Field Installation of the 266-2409 Backhoe Auxiliary Lines Gp KIT{5057} Caterpillar

Backhoe Loader:

420E (S/N: DJL1-UP; DAN1-UP; PRA1-UP; PHC1-UP; HLS210-UP; KMW150-UP)

Introduction

ReferenceDisassembly and Assembly, RENR6485, "420E, Backhoe Loader Machine Systems"

This Special Instruction explains the installation of the new hoses for the backhoe. Do not begin the installation until you have read the information that is contained in this instruction.

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 should 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.

This Special Instruction outlines the basic procedures that are required in order to install the auxiliary lines onto 420E Backhoe Loader that is equipped with a standard 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 required parts for the field installation of the new hoses for the backhoe are listed in Table 1.

Preparing the Machine

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Illustration 1	g01194613

1. Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel.

2. Engage the parking brake.

3. Lower the work tools to the ground. Stop the engine.

4. Release hydraulic system pressure.

   Note: Refer to "Hydraulic System Pressure - Release" in the Disassembly and Assembly manual for your machine.

Routing of the Hydraulic Lines

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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 work tools 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.

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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.

Installation of the Return Line

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Illustration 2	g01261829
(A) Cap (B) Filter housing

1. Remove the cap (A) from the hydraulic filter housing (B) .

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Illustration 3	g01273122
(9) 262-3038 Hose As (B) Filter housing

2. Attach the 262-3038 Hose As (9) to the filter housing (B) .

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Illustration 4	g01283593
(C) Frame (D) Cross Brace (8) 262-3036 Bracket (14) 277-4543 Bracket As (39) 8T-4121 Hard Washers (42) 8T-4137 Bolts (45) 8T-4196 Bolt

3. Attach the 262-3036 Bracket (8), two 8T-4137 Bolts (42) and two 8T-4121 Hard Washers (39) to frame (C) .

4. Attach the 277-4543 Bracket As (14), two 8T-4196 Bolts (42) and two 8T-4121 Hard Washers (39) to cross brace (D) .

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Illustration 5	g01283607
(6) 235-5729 Manual Valve As (8) 262-3036 Bracket (9) 262-3038 Hose As (16) 148-8327 Connector As (13) 262-3039 Tube As (17) 148-8335 Connector As (25) 5P-4116 Hard Washer (31) 7I-7412 Elbow (39) 8T-4121 Hard Washers (44) 8T-4189 Bolts (5) 257-0475 Relief Valve

5. Attach the 235-5729 Manual Valve As (6), two 8T-4189 Bolts (44) and two 5P-4116 Hard Washer (25) to the 262-3036 Bracket (8) .

6. Attach the 148-8335 Connector As (17) to the 235-5729 Manual Valve As (6) .

7. Attach the 262-3038 Hose As (9) to the 148-8335 Connector As (17) .

8. Attach the 262-3039 Tube As (13) to the bottom side of the 235-5729 Manual Valve As (6) .

9. Attach the 7I-7412 Elbow (31) to the 262-3039 Tube As (13) .

10. Attach the 148-8327 Connector As (16) to the 7I-7412 Elbow (31).

11. Attach 257-0475 Relief Valve to B port on the auxiliary section.

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Illustration 6	g01276564
(5) 144-8344 Spacer (14) 277-4543 Bracket As (15) 286-0689 Tube As (20) 260-9143 Elbow As (21) 290-6711 Hose As (30) 6V-9746 O-Ring Seal (35) 8T-1887 Clip (36) 8T-1888 Clip (39) 8T-4121 Hard Washers (40) 8T-4133 Nut (43) 8T-4185 Bolt

12. Connect the 260-9143 Elbow As (20) to the top side of the 235-5729 Manual Valve As (6) .

13. Insert one 6V-9746 O-Ring Seal (30) into the 286-0689 Tube As (15). Connect the 286-0689 Tube As (15) to the 260-9143 Elbow As (20) .

14. Assemble one 8T-1887 Clip (35), and one 8T-1888 Clip (36) on the 286-0689 Tube As (15). Insert one 8T-4185 Bolt (43) and one 8T-4121 Hard Washer (39) through the assembled clips. Assemble one 8T-4121 Hard Washers (39), one 144-8344 Spacer and one 8T-4121 Hard Washer (39) onto the 8T-4185 Bolt (43). Secure the assembled hardware to the 277-4543 Bracket As (14) with one 8T-4121 Hard Washers (39) and one 8T-4133 Nut (40) .

