strap | |
| 1 | Washer | |
| 1 | Nut | |
| 4 | Bolt | |
Installation Procedure Installing Harness on the Machine
Note: The following steps apply for both Extended Arm Machines and Radial Lift Machines.
- Route harness 422-5526 Work Tool Harness As inside left lift arm. Start from the rear of the machine and feed the harness assembly with the receptacle assembly (3) in first until the receptacle reaches the slot (2) near the end of the lift arm. Refer to illustrations 1 and 2.
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Illustration 3 g03895935 (B) Left Arm Front Work Area Show/hide table
Illustration 4 g03895938 Showing view of work area (B) in illustration 3
(1)422-5526 Work Tool Harness As
(2) Slot
(3)344-6145 Receptacle As
(4)421-0030 Plate
(5) Bolt
(6)159-9496 Lockwasher
(7)159-9495 Nut
(8)156-1458 Cover - Attach provided 421-0030 Plate to coupler assembly from the auxiliary lines on the lift arm in the orientation shown in illustration 4. Secure plate (4) using existing bolts (5) on the coupler assembly cover.
- Insert receptacle (3) through hole in plate (2). Secure receptacle using lock washer (6) and nut (7). Tighten nut to
30 ± 1 N·m (22 ± 1 lb ft) . Install provided cover (8) on receptacle assembly to protect from debris while not in use.
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| Illustration 1 | g03895798 |
| (A) Left Arm Rear Work Area | |
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| Illustration 2 | g03895860 |
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Showing view of work area (A) in illustration 1 Extended arm machine shown in this illustration. Same procedure applies to radial lift machines. (1) | |
Connecting the Harness
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| Illustration 5 | g03895953 |
| (C) Left Arm Side Work Area | |
- Return to rear of machine and locate RL-C19 connector (6) from left platform harness assembly inside left rear tower. Remove cap seal (7) from RL-C19 connector by cutting the cable strap that secures connector to left platform harness assembly and discard cap seal. Refer to Illustrations 5 and 6.
- Connect TC-1 connector (4) from 422-5526 Work Tool Harness As, to RL-C19 Connector on machine (6). Refer to Table 3 for the correct connector configuration.
- Secure wire harness ground terminal (5) from 422-5526 Work Tool Harness As to ground stud (1) located in the left rear tower. Use washer (2) and nut (3) to secure ground terminal (5). Tighten nut to
30 ± 7 N·m (22 ± 5 lb ft) . Secure connection to auxiliary lines using cable strap .Show/hide tableTable 3 422-5526 Harness As. Connection TC-1 to Left Platform Harness As. Connection RL-C19 Position Wire Name Color - Gage 1 A571-T2 PURPLE-14-GXL 2 A572-T8 PINK-16-GXL 3 M906-T3 BLUE-18-GXL 4 M907-T4 GRAY-14-GXL 5 H759-T12 ORANGE-14-GXL 6 H758-T11 BROWN-14-GXL 7 C460-T7 BLUE-16-GXL 8 C481-T5 GREEN-16-GXL Ground 200-T1 BLACK-14-GXL
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| Illustration 6 | g03895956 |
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Showing view of work area (C) in illustration 5 (1) Ground Stud (2) (3) (4) TC-1 connector - Work Tool Kit Harness (5) Wire Harness Ground Terminal (6) RL-C19 Connector - Machine Harness (7) Cap Seal | |
Securing the Work Tool Harness
- Use one 7K-1181 Cable Strap to secure 422-5526 Work Tool Harness As to weld link (2) on the lift arm as shown in Illustration 7.
Note: For Extended Arm Machines, follow step 2 below. For Radial Lift Machines, follow step 3 below.
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Illustration 8 g03896060 Securing Work Tool Harness Assembly on Extended Arm machines (Some hoses and other components removed for clarity)
(3)178-3620 StrapShow/hide table
Illustration 9 g03896072 Securing Work Tool Harness Assembly on Extended Arm machines (Some hoses and other components removed for clarity)
(4)178-3620 Strap - For extended arm machines, use four 178-3620 Straps to secure the harness assembly to the auxiliary lines in the locations shown in illustrations 8 and 9.
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Illustration 10 g03896075 Showing Strapping Work Tool Harness Assembly on Radial Lift machines
(5)178-3620 Strap - Use four 178-3620 Straps to secure 422-5526 Work Tool Harness As to auxiliary lines on the locations shown in illustration 10. Coil and secure any excess of harness assembly inside the left rear tower using one cable strap.
Note: Ensure that there is sufficient slack to allow for free movement at pivot point of the lift arms for both extended arm machines and radial lift machines.
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| Illustration 7 | g03896047 |
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(1) (2) Weld Link | |
Installing the Work Tool Rocker Switch
- Enter cab and locate switch cover, which is part of left instrument panel. Remove switch cover from instrument panel.
Note: Movement of switch cover will be hindered by the connections behind switch. Use caution when removing the switch cover.
- Use thin blade screwdriver in order to release locking tab on sides of the switch cover.
- Remove switch cover from panel.
- The switch cover has provisions for four rocker switches. Remove plug 109-2356 Plug from location on switch cover shown in illustration 12 (Fourth slot from front to rear).
