Field Installation of the 239-1117 Backhoe Auxiliary Lines (KIT) (EXTENDABLE STICK){5057} Caterpillar

Backhoe Loader:

416D (S/N: BFP1-UP)

Introduction

This Special Instruction outlines the basic procedures that are required in order to install the auxiliary lines onto a 416D Backhoe Loader that is equipped with an extendable stick assembly.

The auxiliary lines are capable of powering work tools that require one-way flow or two-way flow. Work tools that require one-way flow include hammers and compactors. Work tools that require two-way flow include thumbs and augers.

The information in this article should be read and understood before you proceed with any modifications. Also, refer to the appropriate Service Manual for your machine.

Required Parts

The following parts are required in order to install the auxiliary lines onto a 416D Backhoe Loader that is equipped with an extendable stick.

Preparing the Machine for Servicing

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Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted. When possible, the bucket or attachment must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket or attachment have correct support. The swing lock (if equipped) must be engaged before service is started. 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. Prepare the Backhoe Loader for servicing. Refer to the machine's Service Manual for all safety and operation instructions.

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Illustration 1	g00287246

2. Position the Backhoe Loader in the servicing positions. Refer to Illustration 1.

Installation Procedures

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: Various hydraulic hoses that are attached to the backhoe valve may need to be routed differently in order to install the auxiliary lines.

Removing the Existing Hardware

1. Remove the existing hardware that is securing the hydraulic hoses onto the swing casting. The 191-4852 Block will be replaced with the 238-9569 Block (40). The 193-6353 Block will be replaced with the 238-9570 Block (41). The 193-6352 Block will be replaced with the 238-9571 Block (42). The existing nuts will be replaced with the 6V-9189 Locknuts (6). The remaining parts will be required in order to secure the hydraulic hoses onto the swing casting.

2. Remove the metal plates and rubber blocks that are securing the hydraulic hoses onto the boom assembly. The 172-2363 Blocks will be replaced with the 238-9565 Blocks (38). The 201-1034 Blocks will be replaced with the 238-9573 Blocks (44). The 201-1035 Blocks will be replaced with the 238-9572 Blocks (43). The 8T-4136 Bolts will be replaced with the 8T-4195 Bolts (20). The existing washers will be replaced with the 8T-4121 Hard Washers (15) .

3. Remove the bolts and washers that are securing the bracket onto the frame assembly. The 8T-4136 Bolts will be replaced with the 8T-4195 Bolts (20). The washers will be replaced with the 8T-4121 Hard Washers (15) .

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Illustration 2	g01117930
180-8594 Bank Valve (Six) (A) Supply Port (B) Return Port

4. Remove the plugs that are installed in the supply port (A) and the return port (B) of the backhoe valve.

Installing the Hydraulic Hoses

Illustration 3	g01118501
Left side of backhoe

Illustration 4	g01118504
238-9567 Bracket (39) and hardware

Illustration 5	g01118205
235-5729 Valve As (36) in the two-way flow position

Illustration 6	g01135788
235-5729 Valve As (36) in the position for one-way flow

5. Install the 148-8327 Connector (27) into port (A) of the backhoe valve.

6. Install one 3D-2824 O-Ring Seal (2) onto the 7I-8310 Coupling As (10). Install the 7I-8310 Coupling As (10) into port (B) of the backhoe valve.

7. Attach the 172-2252 Hose As (32) to the 148-8327 Connector (27) .

8. Attach port (D) of the 235-5729 Valve As (36) to the 235-5730 Hose As (37) .

9. Attach one 148-8335 Connector (28) to port (E) of the 235-5729 Valve As (36) .

10. Attach port (C) of the 235-5729 Valve As (36) to the 7I-8310 Coupling As (10) .

11. Attach one 148-8352 Elbow As (29) to the 90 degree coupling on the 239-1104 Hose As (45) .

12. Attach the other end of the 148-8352 Elbow As (29) to the 148-8335 Connector (28) .

Routing the Hydraulic Hoses

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Illustration 7	g01118090
(F) Auxiliary Supply (G) Auxiliary Return (H) Rod End of the Boom (J) Rod End of the Extendable Stick (K) Head End of the Stick (L) Head End of the Bucket (M) Rod End of the Stick (N) Head End of the Boom (O) Head End of the Extendable Stick (P) Rod End of the Bucket

13. Route the 172-2252 Hose As (32) and the 235-5730 Hose As (37) through the swing casting. Refer to Illustration 7 for the correct hose locations.

