Installing The 421-0322 Work Tool Positioner Kit {1408} Caterpillar

Compact Track Loader

249D (S/N: AH91-UP; D9E1-UP; GWR1-UP)

Skid Steer Loader

232D (S/N: EH21-UP; KXC1-UP; DPR1-UP)

Introduction

This Special Instruction provides information that is necessary to install the 421-0322 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, "249D CTL and 232D SSL Machine System""

Required Parts

Illustration 1	g03875711

Illustration 2	g03875734
Harness assembly connector locations (A) LE-C3 (B) LE-C4 (C) LE-C2 (D) LK-C1

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	g03875750
(4) 266-2337 Position Sensor Gp (5) 298-0663 Clip (10) 418-5649 Plate (18) 5C-7261 Nuts (22) 8T-4197 Bolts (25) 8T-4224 Hard Washers

1. Mount the Position Sensor (4) on to the Plate (10) by using five Bolts (22), ten Washers (25) and five Nuts (18). Tighten the Nuts (18) to 15 ± 3 N·m (11 ± 2 lb ft). Mount the Clip (5) on one of the bolt locations shown. Refer to Illustration 3.
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   Illustration 4	g03875769
   (4) 266-2337 Position Sensor Gp (6) 310-6660 Spring Pin (8) 418-5645 Plate (9) 418-5646 Plate (19) 5H-3182 Spring Pin (21) 8C-8451 Bolt (24) 8T-4205 Hard Washer

2. 2. Insert the Plate (8) on the driver of the Sensor gp (4) and fix the orientation by using Spring Pin (19). On the plate (9), insert the washer (24) and bolt (21) into the mounting slot and keep them hand tight. Use the slot on the plate (9) and slide the Spring Pin (6). Refer to Illustration 4

   Note: Be careful how much pressure is applied to the sensor shaft when inserting Pin (19). If the shaft is damaged, it will cause the sensor to malfunction. Use a fixture or a similar apparatus to firmly hold the Sensor gp (4) while pressing the Pin into the place.

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   Illustration 5	g03876154

3. Completed assembly.
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   Illustration 6	g03876145
   (9) 418-5646 Plate (21) 8C-8451 Bolt (23) 8T-4200 Bolt (24) 8T-4205 Hard Washer (25) 8T-4224 Hard Washer (A) N-Pin

4. Mount the already assembled components from Illustration 5to the boss on the frame using three bolts (23) and three washers (25). Tighten the bolts (23) to 30 ± 7 N·m (22 ± 5 lb ft). Mount the plate (9) on Pin (A) and fasten with bolt (21) and washer (24). Tighten the bolt (21) to 12 ± 3 N·m (9 ± 2 lb ft). Refer to Illustration 6.

Installation Procedure of Sensor As. and Corresponding Components

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Illustration 7	g03876170
(13) 441-6585 Bracket As (14) 458-1051 Position Sensor As (20) 7X-2537 Bolt (25) 8T-4224 Hard Washer

1. Mount Sensor Assembly (14) onto the Bracket (13). Use Bolts (20) and washers (25) to secure the sensor.
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   Illustration 8	g03876178
   (13) 441-6585 Bracket As (16) 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 9	g03876188
   View just behind right-hand lift arm (11) 422-5528 Sensor Harness As

3. Feed the LE-C3 connector from the Harness Assembly (11) 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 9
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   Illustration 10	g03876198
   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 (11) 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 (11) 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 11.
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   Illustration 11	g03876210
   (2) 7K-1181 Cable Strap (11) 422-5528 Sensor Harness As (13) 441-6585 Bracket As (14) 458-1051 Position Sensor As

5. Continue to route harness assembly (11) 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 (14) to the LE-C3 connector on harness assembly (11). Secure the connection with one cable strap (2) to the slot on the bracket (13). Ensure that the connection matches the one shown in the table below. Refer to Illustration 11.

   Note: Note the lower portion of harness (11) 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 12	g03876212
   (11) 422-5528 Sensor Harness As

6. Secure harness (11) 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 12.

   Note: The thicker portion of harness assembly (11) should fit in between both sets of clamps as indicated in Illustration 13. 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 13	g03876278
   View on inner side of right-hand lift arm (15) 178-3620 Strap

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

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 14	g03876304
    (2) 7K-1181 Cable Strap (11) 422-5528 Sensor Harness As

11. Continue routing harness (11) down the right tower of the machine by following the tilt line towards the implement valve as shown in Illustration 15. Use three Straps (2) to secure the harness (11) along with the tilt lines.
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    Illustration 15	g03876320
    (7) 344-7391 Pressure Sensor Gp (11) 422-5528 Sensor Harness As (17) 3J-1907 O-Ring Seal (C) 451-0482 Tee As

12. Install O-ring (17) onto Sensor (7). Install Sensor (7) into the lower port of the Tee As. (C), connected on the implement valve as shown in Illustration 15.

13. Connect the LE-C4 connector on harness (11) to sensor (7). Ensure that the configuration matches the one provided in the table below. Refer to Illustration 15.
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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 16	g03876340
    (11) 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 (11) to the C-C25 connector on the cab harness assembly. Secure the connectors to the harness with one cable strap (E). Refer to Illustration 16.

    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 17	g03876342
    (1) 3S-2093 Cable Strap (2) 7K-1181 Cable Strap (4) 266-2337 Position Sensor Gp (12) 422-5581 Sensor Harness As

15. Connect the receptacle adapter on the Sensor(4) with the LK-C2 connector in the Harness As (12). Secure the connecting wires with two straps (1) and one strap (2) . Refer the Illustration 17. Ensure that the connection matches the one 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 18	g03876415
    (1) 3S-2093 Cable Strap (12) 422-5581 Sensor Harness As (J) LK-C1 connector (K) RP-C20 terminal (L) 422-5518 Platform Harness As

16. Connect the terminal (J) of the Harness (9) with the terminal (K) on the Platform Harness As. As shown in Illustration 18.

17. Use three Straps (1) to secure the Harness As. (12) along the inner tower of the machine. Refer to Illustration 18.

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 19	g03875127

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Illustration 20	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 21	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 22	g03875547

3. Reinstall the Switch Cover (A).

Machine Configuration

The 421-0322 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 23	g03875565

2. Start the Cat ET and select the Machine ECM.
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   Illustration 24	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 25	g03875576

5. In the Pop-up window, click "Yes".
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   Illustration 26	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 27	g03875583

11. In the configuration screen, doubleclickon the "Lift Linkage Sensor Configuration" ink.
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    Illustration 28	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 421-0322 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 29	g03875565

2. Start the Cat ET and select the Machine ECM.
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   Illustration 30	g03875573

3. From the menu select "Service", then "Configuration".
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   Illustration 31	g03875601

4. In the configuration screen, doubleclickon the "Return to Dig Feature Installation Status" link.
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   Illustration 32	g03875605

5. 5. In the pop-up window, change the new value field to "Installed". Click "OK".
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   Illustration 33	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 34	g03875565

2. Start the Cat ET and select the Machine ECM.
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   Illustration 35	g03875644

3. From the menu select "Service", then "Calibration".
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   Illustration 36	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.