Installing The 421-0122 Work Tool Positioner Kit {1408} Caterpillar

Compact Track Loader

239D (S/N: CD41-UP; BL91-UP; T9S1-UP)

Skid Steer Loader

226D (S/N: HR61-UP; HRD1-UP)

Introduction

This Special Instruction provides information that is necessary to install the 421-0122 Work Tool Positioner Kit on the listed machines. Do not begin installation of this kit until you have read and understand the instructions that are 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.

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.

Reference Material

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

Reference: Disassembly and Assembly, UENR4245, "239D CTL and 226D SLL Machine System""

Required Parts

Illustration 1	g03873036

Illustration 2	g03873101
Harness assembly connector locations (A) LE-C2 (B) LE-C4 (C) LK-C2 (D) LK-C1 (E) LE-C3

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 in order 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.

Assembling the 266-2337 Position Sensor Gp

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Illustration 3	g03873192
(5) 421-0128 Bracket As (7) 421-0195 Link (16) 5C-7261 Nut (21) 8T-4224 Hard Washer

1. Insert either end of the Link (7) onto the shorter bend side of Bracket As. (5) and secure using one Washer (21) and one Nut (16). Tighten Nut (16) to 15 ± 3 N·m (11 ± 2.2 lb ft).
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   Illustration 4	g03873249
   (3) 266-2337 Position Sensor Gp (5) 421-0128 Bracket As (18) 5H-3182 Spring Pin

2. Insert the other end of the Bracket As. (5) onto the shaft on the Sensor (3) with the flat side of the shaft facing down, as shown in Illustration 4. Insert Spring Pin (18) into the driver on the Bracket As. (5) and install into the Sensor (3).

   Note: Be careful how much pressure is applied to the sensor shaft when inserting Pin (18). Damage to the shaft will cause the sensor to malfunction. Use a fixture or a similar apparatus to hold the Bracket As. (5) while pressing the Pin (18) into the place.

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   Illustration 5	g03873306
   (6) 421-0129 Bracket (7) 421-0195 Link (16) 5C-7261 Nut (21) 8T-4224 Hard Washer

3. Insert the Bracket (6) to the free end of the Link (7). Orient the flange on the bracket as shown in Illustration 5. Secure bracket using one Washer (21) and one Nut (16). Tighten Nut (16) to 15 ± 3 N·m (11 ± 2.2 lb ft).

Installation Procedure

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Illustration 6	g03873339
(10) 441-6585 Bracket As (11) 458-1051 Position Sensor As (19) 7X-2537 Bolt (21) 8T-4224 Hard Washer

1. Mount Sensor Assembly (11) onto the Bracket (10). Use Bolts (19) and washers (21) to secure the sensor.
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   Illustration 7	g03873708
   (10) 441-6585 Bracket As (14) 266-3316 Bolt

2. Use Bolts (14) to secure the bracket and sensor assembly to the right side of the coupler assembly. Torque the bolts to 40 ± 4 N·m (29.5 ± 3 lb ft).
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   Illustration 8	g03873812
   View just behind right-hand lift arm (8) 422-5528 Sensor Harness As

3. Feed the LE-C3 connector from the Harness Assembly (8) through the right-hand lift arm from the rear of the machine so that the harness assembly can be pulled down much easier by gravity. Route the harness along the Tilt Cylinder Lines Gp as shown in Illustration 8
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   Illustration 9	g03873880
   I: View of right-hand lift arm, cover to be removed. II: Underside view of right-hand lift arm, routing harness. (A) Screws (B) Bolt (8) 422-5528 Sensor Harness As

4. Remove the cover from the right-hand lift arm by removing the screws and bolts on the top and on the side of the cover, respectively. Set aside for reinstallation. Pull the end of harness assembly (8) from underneath the right-hand lift arm. Continue to route the harness towards the slot on the cross plate that joins the lift arms in front of the machine. Refer to Illustration 9.
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   Illustration 10	g03873915
   (1) 7K-1181 Cable Strap (8) 422-5528 Sensor Harness As (10) 441-6585 Bracket As (11) 458-1051 Position Sensor As

5. Continue to route harness assembly (8) from the hole behind the plate that joins the lift arms. Then pull the harness towards the previously installed sensor assembly. Connect the sensor assembly (11) to the LE-C3 connector on harness assembly (8). Secure the connection with one cable strap (1) to the slot on the bracket (10). Ensure that the connection matches the one shown in the table below. Refer to Illustration 10.