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Illustration 8	g01118097
(Q) Rod End of the Boom (R) Head End of the Stick (S) Head End of the Boom (T) Auxiliary Supply (U) Auxiliary Return (V) Head End of the Extendable Stick (W) Rod End of the Extendable Stick (X) Rod End of the Stick (Y) Head End of the Bucket (Z) Rod End of the Bucket

14. Route the 172-2252 Hose As (32) and the 235-5730 Hose As (37) along the boom assembly with the existing hoses. Refer to Illustration 8 for the correct hose locations.

15. Route the 239-1104 Hose As (45) along the inside of the frame to the oil filter.

Installing the Hydraulic Tubes and the Quick Disconnects

Illustration 9	g01118496
Right side of backhoe

16. Install the two 148-8450 Tees (30) onto the boom assembly. Secure Tees (30) with two of the 2P-1293 Locknuts (1). Tighten locknuts (1) to a torque of 225 ± 20 N·m (166 ± 15 lb ft).

17. Install the 6V-9832 Cap Assemblies (8) onto the ends of the tees (30) that are facing away from the machine.

18. Attach the 172-2252 Hose As (32) to the tee (30) on the supply side. When the operator is facing the backhoe, the supply side is on the right side of the boom.

19. Attach the 235-5730 Hose As (37) to the tee (30) on the return side. When the operator is facing the backhoe, the return side is on the left side of the boom.

20. Attach a 148-8352 Elbow Gp (29) onto each tee (30) .

21. Attach a 6V-9746 O-Ring Seal (7) and a 110-7709 Tube As (26) onto each elbow group (29). Secure each tube assembly (26) onto the boom with the following hardware: 7S-3916 Clip (11), 7S-3919 Clip (12), 8T-4192 Bolt (19) and 8T-4223 Hard Washer (21) .

22. Attach each 109-1260 Bracket (25) onto the stick assembly with the following hardware: 8T-4136 Bolt (16) and 8T-4121 Hard Washer (15) .

23. Install the 3D-2824 O-Ring Seals (2) and the 6V-9746 O-Ring Seals (7) onto the 235-3583 Connectors (35) .

24. Install the 235-3583 Connectors (35) onto brackets (25). Secure connector assemblies (35) with the 2P-1293 Locknuts (1). Tighten locknuts (1) to a torque of 150 ± 10 N·m (111 ± 7 lb ft).

25. Attach the 187-3226 Fitting As (Quick Disconnect) (34) onto connector assembly (35) that is installed on the supply line. When the operator is facing the backhoe, the supply line is attached to the right side of the stick. Attach the 187-3225 Fitting As (Quick Disconnect) (33) onto connector assembly (35) that is installed on the return line. When the operator is facing the backhoe, the return line is attached to the left side of the stick.

26. Attach one 168-8493 Hose As (31) to the tube assembly (26) on the left side of the boom and to the connector assembly (35) on the left side of the stick.

27. Attach the other 168-8493 Hose As (31) to the tube assembly (26) on the right side of the boom and to the connector assembly (35) on the right side of the stick.

28. For (S/N: BFP1-12899), attach one 148-8352 Elbow As (29) to the free end of the 239-1104 Hose As (45). Attach the elbow (29) to the tee in the oil filter.

29. For (S/N: BFP12900-UP), attach one 148-8335 Connector (28) to the free end of the 239-1104 Hose As (45). Attach the connector (28) to the oil filter.