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Illustration 7	g01276569
(15) 286-0689 Tube As (21) 290-6711 Hose As (30) 6V-9746 O-Ring Seal

15. Insert one 6V-9746 O-Ring Seal (30) into the 286-0689 Tube As (15). Connect the 290-6711 Hose As (21) to the 286-0689 Tube As (15) .

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Illustration 8	g01276588
(E) Backhoe frame (F) Bolt (G) Boom (H) Bolt (11) 251-9360 Tube As (21) 290-6711 Hose As (24) 5K-9090 O-Ring Seal (33) 8S-0023 Clip (34) 8S-0024 Clip (37) 8T-1889 Clip (38) 8T-1890 Clip

16. Route the 290-6711 Hose As (21) through backhoe frame (E).

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Illustration 9	g02305280
(F) Bolt (G) Boom (21) 290-6711 Hose As (33) 8S-0023 Clip (34) 8S-0024 Clip

17. Use the existing bolt (F), one 8S-0023 Clip (33), and one 8S-0024 Clip (34) in order to attach the 290-6711 Hose As (21) to the boom (G) .

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Illustration 10	g02305394
(G) Boom (H) Bolt (11) 251-9360 Tube As (21) 290-6711 Hose As (24) 5K-9090 O-Ring Seal (37) 8T-1889 Clip (38) 8T-1890 Clip

18. Insert one 5K-9090 O-Ring Seal (24). Connect the 251-9360 Tube As (11) to the 290-6711 Hose As (21). In order to attach the 262-3034 Tube As (11) to the boom (G), use the existing bolt (H), one 8T-1889 Clip (37), and one 8T-1890 Clip (38) .

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Illustration 11	g01274178
(J) Plate

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Illustration 12	g01283824
(G) Boom (J) Plate (11) 251-9360 Tube As (12) 262-4203 Hose As (19) 155-2026 Union As (29) 6V-9172 Nut

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Illustration 13	g02305433
(J) Plate (11) 251-9360 Tube As (12) 262-4203 Hose As (19) 155-2026 Union As (29) 6V-9172 Nut

19. Insert the 155-2026 Union As (19) into the plate (J). Use the 6V-9172 Nut (29) in order to secure the 155-2026 Union As (19) into the plate (J) .

20. Tighten the 6V-9172 Nut (29) to a torque of 200 ± 20 N·m (146 ± 15 lb ft).

21. Attach the 251-9360 Tube As (11) to the 155-2026 Union As (19).

22. Attach the 251-9360 Hose As (12) to the 155-2026 Union As (19) .

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Illustration 14	g01283934
(G) Boom (L) Stick (K) Existing bolt (1) 4W-3753 Spacer (12) 262-4203 Hose As (26) 5P-7466 Clip (27) 5P-7467 Clip (28) 5P-8112 Grommet (32) 8T-4910 Bolt

23. Secure the 262-4203 Hose As (12) to the boom (G) with one 5P-7466 Clip (26), one 5P-7467 Clip (27), and one 5P-8112 Grommet (28). Use the existing bolt (K) in order to secure the clips.

24. Secure the 262-4203 Hose As (12) to the stick (L) with one 5P-7466 Clip (26), one 5P-7467 Clip (27), and one 5P-8112 Grommet (28). Remove the existing bolt and replace the bolt with the longer 7X-2549 Bolt (32), the 8T-4223 Hard Washer (38), and the 4W-3753 Spacer (1) in order to secure the clips.

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Illustration 15	g01283948
(L) Stick (2) 106-0401 Fitting (4) 109-1260 Bracket (7) 241-8448 Film (18) 150-3053 Connector As (12) 262-4203 Hose As (23) 2P-1293 Locknut (39) 8T-4121 Hard Washer (41) 8T-4136 Bolt

25. Use two 8T-4136 Bolts (41) and two 8T-4121 Hard Washers (39) in order to attach the 109-1260 Bracket (4) to the stick (L). Insert the 150-3053 Connector As (18) into the 109-1260 Bracket (4). Install the 2P-1293 Locknut (23) and tighten to a torque of 225 ± 20 N·m (166 ± 15 lb ft).