   Note: Note the lower portion of harness (8) is thicker.

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   Table 4

   422-5528 Sensor Harness As Connector LE-C3 to Inclinometer Connector
   Position	Wire Name	Color - Gauge
   1	P769-LE3	YL-16-GXL
   2	P770-LE5	WH-16-GXL
   3	A426-LE10	BU-16-GXL

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   Illustration 11	g03873945
   (8) 422-5528 Sensor Harness As

6. Secure harness (8) onto the coupler by removing the existing bolt, plate, and the clamp on top of the coupler. Route harness (8) through the empty slot on the clamp closest to the right side of the machine. Reinstall the clamp, plate and bolt. Repeat this process for the second clamp located behind the Cross Plate that joins the lift arms. Refer to Illustration 11.

   Note: The thicker portion of harness assembly (8) should fit in between both sets of clamps as indicated in Illustration 11. The thinner portion should be routed towards the inside of the lift arms. This step ensures that the proper amount of slack is created to accommodate the rotation of the bucket and/or work tool.

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   Illustration 12	g03874004
   View on inner side of right-hand lift arm (13) 178-3620 Strap

7. Use six Straps (13) to secure the harness to the Tilt Lines on the locations shown in Illustration 12.

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

9. Lift the cab and secure. Refer to the Operation and Maintenance Manual for your machine. See Section "Reference Material" for more details.

10. Release the system pressure before continuing the installation. Refer to Testing and Adjusting manual for your machine. Refer to "Hydraulic system pressure-Release" for the proper procedure.
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    Illustration 13	g03874054
    (1) 7K-1181 Cable Strap (8) 422-5528 Sensor Harness As (13) 178-3620 Strap

11. Continue routing harness (8) down the right tower of the machine by following the tilt line towards the implement valve as shown in Illustration 13. Use one Strap (13) to secure the LE-C1 connector to harness (8).
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    Illustration 14	g03874300
    (4) 344-7391 Pressure Sensor Gp (8) 422-5528 Sensor Harness As (15) 3J-1907 O-Ring Seal (C) 451-0482 Tee As

12. Install O-ring (15) onto Sensor (4). Install Sensor (4) into the lower port of the Tee As. (C), connected on the implement valve as shown in Illustration 14.

13. Connect the LE-C4 connector on harness (8) to sensor (4). Ensure that the configuration matches the one provided in the table below. Refer to Illustration 14.
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    Table 5

    422-5528 Sensor Harness As Connector LE-C4 to Pressure Sensor Connector
    Position	Wire Name	Color - Gauge
    1	P769-LE12	YL-16-GXL
    2	P770-LE11	WH-16-GXL
    3	E416-LE7	PU-16-GXL

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    Illustration 15	g03874347
    (8) 422-5528 Sensor Harness As (D) 7K-1181 Cable Strap (E) 3S-2093 Cable Strap (F) LE-C2 connector (G) C-C25 connector (H) Seal cap

14. Remove the seal cap (not shown) from the C-C25 connector on the cab harness assembly and discard. Connect the LE-C2 connector on harness (8) to the C-C25 connector on the cab harness assembly. Secure the connectors to the harness with one cable strap (E). Refer to Illustration 15.

    Ensure that the configuration of the C-C25 connector matches the configuration that is provided in the table below.

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    Table 6

    422-5528 Sensor Harness As Connector LE-C2 to Cab Harness Assembly Connector C-C25
    Position	Wire Name	Color - Gauge
    1	P769-LE1	YL-16-GXL
    2	P770-LE4	WH-16-GXL
    3	A426-LE10	BU-16-GXL
    4	E416-LE7	PU-16-GXL

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    Illustration 16	g03874396
    (3) 266-2337 Position Sensor Gp (12) 458-3766 Bolt

15. Install the Position Sensor (3) as shown in Illustration 16. Use bolt (12) to secure sensor (3).

    Note: Position Sensor (3) is not pre-assembled. Assemble sensor (3) as per steps indicated in these instructions before.

