Field Installation of the Caterpillar Cushion Swing System{5057, 5105} Caterpillar

Backhoe Loader:

416D (S/N: BFP1-UP)

420D (S/N: BLN1-UP; FDP1-UP)

430D (S/N: BNK1-UP; BML1-UP)

Introduction

This special instruction outlines the basic procedures in order to install a 202-6126 Cushion Swing Conversion Ar (Kit). The 202-6126 Cushion Swing Conversion Ar (Kit) can be installed on machines that are equipped with an anti-drift valve or machines that are not equipped with the anti-drift valve. The Caterpillar Cushion Swing System (CCSS) provides a precise operation of the swing system on the Backhoe Loader. The system improves the ability of the operator to return the backhoe boom to the desired position. The Caterpillar Cushion Swing System (CCSS) reduces the shock loads that are created with the operation of the swing cylinders.

Do not perform any of the procedures until you have read the information in this publication.

Required Parts

The following tables will describe the parts that are required in order to install the 202-6126 Cushion Swing Conversion Ar (Kit). Some parts are not serviceable.

Note: Machines that are equipped with the anti-drift valve and machines that are not equipped with the anti-drift valve will require different parts. Parts for both types of backhoe valves are included with the kit. Discard any parts that are not required on your machine. Table 1 and Table 2 identify the parts that are required for each type of backhoe valve.

Preparing the Machine for the Installation of the Caterpillar Cushion Swing System

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Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component. Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

1. Check the machine in order to determine if the machine is equipped with the Caterpillar Cushion Swing System.

2. Check the machine in order to determine the type of backhoe valve that is installed on your machine. Refer to ""Installing the Caterpillar Cushion Swing System on Machines That Are Equipped with the Anti-Drift Valve" " for machines that are equipped with the anti-drift valve. Refer to Table 8 for serial number effectivity. Refer to ""Installing the Caterpillar Cushion Swing System on Machines That Are Not Equipped with the Anti-Drift Valve" " for machines that are not equipped with the anti-drift valve. Refer to Table 9 for serial number effectivity.
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   Table 8

   Serial Number Effectivity for Machines That Are Equipped with the Anti-Drift Valve
   Model	Serial Number Effectivity
   420D	(S/N: FDP7199-UP; BLN4544-UP)
   430D	(S/N: BNK2502-UP; BML2281-UP)

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   Table 9

   Serial Number Effectivity for Machines That Are Not Equipped with the Anti-Drift Valve
   Model	Serial Number Effectivity
   416D	(S/N: BFP1-UP)
   420D	(S/N: FDP1-7198; BLN1-4543)
   430D	(S/N: BNK1-2501; BML1-2280)

3. Check the mounting location of the 206-3685 Crossover Relief Valve Assembly in order to determine if the 8T-3612 Weld Nuts (8) are installed on your machine. Refer to ""Installing the 8T-3612 Weld Nuts " " for instructions on installing weld nuts (8) .

   Note: The weld nuts (8) must be installed in order to install relief valve (5) .

4. Prepare the Backhoe Loader for servicing. Refer to the machine's Service Manual for all safety and operation instructions.

   Note: The boom swing lock pin should be installed before any hoses are removed from the hydraulic circuit for the swing cylinder.

Installation Procedures

Installing the 8T-3612 Weld Nuts

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Illustration 1	g00928830
(J) 36 mm (1.4 inch) (K) 70 mm (2.8 inch) (L) 156 mm (6.1 inch) (M) 94 mm (3.7 inch)

1. Drill two 11.5 mm (0.453 inch) holes in the frame in order to install two 8T-3612 Weld Nuts (8). Refer to Illustration 1 for the correct location of the holes.

2. Weld two 8T-3612 Weld Nuts (8) onto the frame.

Installing the Caterpillar Cushion Swing System on Machines That Are Equipped with the Anti-Drift Valve

Note: Use standard torque on all parts that are installed during the installation process.

1. Remove the plastic plugs that are installed in the 206-3685 Crossover Relief Valve Assembly (5). Clean the ports in order to remove any contamination.

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Illustration 2	g00933805

2. Install two 226-5634 Connectors (3) into relief valve (5). Install one 148-8351 Elbow Gp (4) onto connector (3) .

3. Install relief valve (5) onto the inside of the left side frame near the left hand swing assembly. Secure relief valve (5) to the machine with the 8T-6870 Bolts (2) and 8T-4224 Hard Washers (1) .

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Illustration 3	g00928839

4. Remove the 6V-9828 Cap As from the 214-4252 Tee that is connected to Port (A) of the backhoe valve. Remove the 6V-9828 Cap As from the 214-4254 Tee that is connected to Port (B) of the backhoe valve.

