- Backhoe Loader:
- 416E (S/N: SHA1-UP; BWC1-UP)
Introduction
ReferenceDisassembly and Assembly, RENR6485, "416E, Backhoe Loader Machine Systems"
ReferenceDisassembly and Assembly, KENR7659, "416E, 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.
Required Parts
The required parts for the field installation of the new hoses for the backhoe are listed in Table 1.
| 258-8355 Backhoe Auxiliary Lines Gp Parts | |||
| Number | Qty | Part Number | Part Name |
| 1 | 2 | 4W-3753 | Spacers |
| 2 | 1 | 106-0401 | Fitting |
| 3 | 1 | 106-0406 | Fitting |
| 4 | 2 | 109-1260 | Brackets |
| 5 | 1 | 144-8344 | Spacer |
| 6 | 1 | 155-2026 | Union As |
| 7 | 1 | 217-2617 | Tube As |
| 8 | 1 | 217-2699 | Hose As |
| 9 | 1 | 241-6226 | Tee As |
| 10 | 2 | 241-8448 | Films |
| 11 | 1 | 251-9360 | Tube As |
| 12 | 1 | 252-0200 | Hose As |
| 13 | 1 | 290-6711 | Hose As |
| 14 | 1 | 277-4543 | Bracket As |
| 15 | 2 | 281-4726 | Films |
| 16 | 1 | 148-8392 | Elbow As |
| 17 | 2 | 150-3053 | Connector As |
| 18 | 1 | 262-4459 | Hose As |
| 19 | 2 | 2P-1293 | Locknuts |
| 20 | 2 | 5K-9090 | O-Ring Seals |
| 21 | 4 | 5P-7466 | Clips |
| 22 | 4 | 5P-7467 | Clips |
| 23 | 4 | 5P-8112 | Grommets |
| 24 | 1 | 6V-9170 | Bulkhead Nut |
| 25 | 1 | 6V-9172 | Nut |
| 26 | 1 | 6V-9746 | O-Ring Seal |
| 27 | 2 | 7X-7729 | Washers |
| 28 | 1 | 8S-0023 | Clip |
| 29 | 1 | 8S-0024 | Clip |
| 30 | 3 | 8T-1889 | Clips |
| 31 | 3 | 8T-1890 | Clips |
| 32 | 8 | 8T-4121 | Hard Washers |
| 33 | 1 | 8T-4133 | Nut |
| 34 | 5 | 8T-4136 | Bolts |
| 35 | 2 | 7X-2549 | Bolts |
| 36 | 1 | 8T-4185 | Bolt |
| 37 | 2 | 8T-4196 | Bolts |
| 38 | 2 | 8T-4223 | Hard Washers |
Preparing the Machine
- Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel.
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| Illustration 1 | g01194613 |
- Engage the parking brake.
- Lower the work tools to the ground. Stop the engine.
- 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. |
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| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
Installation of the Return Line
- Remove the cap (A) from the hydraulic filter housing (B) .
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| Illustration 2 | g01261829 |
(A) Cap (B) Filter housing | |
- Attach the 217-2699 Hose As (8) to the filter housing (B) .
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| Illustration 3 | g01261972 |
(8) 217-2699 Hose As (B) Filter housing | |
- Insert one 5K-9090 O-Ring Seal (20). Connect the 217-2617 Tube As (7) to the 217-2699 Hose As (8). Use one 8T-1889 Clip (30), one 8T-1890 Clip (31), one 8T-4121 Hard Washer (32) and one 8T-4136 Bolt (34) in order to secure the 217-2617 Tube As (7) to the frame.
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| Illustration 4 | g01262463 |
(7) 217-2617 Tube As (8) 217-2699 Hose As (20) 5K-9090 O-Ring Seal (30) 8T-1889 Clip (31) 8T-1890 Clip (32) 8T-4121 Hard Washer (34) 8T-4136 Bolt | |
- Use the two 8T-4196 Bolts (37) and two 8T-4121 Hard Washers (32) in order to attach the 277-4543 Bracket As (14) to the frame.
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| Illustration 5 | g01259326 |
(7) 217-2617 Tube As (14) 277-4543 Bracket As (32) 8T-4121 Hard Washers (33) 8T-4133 Nut (36) 8T-4185 Bolt (37) 8T-4196 Bolts | |
- In order to attach the 217-2617 Tube As (7) to the 277-4543 Bracket As (14), use one 8T-1889 Clip (30), one 8T-1890 Clip (31), the 144-8344 Spacer (5), two 7X-7729 Washers , one 8T-4185 Bolt (36), one 8T-4121 Hard Washer (32), and one 8T-4133 Nut (33) .