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    Illustration 17	g03874485
    (6) 421-0129 Bracket (17) 5C-9553 Bolt (20) 8T-4205 Hard Washer

16. Place the Bracket (6) (Part of Mounting and Sensor Gp) on top of the lift arm on the location shown in Illustration 17. Use bolts (17) and Washers (20) to mount the bracket. Torque the bolts to 40 ± 4 N·m (29.5 ± 3 lb ft).
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    Illustration 18	g03874510
    (3) 266-2337 Position Sensor Gp (9) 422-5581 Sensor Harness As

17. Connect the terminal of the Position Sensor (3) to the LK-C1 connector on the harness (9). Ensure that the connection matches the one indicated in the table below.
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    Table 7

    422-5581 Sensor Harness As Connector LK-C1 to Mounting and Sensor Connector
    Position	Wire Name	Color - Gauge
    A	117-LK1	YL-18-GXL
    B	200-LK2	BK-18-GXL
    C	C530-LK3	YL-18-GXL

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    Illustration 19	g03874932
    (9) 422-5581 Sensor Harness As (J) LK-C1 connector (K) RP-C20 terminal (L) 422-5518 Platform Harness As

18. Connect the terminal (J) of the Harness As (9) with the terminal (K) on the Harness As (L) as shown in Illustration 19.

Installing Self Level Switch

Lower the cab. Refer to the proper Disassembly and Assembly manual for your machine. See section "Reference Material" for more details.

Illustration 20	g03875127

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Illustration 21	g03875198
(A) 345-6007 Switch Cover (B) 345-6026 Console As

1. Locate switch cover (A) which is part of Console (B). Remove switch cover (E) from the control panel.
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   Illustration 22	g03875523
   (C) Rocker switch location (2) 263-5417 Rocker Switch

2. Remove the 109-2356 Plug from location (C) in the switch cover.

   Install, Rocker Switch (2) in the switch cover at location (C).

   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.

   Locate harness connector L-C10 on the 378-1026 Panel Harness As that is behind 345-6026 Console As. Connect the harness connector to the rocker switch.

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   Table 8

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

   Note: Ensure that the configuration of the harness connector matches the configuration that is provided in Table 8.

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   Illustration 23	g03875547

3. Reinstall the Switch Cover (A).

Machine Configuration

The 421-0122 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 ^® Electronic Technician (Cat ET) Service Tool to the machine. Turn the start key to the ON position. Do not start the engine.
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   Illustration 24	g03875565

2. Start the Cat ET and select the Machine ECM.
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   Illustration 25	g03875573

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

4. In the configuration screen, doubleclickon the "Work Tool Self Level System Installation Status" link.
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   Illustration 26	g03875576

5. In the Pop-up window, click "Yes".
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   Illustration 27	g03875578

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

7. Enter the required information.

8. Obtain the passwords and enter 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. 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 28	g03875583

11. In the configuration screen, doubleclickon the "Lift Linkage Sensor Configuration" ink.
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    Illustration 29	g03875589

12. In the Pop-up window, select "Rotary Position Sensor" and click "Yes".

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

RTD (Return to Dig) Machine Configuration (Optional)

The 421-0122 Work Tool Positioner Kit can also be configured for the RTD (Return to Dig) feature by using Cat^® Electronic Technician (Cat ET) Service Tool. This feature consists of two additional modes. "Work Tool Positioner Mode" enables the work tool to return automatically to an operator selectable preset angle. "Return to Dig" enables the work tool to return automatically to an operator selectable preset angle and automatically lowers the lift arms to the stops. Refer to the Operation and Maintenance Manual for your machine for more information on using these modes.

1. Connect the Cat ^® Electronic Technician (Cat ET) Service Tool to the machine. Turn the start key to the ON position. Do not start the engine.
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   Illustration 30	g03875565

2. Start the Cat ET and select the Machine ECM.
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   Illustration 31	g03875573

3. From the menu select "Service", then "Configuration".
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   Illustration 32	g03875601

4. In the configuration screen, doubleclickon the "Return to Dig Feature Installation Status" link.
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   Illustration 33	g03875605

5. 5. In the pop-up window, change the new value field to "Installed". Click "OK".
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   Illustration 34	g03875578

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

7. Enter the required information.

8. Obtain the passwords and enter 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 ^® Electronic Technician (Cat ET) Service Tool to the machine. Turn the start key to the ON position. Do not start the engine.
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   Illustration 35	g03875565

2. Start the Cat ET and select the Machine ECM.
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   Illustration 36	g03875644

3. From the menu select "Service", then "Calibration".
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   Illustration 37	g03875646

4. 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.