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Table 4 263-5418 Rocker Switch Connection to Instrument Panel Harness As. Connection L-C8 Position Wire Name Color - Gage 1 NA 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 PURPLE-18-GXL 9 N/A N/A 10 N/A N/A Show/hide table
Illustration 13 g03896324 Showing view of work area (D) in illustration 11
(3)263-5418 Rocker Switch
(4) Switch Cover - Carefully pull out the L-C8 connector from the panel harness assembly by pushing the connector from the back of the switch cover. Install 263-5418 Rocker Switch onto the L-C8 connector and push the rocker switch into new opening from the front of the Switch Cover. Push the rocker switch until the locking tabs on the rocker switch are engaged. Refer to illustration 13. Ensure that wire connection corresponds to Table 4.
- Reinstall switch cover into control panel.
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| Illustration 11 | g03896306 |
| (D) Switch Panel Work Area | |
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| Illustration 12 | g03896311 |
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Showing view of work area (D) in illustration 11 (1) (2) Switch Cover | |
Installing the Relays
- Locate the fuse panel in the rear liner of the cab at right-hand side. Remove the cover assembly (1) to expose panel. Refer to illustration 14.
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Illustration 15 g03896338 (2) 146-9439 Relay As
(3) Upper Fuse Block - Install five relays (2) into positions R1 through R5 onto the upper fuse block as shown in illustration 15.
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| Illustration 14 | g03896331 |
| (1) Rear Panel Cover Assembly | |
Installing the Deluxe Left-Hand Joystick
Note: Retain hardware for reuse in the installation of the new Joystick.
- Remove the two screws (1) from the outside pod cover. See illustration 16 for the location of the screws on a mechanical seat and illustration 17 for the location of the screws on an air ride seat.
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Illustration 18 g03896355 View showing Mechanical Seat Show/hide table
Illustration 19 g03896400 View showing Air Ride Seat - Remove four screws (2) from the inside pod cover. See illustration 18 for the location of the screws on a mechanical seat and illustration 19 for the location of the screws on an air ride seat.
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Illustration 20 g03896407 (3) Tab - Remove pod covers from the seat. Use caution when removing the pod covers so that the tabs (3) inside the covers do not break.
Note: Do not use any type of prying tools to remove the covers as tools may damage the covers.
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Illustration 21 g03896412 (4) Boot
(5) Joystick Control Group - (Old Joystick Group)
(6) Bolt - Quantity Four - Carefully remove the boot from the current joystick (4) in the direction shown in illustration 21. Remove the four bolts (6) securing the joystick to the armrest. Remove any straps retaining the connector to the joystick harness, if necessary. Disconnect the harness. Remove old joystick
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Illustration 22 g03896426 (6) Bolt - Quantity Four
(7)460-5345 Joystick Control Gp (New Joystick Group) - Install new joystick control group 460-5345 Joystick Control Gp as shown in illustration 22. Route connectors on joystick through inside of armrest. Connect 12-pin connector (Handle) on the joystick to the CH-C4 connector on the seat deck harness assembly inside the armrest. Refer to Table 5 to confirm the connector configuration.
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Table 5 460-5345 Joystick Control Gp. 12-Pin Connection to Seat Deck Harness As. Connection CH-C4 Position Function Wire Name Color - Gage 1 Plugged N/A N/A 2 SW 1 Common 322-CH6 GRAY-14-GXL 3 SW 1 N/O 114-CH7 RED-14-GXL 4 Plugged N/A N/A 5 SW 1 and SW 2 Common G985-CH10 PURPLE-18-GXL 6 SW 3 N/O 781-CH11 PINK-18-GXL 7 Trigger Common 203-CH20 BLACK-18-GXL 8 SW 4 N/O 782-CH12 GRAY-18-GXL 9 Plugged N/A N/A 10 Trigger N/O P814-CH13 BLUE-18-GXL 11 SW 2 N/O F763-CH14 WHITE-18-GXL 12 SW 2 Common 203-CH15 BLACK-18-GXL - Connect 6-pin connector (Base) on joystick (7) to the CH-C5 connector on the seat deck harness assembly. Refer to Table 6 to confirm the correct connector configuration.
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Table 6 460-5345 Joystick Control Gp. 6-Pin Connection to Seat Deck Harness As. Connection CH-C5 Position Function Wire Name Color - Gage 1 Power 126-CH24 PINK-16-GXL 2 Ground 203-CH25 BLACK-16-GXL 3 Signal - X Axis E847-CH26 GRAY-18-GXL 4 Calibration - S N/A N/A 5 Signal - Y Axis E848-CH27 GREEN -18-GXL 6 Calibration - R N/A N/A - Secure the Connectors by using two 3S-2093 Cable Straps .
- Secure joystick 460-5345 Joystick Control Gp to armrest using four bolts (6). Refer to illustration 22. Tighten bolts to
6 ± 1 N·m (53 ± 9 lb in) . - Replace the boot onto the new joystick.
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Illustration 23 g03865504 - Reinstall pod covers onto the left armrest. Refer to illustration 23.
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| Illustration 16 | g03896328 |
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View showing Mechanical Seat (Some components removed for clarity) (1) Screws | |
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| Illustration 17 | g03896347 |
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View showing Air Ride Seat (Some components removed for clarity) (1) Screws | |