26. Attach the 262-4203 Hose As (12) to the 150-3053 Connector As (18). Attach the 106-0401 Fitting (2) to the 150-3053 Connector As (18) .

27. Clean the area on the stick (L) for the film. Attach the 241-8448 Film (7) to the stick (L) .

Installation of the Supply Line

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Illustration 16	g01284489
(16) 148-8327 Connector As (22) 290-6712 Hose As

1. Connect the 148-8327 Connector As (16) to the 290-6712 Hose As (22) .

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Illustration 17	g01276575
(E) Backhoe Frame (22) 290-6714 Hose As

2. Route the 290-6712 Hose As (22) through the backhoe frame (E) .

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Illustration 18	g01274806
(F) Bolt (G) Boom (22) 290-6712 Hose As (33) 8S-0023 Clip (34) 8S-0024 Clip

3. Use the existing bolt (F), one 8S-0023 Clip (33), and one 8S-0024 Clip (34) in order to attach the 290-6712 Hose As (13) to the boom (G) .

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Illustration 19	g01274850
(G) Boom (H) Bolt (10) 262-4217 Tube As (22) 290-6712 Hose As (24) 5K-9090 O-Ring Seal (37) 8T-1889 Clip (38) 8T-1890 Clip

4. Insert one 5K-9090 O-Ring Seal (24). Connect the 262-4217 Tube As (10) to the 290-6712 Hose As (22). In order to attach the 262-4217 Tube As (10) to the boom (G), use the existing bolt (H), one 8T-1889 Clip (37), and one 8T-1890 Clip (38) .

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Illustration 20	g01276552
(G) Boom (J) Plate (10) 262-4217 Tube As (12) 262-4203 Hose As (19) 155-2026 Union As (29) 6V-9172 Nut

5. Insert the 155-2026 Union As (19) into the plate (J). Use the 6V-9172 Nut (29) in order to secure the 155-2026 Union As (19) into the plate (J) .

6. Tighten the 6V-9172 Nut (29) to a torque of 200 ± 20 N·m (146 ± 15 lb ft).

7. Attach the 262-4217 Tube As (10) to the 155-2026 Union As (19).

8. Attach the 262-4203 Hose As (12) to the 155-2026 Union As (19) .

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Illustration 21	g01284033
(G) Boom (L) Stick (K) Existing bolt (26) 5P-7466 Clip (27) 5P-7467 Clip (28) 5P-8112 Grommet

9. Secure the 262-4203 Hose As (12) to the boom (G) with one 5P-7466 Clip (26), one 5P-7467 Clip (27), and one 5P-8112 Grommet (28). Use the existing bolt (K) in order to secure the clips.

10. Secure the 262-4203 Hose As (12) to the stick (L) with one 5P-7466 Clip (26), one 5P-7467 Clip (27), and one 5P-8112 Grommet (28). Remove the existing bolt and replace the bolt with the longer 7X-2549 Bolt (32), the 8T-4223 Hard Washer (46), and the 4W-3753 Spacer (1) in order to secure the clips.

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Illustration 22	g01284199
(L) Stick (3) 106-0406 Fitting (4) 109-1260 Bracket (7) 241-8448 Film (12) 262-4203 Hose As (18) 150-3053 Connector As (23) 2P-1293 Locknut (29) 6V-9172 Locknut (39) 8T-4121 Hard Washer (41) 8T-4136 Bolt

11. Use two 8T-4136 Bolts (41) and two 8T-4121 Hard Washers (39) in order to attach the 109-1260 Bracket (4) to the stick (L). Insert the 150-3053 Connector As (18) into the 109-1260 Bracket (4). Install the 6V-9172 Locknut (29) and tighten to a torque of 225 ± 20 N·m (166 ± 15 lb ft).

12. Attach the 262-4203 Hose As (12) to the 150-3053 Connector As (18). Attach the 106-0406 Fitting (3) to the 150-3053 Connector As (18) .

13. Clean the area on the stick (L) for the film. Attach the 241-8448 Film (7) .