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| Illustration 6 | g01262083 |
(5) 144-8344 Spacer (7) 217-2617 Tube As (8) 217-2699 Hose As (13) 290-6711 Hose As (14) 277-4543 Bracket As (27) 7X-7729 Washers (20) 5K-9090 O-Ring Seal (26) 6V-9746 O-Ring Seal (30) 8T-1889 Clip (31) 8T-1890 Clip (32) 8T-4121 Hard Washers (33) 8T-4133 Nut (34) 8T-4136 Bolt (36) 8T-4185 Bolt (37) 8T-4196 Bolts | |
- Insert one 6V-9746 O-Ring Seal (26). Connect the 290-6711 Hose As (13) to the 217-2617 Tube As (7) .
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| Illustration 7 | g01302372 |
(7) 217-2617 Tube As (13) 290-6711 Hose As (26) 6V-9746 O-Ring Seal | |
- Route the 290-6711 Hose As (13) through backhoe frame (C).
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| Illustration 8 | g01302373 |
(C) Backhoe frame (D) Bolt (E) Boom (F) Bolt (11) 251-9360 Tube As (13) 290-6711 Hose As (20) 5K-9090 O-Ring Seal (28) 8S-0023 Clip (29) 8S-0024 Clip (30) 8T-1889 Clip (31) 8T-1890 Clip | |
- Use the existing bolt (D), one 8S-0023 Clip , and one 8S-0024 Clip in order to attach the 290-6711 Hose As (13) to the boom (E) .
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| Illustration 9 | g02308673 |
(D) Bolt (E) Boom (13) 290-6711 Hose As (28) 8S-0023 Clip (29) 8S-0024 Clip | |
- Insert one 5K-9090 O-Ring Seal (20). Connect the 251-9360 Tube As (11) to the 290-6711 Hose As (13). In order to attach the 251-9360 Tube As (11) to the boom (E), use the existing bolt (F), one 8T-1889 Clip (30), and one 8T-1890 Clip (31) .
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| Illustration 10 | g02308733 |
(E) Boom (F) Bolt (11) 251-9360 Tube As (13) 290-6711 Hose As (20) 5K-9090 O-Ring Seal (30) 8T-1889 Clip (31) 8T-1890 Clip | |
- Insert the 155-2026 Union As (6) into the plate (G). Use the 6V-9172 Nut (25) in order to secure the 155-2026 Union As (6) into the plate (G) .
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| Illustration 11 | g01262944 |
(G) Plate | |
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| Illustration 12 | g01262937 |
(E) Boom (G) Plate (6) 155-2026 Union As (11) 251-9360 Tube As (18) 262-4459 Hose As (25) 6V-9172 Nut | |
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| Illustration 13 | g02308753 |
(G) Plate (6) 155-2026 Union As (11) 251-9360 Tube As (18) 262-4459 Hose As (25) 6V-9172 Nut | |
- Tighten the 6V-9172 Nut (25) to a torque of 150 ± 10 N·m (110 ± 7 lb ft).
- Secure the 262-4459 Hose As (18) to the boom (E) with one 5P-7466 Clip (21), one 5P-7467 Clip (22), and one 5P-8112 Grommet (23). Use the existing bolt (J) in order to secure the clips.
Note: Leave 883 ± 5 mm (34.8 ± 0.2 inch) of 262-4459 Hose As (18) between the 155-2026 Union As (6) and the 5P-7467 Clip (22) on the boom (E) .
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| Illustration 14 | g01269245 |
(E) Boom (H) Stick (J) Existing bolt (1) 4W-3753 Spacer (18) 262-4459 Hose As (21) 5P-7466 Clip (22) 5P-7467 Clip (23) 5P-8112 Grommet (35) 7X-2549 Bolt (38) 8T-4223 Hard Washer | |
- Secure the 262-4459 Hose As (18) to the stick (H) with one 5P-7466 Clip (21), one 5P-7467 Clip (22), and one 5P-8112 Grommet (23). Remove the existing bolt and replace the bolt with the longer 7X-2549 Bolt (35), the 8T-4223 Hard Washer (38), and the 4W-3753 Spacer (1) in order to secure the clips.