Securing the Hydraulic Hoses

30. Secure each hose assembly (31) onto the stick assembly with the following items: 5P-7466 Clip (3), 5P-7467 Clip (4), 5P-8112 Grommet (5), 8T-4139 Bolt (18) and 8T-4223 Hard Washer (21) .

31. Align the hydraulic hoses that are routed along the boom assembly with the following items: 238-9565 Blocks (38), 238-9573 Blocks (44) and 238-9572 Blocks (43). Use the following items in order to secure the blocks to the boom assembly: 8T-4195 Bolts (20) and 8T-4121 Hard Washers (15). Refer to Illustration 8 for the correct hose locations.

32. Align the hydraulic hoses that are routed through the swing casting with the following items: 238-9571 Block (42), 238-9570 Block (41) and 238-9569 Block (40). Secure the hydraulic hoses with the existing hardware. Install the 6V-9189 Locknuts (6) onto the existing bolts. Discard the existing locknuts. Refer to Illustration 7 for the correct hose locations.

33. Secure the 239-1104 Hose As (45) to the frame assembly with the following hardware: 7D-7233 Clip (9), 8T-4137 Bolt (17) and 8T-4121 Hard Washer (15) .

34. Attach the 7D-7233 Clip (9) to the 239-1104 Hose As (45). Remove the bolt that holds the grounding strap to the frame and remove the washer. Place the clip (9) behind the grounding strap. Use the bolt and the washer to attach the clip (9) and the grounding strap to the frame.

35. Attach the 238-9567 Bracket (39) onto the 172-2252 Hose As (32) and onto the 235-5730 Hose As (37) with the following hardware: 8S-0023 Clips (13), 8S-0024 Clips (14), 8T-4139 Bolts (18), 8T-4223 Hard Washers (21) and 8T-4224 Nuts (22) .

36. Attach the 238-9567 Bracket (39) onto the frame assembly with the following hardware: 8T-4195 Bolts (20) and 8T-4121 Hard Washers (15). To mount the bracket (39), you may need to use additional hard washers (15) .

    Note: Tighten the bolts (18) in Step 35 before you tighten the bolts (20) in Step 36.

Completing the Installation

Illustration 10	g01118945

1. Place the 106-0425 Plate As (24) on the underside of the boom assembly. Apply a 4 mm (0.16 inch) weld to the plate (24). Weld around the plate from corner (AA) to corner (BB) .

2. Install the 101-0863 Films (23) onto the stick assembly.

   Note: When the operator faces the backhoe, the arrow on the film (23) on the right side of the stick will point toward the bucket. The arrow on the film (23) on the left side of the stick will point toward the boom.

3. Install the 241-8448 Films (46) onto both sides of the stick and onto both sides of the boom.

4. Check over the machine for any loose items.

5. Fill the machine with hydraulic fluid to the FULL position.

6. Attach a work tool that requires two-way flow. Before you install a work tool, read Operation and Maintenance Manual, "Work Tool Flow Mode Control".

   Note: Make sure that the 235-5729 Valve As is in the two-way flow position. Refer to Illustration 5.

7. Operate the machine, and operate the work tool. Check for hydraulic leaks. Check the hydraulic hoses during operation. The hoses should not be pinched and the hoses should not be twisted.

Operation of the Auxiliary Lines

The auxiliary lines are capable of providing one-way flow or two-way flow.

The one-way flow is used with attachments such as hydraulic hammers. The two-way flow is used with attachments such as augers.

Before you change the flow mode of the hydraulic auxiliary circuit, place the machine in the servicing position. Install the swing lock pin and shut off the engine.

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Make sure that all attachments are in the recommended servicing position and personnel are clear of the attachment before the manual lever on the ball valve is moved. Changing the valve position may cause the attachment to move unexpectedly. Serious injury or death may result.

Illustration 11	g01136666

Illustration 12	g01135965
Valve in the two-way flow position

Illustration 13	g01135966
Valve in the position for one-way flow

Use the lever to turn the valve. Make sure that you fully turn the ball valve until the valve stops.