5. Connect the straight end of the 208-3600 Hose As (6) onto the 214-4254 Tee that is connected to Port (B) of the backhoe valve. Connect the other end of hose (6) to fitting (3) that is installed into relief valve (5) .

6. Connect the straight end of the 208-3601 Hose As (7) onto elbow (4) that is installed onto connector (3) on relief valve (5) .

7. Connect the other end of hose (7) onto the 214-4252 Tee that is connected to Port (A) of the backhoe valve.

8. Correctly position the hose assemblies. The hose assemblies should not rub other components.

Installing the Caterpillar Cushion Swing System on Machines That Are Not Equipped with the Anti-Drift Valve

Note: Use standard torque on all parts that are installed during the installation process.

1. Remove the plastic plugs that are installed in the 206-3685 Crossover Relief Valve Assembly (5). Clean the ports in order to remove any contamination.

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Illustration 4	g00933944

2. Install two 226-5634 Connectors (3) into relief valve (5) .

3. Install two 148-8351 Elbows (4) onto connectors (3) .

4. Install relief valve (5) onto the inside of the left side frame near the left hand swing assembly. Secure relief valve (5) to the machine with the 8T-6870 Bolts (2) and 8T-4224 Hard Washers (1) .

5. Disconnect the swing cylinder hoses at the Port (A) and Port (B) on the backhoe valve.

6. Remove the 148-8364 Elbow Gp that is attached to the 148-8340 Connector Gp . Remove the 148-8340 Connector Gp that is installed into Port (A) on the backhoe valve.

7. Remove the 148-8370 Elbow Gp that is attached to the 148-8340 Connector Gp . Remove the 148-8340 Connector Gp that is installed into Port (B) on the backhoe valve.

8. Install the 148-8428 Tee (9) into Port (A) .

9. Install the 164-8908 Connector Gp (10) into Port (B). Attach the 214-4253 Tee (11) to connector (10) .

10. Connect the swing cylinder hoses to tee fittings (9) and (11) .

11. Attach the angled fitting of the 208-3600 Hose As (6) to tee fitting (9). Connect the other end of hose (6) to elbow (4) that is installed on relief valve (5) .

12. Attach the angled fitting of the 217-1387 Hose As (12) to tee fitting (11). Connect the other end of hose (12) to elbow (4) that is installed on relief valve (5) .

13. Correctly position the hose assemblies. The hose assemblies should not rub other components.

Test Procedures

The following tests should be performed after the installation of the Caterpillar Cushion Swing System. The hydraulic oil temperature should be at a minimum of 40 °C (104 °F) at the tank.

Leakage Test

1. Install the boom swing lock pin. Set the machine on low idle.

2. Raise the boom. Secure the boom with the boom lock.

3. Extend the stick cylinder in order to get the machine in the roading position.

4. Pressurize the swing cylinders by stalling the swing circuit against the boom swing lock pin.

5. Ensure that there is no leakage from the components that were installed on the machine.

Purging the Air from the Hydraulic Circuit

This test will ensure that oil is circulated into the CCSS valve (5) .

6. Raise the rear of the machine with the stabilizers. Raise the front of the machine with the front bucket.

7. Completely retract the stick cylinder. Completely extend the rear bucket cylinder.

8. Lower the boom until the rear bucket is approximately 0.3 m (1 ft) from the ground.

9. Increase the engine speed to 2200 rpm.

10. Operate the swing cylinders. Maneuver the backhoe to the far left position. Maneuver the backhoe to the far right position.

    Note: Avoid coming into contact with the machine frame with the swing casting.

Performance Test

11. Park the machine on a level surface.

12. Swing the backhoe to the far left position. Swing the backhoe to the machine centerline and release the backhoe control lever. The backhoe should come to a rest within six seconds of releasing the backhoe control lever.

13. Repeat Step 12 swinging the backhoe from the far right position.

Load Test

14. Raise the machine to a ten degree incline with the left side stabilizer.

15. Swing the backhoe to the far left position.

16. Swing the backhoe toward the center of the machine and release the backhoe control lever. The backhoe should come to a rest in a maximum of fifteen seconds.

17. Raise the machine to a ten degree incline with the right side stabilizer. Repeat Step 14 through Step 16.

Note: If the ""Load Test" " fails, perform the ""Purging the Air from the Hydraulic Circuit" " at a minimum of five times in order to purge the air from the hydraulic system. Perform the ""Load Test" " again. If the machine fails, replace the 206-3685 Crossover Relief Valve Assembly .