422E, 428E, 432E, 434E, 442E and 444E Backhoe Loaders Machine Systems Caterpillar

Assembly Procedure

Illustration 1	g01738917

Note: Do not damage the discs and the balls that are located on the valve assemblies, during the assembly procedures. The discs and the balls are not serviceable components.

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Illustration 2	g01732697

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

1. Use Tooling (D) in order to install retaining ring (67). Install the ball, the spring, check valve (68), and the retaining ring (67) .

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Illustration 3	g01732696

2. Install the O-ring seal and plug (66). Tighten plug (66) to a torque of 23 to 26 N·m (205 to 230 lb in).

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Illustration 4	g01154672

3. Use Tooling (C) in order to install relief valve (65). Tighten relief valve (65) to a torque of 10 to 15 N·m (89 to 133 lb in).

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Illustration 5	g01154671

4. Install cap (64) .

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Illustration 6	g01151916

5. Install spool (63) .

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Illustration 7	g01151915

6. Install spring (62) .

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Illustration 8	g01151914

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

7. Install the O-ring seal and plug (61). Tighten plug (61) to a torque of 40 to 47 N·m (30 to 35 lb ft).

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Illustration 9	g01151913

8. Install studs (59) onto inlet manifold (60) .

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Illustration 10	g01732457

Note: Make sure that the relief valve is seated in the bottom of the port prior to the installation of plug (53) .

9. Install the relief valve, the O-ring seal, and plug (53). Tighten plug (53) to a torque of 35 to 45 N·m (26 to 33 lb ft). Repeat for the opposite side.

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Illustration 11	g01732456

10. Install spool (52) and spring (51) .

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Illustration 12	g01732455

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

11. Install the O-ring seal and plug (50). Tighten plug (50) to a torque of 50 to 70 N·m (37 to 52 lb ft).

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Illustration 13	g01732453

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Note: Do not slide the surface of seals in cover assembly (49) across the lands of spool (46) .

12. Clamp the tang of spool (46) into a suitable vise in order to install bolt (47). Install cover assembly (49), plate (48), retainer (45), spring (44), retainer (43), and bolt (47) onto spool (46). Tighten bolt (47) to a torque of 7 to 10 N·m (62 to 89 lb in).

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Illustration 14	g01740943

13. Install cover (42) and bolts (41). Tighten bolts (41) to a torque of 7 to 10 N·m (62 to 89 lb in).

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Illustration 15	g01740843

14. Install spool assembly (36) and bolts (37). Tighten bolts (37) to a torque of 7 to 10 N·m (62 to 89 lb in).

15. Install cover assembly (39) and bolts (38). Tighten bolts (38) to a torque of 7 to 10 N·m (62 to 89 lb in).

16. Install O-ring seals (40) .

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Illustration 16	g01151912

17. Install auxiliary valve (58), if equipped.

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Illustration 17	g01151910

18. Repeat Steps 9 through Steps 16 for boom valve (57) .

19. Install boom valve (57) .

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Illustration 18	g01151909

20. Repeat Steps 9 through Steps 16 for swing valve (56) .

21. Install swing valve (56) .

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Illustration 19	g01151908

22. Repeat Steps 9 through Steps 16 for bucket valve (55) .

23. Install bucket valve (55) .

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Illustration 20	g01151907

24. Repeat Steps 9 through Steps 16 for stick valve (54) .

25. Install stick valve (54) .

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Illustration 21	g01740995

26. Repeat Steps 9 through Steps 16 for extendable stick valve (31) .

Note: Ensure that the spools in the valve assemblies move freely.

27. Install extendable stick valve (35), if equipped. Install nuts (34). Tighten nut (34) in increments of 10 N·m (89 lb in). Tighten nuts (34) until a torque of 38 to 42 N·m (28 to 31 lb ft) is achieved.

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Illustration 22	g01740993

28. Install O-ring seals (33) and backup ring (32) onto cartridge (31) .

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Illustration 23	g01740981

29. Install cartridge (31). Tighten cartridge (31) to a torque of 32 to 40 N·m (24 to 30 lb ft).

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Illustration 24	g01740979

30. Install coil assembly (29), the O-ring seals, and nut (30). Tighten nut (30) to a torque of 3 to 5 N·m (27 to 44 lb in).

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Illustration 25	g01684919

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Illustration 26	g01740973

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Note: Ensure that plugs (22) are flush with the surface of valve assembly.

31. Lubricate O-ring seals (23) and backup rings (24) with lubricant that is being sealed prior to installation. Install poppet (26), spring (25), backup rings (24), O-ring seals (23), and plugs (22) .

32. Install the piston, the spring, the O-ring seal, and plug (21). Repeat for the opposite side.

33. Install the O-ring seal, cover (20), and bolts (19). Tighten bolts (19) to a torque of 7 to 10 N·m (62 to 89 lb in).

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Illustration 27	g01732293

34. Install backup ring (17) and O-ring seals (18) onto thermal valve (16) .

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Illustration 28	g01685078

35. Install thermal valve (16) .

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Illustration 29	g01685074

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

36. Use Tooling (A) and a suitable vise in order to secure spool (11). Install retainer (12), spring (13), retainer (14), the O-ring seal, and rod (15) onto spool (11). Install the O-ring seal and plug (10) into spool (11) .

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Illustration 30	g01732121

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Illustration 31	g01732120

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

37. Install lever (9). Tighten the set screw for lever (9) to a torque of 3 to 5 N·m (27 to 44 lb in). Tighten the bolt for lever (9) to a torque of 7 to 9 N·m (62 to 80 lb in).

38. Install the seals into housing assembly (7) .

39. Install spool assembly (8) into housing assembly (7) .

40. Install housing assembly (7) and spool assembly (8) as a unit. Install bolts (6). Tighten bolts (6) to a torque of 7 to 10 N·m (62 to 89 lb in).

41. Install O-ring seals (5) .

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Illustration 32	g01151877

42. Install studs (24) and stabilizer valve (23) .

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Illustration 33	g01731917

43. Repeat Steps 31 through Steps 41 for stabilizer valve (4) .

44. Install stabilizer valve (4) .

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Illustration 34	g01151866

45. Install O-ring seal (3) onto cover (2) .

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Illustration 35	g01731914

Note: Ensure that the spools in the valve assemblies move freely.

46. Install cover (2) and nuts (1). Tighten nut (1) in increments of 10 N·m (89 lb in). Tighten nuts (1) until a torque of 20 to 24 N·m (177 to 212 lb in) is achieved.

End By: Install the bank valve. Refer to Disassembly and Assembly, "Bank Valve (Backhoe) - Install".