The Instructions for the Field Installation of the New 284-8547 Backhoe Lines Gp (Kit, Field Conversion){5057} Caterpillar

Backhoe Loader:

430D (S/N: BNK2502-UP; BML1269-UP)

Introduction

ReferenceDisassembly and Assembly, RENR3585, "416D, 420D, 428D, 430D, 432D, 438D and 442D Backhoe Loader Machine Systems", "Hydraulic System Pressure - Release"

ReferenceDisassembly and Assembly, RENR3585, "416D, 420D, 428D, 430D, 432D, 438D and 442D Backhoe Loader Machine Systems", "Boom Cylinder - Remove"

ReferenceDisassembly and Assembly, RENR3585, "416D, 420D, 428D, 430D, 432D, 438D and 442D Backhoe Loader Machine Systems", "Stick Cylinder - Remove"

ReferenceDisassembly and Assembly, RENR3585, "416D, 420D, 428D, 430D, 432D, 438D and 442D Backhoe Loader Machine Systems", "Backhoe Bucket Cylinder - Remove"

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.

Needed 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	g01256584

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.

Removal of Parts

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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.

Mounting Lines Group

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Illustration 2	g01256570

1. Remove bolt (7), washer (8) and locknut (9) .

2. Remove bolt (10) and washer (11). The weldnut (12) is part of the bracket (13) .

3. Remove the three bolts (14) and the three washers (15) .

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Illustration 3	g01256680

4. Remove the two bolts (16), the four hard washers (17) and the two locknuts (18). Remove the blocks (19).

5. Remove the four bolts (20) and the four hard washers (21). Remove the blocks (22) .

Routing of the Hydraulic Lines

Illustration 4	g01258715

For some lines groups, the hydraulic lines can be in different positions in the mounting lines groups. Refer to Illustration 4 for the proper location of the hoses.

(23) In the 235-5851 Backhoe Auxiliary Lines Gp , this is the position for the return line for the auxiliary circuit.

(24) For the 235-5851 Backhoe Auxiliary Lines Gp , this is the auxiliary line or the rod end to the extendable stick.

(25) The head end of the stick cylinder

(26) The rod end of the stick cylinder

(27) For the 235-5851 Backhoe Auxiliary Lines Gp , this is the head end of the extendable stick cylinder. For the 202-5940 Extendable Stick Lines Gp , this is the rod end of the extendable stick cylinder.

(28) The rod end of the boom cylinder

(29) The head end of the bucket cylinder

(30) The head end of the boom cylinder

(31) The rod end of the bucket cylinder

(32) For the 202-5940 Extendable Stick Lines Gp , this is the head end of the extendable stick cylinder.

(33) The rod end of the stick cylinder

(34) For all lines group except the 202-5931 Boom Lines Gp , this is the head end of the bucket cylinder.

(35) The rod end of the bucket cylinder

(36) For the 202-5939 Extendable Stick Lines Gp , this is the rod end of the extendable stick cylinder. For the 202-5946 Backhoe Auxiliary Lines Gp , this is the auxiliary line AF2.

(37) For the 235-5851 Backhoe Auxiliary Lines Gp , this is the auxiliary line or the rod end to the extendable stick.

(38) The rod end of the boom cylinder

(39) The head end of the stick cylinder

(40) For the 202-5932 Boom Lines Gp , this is the head end of the boom cylinder. for the 235-5851 Backhoe Auxiliary Lines Gp , this is the return line for the auxiliary circuit.

Illustration 5	g01256686

Illustration 6	g01258729
View A-A

Refer to Illustration 6 for the correct location for the hoses on the bank valve.

(41) For the 235-5851 Backhoe Auxiliary Lines Gp , this is the auxiliary line or the rod end to the extendable stick.

(42) The head end of the stick cylinder

(43) The head end of the bucket cylinder

(44) The rod end of the boom cylinder

(45) The head end of the boom cylinder

(46) The rod end of the bucket cylinder

(47) The rod end of the stick cylinder

(48) For the 235-5851 Backhoe Auxiliary Lines Gp , this is the head end to the extendable stick.

The Boom Cylinder Lines

The following procedure is used in order to replace the former boom cylinder lines with the new boom cylinder lines. Table 2 lists the former part numbers and the new part numbers.

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Illustration 7	g01256621

1. Disconnect the hydraulic hose (23). Disconnect the hydraulic hose (24) .

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Illustration 8	g01256686

2. Remove the other end of hose (23) from the machine. Remove the other end of hose (24) from the machine.

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Illustration 9	g01256712

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Illustration 10	g01256713

3. Install one end of the new 149-8718 Hose As (1) in the position for hose (24) .

4. Route the hose through the lines mounting groups. Install the other end of the new 149-8718 Hose As (1) to the boom cylinder in the position for hose (24) .

5. Install one end of the new 265-9416 Hose As (6) on the machine in the position for hose (23) .

6. Route the hose through the lines mounting groups. Install the other end of the new 265-9416 Hose As (6) to the boom cylinder in the position for hose (23) .

Stick Cylinder Line

The following procedure is used in order to replace the former line to the rod end of the stick cylinder with the new line to the rod end of the stick cylinder. Table 3 lists the former part number and the new part number.

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Illustration 11	g01256800

1. Disconnect the hydraulic hose (25) .

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Illustration 12	g01256804

2. Remove the other end of hose (25) from the machine.

3. Install one end of the new 249-4816 Hose As (4) on the machine in the position for hose (25) .

4. Route the hose through the lines mounting groups. Install the other end of the new 249-4816 Hose As (25) to the rod end of the stick cylinder.

The Line to the Head End of the Extendable Stick Cylinder or the Auxiliary Line

The following procedure is used in order to replace the former line to the head end of the extendable stick cylinder (if equipped) or the auxiliary line (if equipped) with the new line to the head end of the extendable stick cylinder (if equipped) or the auxiliary line (if equipped). Table 4 lists the former part number and the new part number.

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Illustration 13	g01257052

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Illustration 14	g01257050

1. Disconnect the hydraulic hose (26) from the back of the machine at connection (A) .

2. Remove the other end of hose (26) from the bottom of the boom at connection (B) .

3. Install one end of the new 276-8151 Hose As (3) on the back of the machine at connection (A) .

4. Install one end of the new 276-8151 Hose As (3) to the bottom of the boom at connection (B) .

The Lines to the Bucket Cylinder

The following procedure is used in order to replace the former lines to the bucket cylinder with the new lines to the bucket cylinder. Table 5 lists the former part number and the new part number.

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Illustration 15	g01257568

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Illustration 16	g01257561

1. Disconnect the hydraulic hose (27) from the machine. Disconnect the hydraulic hose (28) from the machine.

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Illustration 17	g01257562

2. Remove the other end of hose (27) from the boom. Remove the other end of hose (28) from the boom.

3. Install one end of the new 172-2251 Hose As (5) on the machine in the position for hose (27) .

4. Route the hose through the lines mounting groups. Install the other end of the new 172-2251 Hose As (5) on the boom in the position for hose (27) .

5. Install one end of the new 199-2567 Hose As (2) on the machine in the position for hose (28) .

6. Route the hose through the lines mounting groups. Install the other end of the new 199-2567 Hose As (2) on the boom in the position for hose (28) .