Note: Leave 1148 ± 5 mm (45.2 ± 0.2 inch) of 262-4459 Hose As (18) between the 5P-7467 Clip (22) on the boom (E) and the 5P-7467 Clip (22) on the stick (H) .
- Use two 8T-4136 Bolts (34) and two 8T-4121 Hard Washers (32) in order to attach the 109-1260 Bracket (4) to the stick (H). Insert the 150-3053 Connector As (17) into the 109-1260 Bracket (4). Install the 2P-1293 Locknut and tighten to a torque of 225 ± 20 N·m (166 ± 15 lb ft).
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| Illustration 15 | g01269428 |
(H) Stick (2) 106-0401 Fitting (4) 109-1260 Bracket (10) 241-8448 Film (15) 281-4726 Film (17) 150-3053 Connector As (18) 262-4459 Hose As (19) 2P-1293 Locknut (32) 8T-4121 Hard Washer (34) 8T-4136 Bolt | |
- Attach the 262-4459 Hose As (18) to the 150-3053 Connector As (17). Attach the 106-0401 Fitting (2) to the 150-3053 Connector As (17) .
- Clean the area on the stick (H) for the films. Attach the 241-8448 Film (10) and the 281-4726 Film (15) to the stick (H) .
Installation of the Supply Line
- Disconnect the existing line (K). Disconnect the existing line (M). Remove the straight fitting (L) .
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| Illustration 16 | g01269520 |
(K) Existing line (L) Existing fitting (M) Existing line | |
- Install the 241-6226 Tee As (9) with the 6V-9170 Bulkhead Nut (24). Tighten the 6V-9170 Bulkhead Nut (24) to a torque of 150 ± 10 N·m (110 ± 7 lb ft).
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| Illustration 17 | g01269541 |
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| Illustration 18 | g01269508 |
(K) Existing line (M) Existing line (9) 241-6226 Tee As (16) 148-8392 Elbow As (12) 252-0200 Hose As (16) 148-8392 Elbow As (24) 6V-9170 Bulkhead Nut | |
- Connect the existing line (K) to the 241-6226 Tee As (9). Connect the existing line (M) to the 241-6226 Tee As (9). Attach the 148-8392 Elbow As (16) to the 241-6226 Tee As (9) .
- Secure the 252-0200 Hose As (12) to the boom (E) with one 5P-7466 Clip (21), one 5P-7467 Clip (22), and one 5P-8112 Grommet (23). Use the existing bolt (J) in order to secure the clips.
Note: Leave 883 ± 5 mm (34.8 ± 0.2 inch) of 252-0200 Hose As (12) between the 148-8392 Elbow As (16) and the 5P-7467 Clip (22) on the boom (E) .
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| Illustration 19 | g01269702 |
(E) Boom (H) Stick (J) Existing bolt (1) 4W-3753 Spacer (12) 252-0200 Hose As (21) 5P-7466 Clip (22) 5P-7467 Clip (23) 5P-8112 Grommet (35) 7X-2549 Bolt (38) 8T-4223 Hard Washer | |
- Secure the 252-0200 Hose As (12) to the stick (H) with one 5P-7466 Clip (21), one 5P-7467 Clip (22), and one 5P-8112 Grommet (23). Remove the existing bolt and replace the bolt with the longer 7X-2549 Bolt (35), the 8T-4223 Hard Washer (38), and the 4W-3753 Spacer (1) in order to secure the clips.
Note: Leave 1148 ± 5 mm (45.2 ± 0.2 inch) of 252-0200 Hose As (12) between the 5P-7467 Clip (22) on the boom (E) and the 5P-7467 Clip (22) on the stick (H) .
- Use two 8T-4136 Bolts (34) and two 8T-4121 Hard Washers (32) in order to attach the 109-1260 Bracket (4) to the stick (H). Insert the 150-3053 Connector As (17) into the 109-1260 Bracket (4). Install the 2P-1293 Locknut and tighten to a torque of 225 ± 20 N·m (166 ± 15 lb ft).
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| Illustration 20 | g01269790 |
(H) Stick (3) 106-0406 Fitting (4) 109-1260 Bracket (10) 241-8448 Film (12) 252-0200 Hose As (15) 281-4726 Film (17) 150-3053 Connector As (18) 262-4459 Hose As (19) 2P-1293 Locknut (32) 8T-4121 Hard Washer (34) 8T-4136 Bolt | |