Field Installation of the 360-2206 Backhoe Auxiliary Lines Gp for the 430E Backhoes with An Extendable Stick{5057} Caterpillar

Backhoe Loader:

430 Series E (S/N: MXB1-UP; SWC1-UP)

Introduction

ReferenceDisassembly and Assembly, UENR0232, "416E, 420E, and 430E Backhoe Loaders Machine Systems"

This Special Instruction applies to the 430E machines built in Leicester, England that are equipped with an extendable stick. This document covers the installation of the auxiliary lines for the Backhoe Loader machines listed above. 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 auxiliary lines group are listed in Table 1 and Table 2.

Preparing the Machine

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Illustration 1	g02318193

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. Extend the extendable stick.

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

5. Release the hydraulic system pressure.

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

Rework E-Stick Lines Group

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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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Illustration 2	g02347162
(25) 153-6241 Elbow As (X) Extendable stick cylinder tube assembly (Y) Extendable stick cylinder hose assembly

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Illustration 3	g02347165
(25) 153-6241 Elbow As (Z) Stick

1. Attach the 153-6241 Elbow As (25) to the existing extendable stick cylinder tube assembly (X) and the existing extendable stick cylinder hose assembly (Y). The 153-6241 Elbow As (25) should be orientated away from the stick (Z) .

2. Repeat Step 1 for the other extendable stick cylinder tube assembly and hose assembly on the other side of the machine.

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Illustration 4	g02301333
Pull to adjust hose assembly where indicated. (P) Grommet

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Illustration 5	g02347243
(25) 153-6241 Elbow As (Y) Extendable stick cylinder hose assembly

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Illustration 6	g02318294
Hose assembly should articulate parallel to the stick.

3. Operate the E-stick in and out. The E-stick hoses should articulate parallel to the stick. If adjustments are needed, refer to Step 4.

4. Loosen the 153-6241 Elbow As (25). Loosen the other end of the existing extendable stick cylinder hose assembly (Y) at the bulkhead plate on the boom. Also loosen existing grommet (P). Adjust and tighten until the hose assembly articulates parallel to the stick.

Installation of Return Line

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Illustration 7	g02301854
(A) Cap (B) Filter housing

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

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Illustration 8	g02318313
(10) 262-3038 Hose As (B) Filter housing

2. Attach the 262-3038 Hose As (10) to the filter housing (B) .

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Illustration 9	g02347262
(C) Frame (D) Cross Brace (9) 262-3036 Bracket (14) 277-4543 Bracket As (42) 8T-4121 Hard Washer (45) 8T-4137 Bolt (48) 8T-4195 Bolt (49) 8T-4196 Bolt

3. Attach the 262-3036 Bracket (9) two 8T-4137 Bolts (45), and two 8T-4121 Hard Washers (42) to frame (C) .

4. Attach 277-4543 Bracket As (14), one 8T-4137 Bolt (48) one 8T-4196 Bolts (49), and two 8T-4121 Hard Washers (42) to cross brace (D) .

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Illustration 10	g02347519
(5) 235-5729 Manual Valve As (9) 262-3036 Bracket (10) 262-3038 Hose As (21) 148-8327 Connector As (13) 262-4211 Tube As (22) 148-8335 Connector As (29) 5P-4116 Hard Washer (8) 260-9143 Elbow (47) 8T-4189 Bolts

5. Attach the 235-5729 Manual Valve As (5), two 8T-4189 Bolts (47) and two 5P-4116 Hard Washer (29) to the 262-3036 Bracket (9) .

6. Attach the 148-8335 Connector As (22) to the 235-5729 Manual Valve As (5) .

7. Attach the 262-3038 Hose As (10) to the 148-8335 Connector As (22) .

8. Attach the 262-4211 Tube As (13) to the bottom side of the 235-5729 Manual Valve As (5) .

9. Attach the 260-9143 Elbow (8) to the 262-4211 Tube As (13) .

10. Attach the 148-8327 Connector As (21) to the 260-9143 Elbow (8). Then connect the assembly to the bottom port of the auxiliary section of the Backhoe Loader valve.

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Illustration 11	g02348076
(3) 144-8344 Spacer (14) 277-4543 Bracket As (17) 286-0689 Tube As (8) 260-9143 Elbow As (18) 290-6713 Hose As (34) 6V-9746 O-Ring Seal (38) 8T-1887 Clip (39) 8T-1888 Clip (42) 8T-4121 Hard Washers (43) 8T-4133 Nut (46) 8T-4185 Bolt (5) 235-5729 Manual Valve As

11. Connect the 260-9143 Elbow As (8) to the top side of the 235-5729 Manual Valve As (5) .

12. Insert one 6V-9746 O-Ring Seal (34) into the 286-0689 Tube As (17). Connect the 286-0689 Tube As (17) to the 260-9143 Elbow As (8) .

13. Assemble one 8T-1887 Clip (38), and one 8T-1888 Clip (39) on the 286-0689 Tube As (17) .

14. Insert one 8T-4185 Bolt (46) and one 8T-4121 Hard Washer (42) through the assembled clips. Assemble one 8T-4121 Hard Washers (42), one 144-8344 Spacer (3), and one 8T-4121 Hard Washer (42) onto the 8T-4185 Bolt (46). Secure the assembled hardware to the 277-4543 Bracket As (14) with one 8T-4121 Hard Washers (42) and one 8T-4133 Nut (43) .

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Illustration 12	g02348096
(17) 286-0689 Tube As (18) 290-6713 Hose As (34) 6V-9746 O-Ring Seal

15. Insert one 6V-9746 O-Ring Seal (34) into the 286-0689 Tube As (17). Connect the 290-6713 Hose As (18) to the 286-0689 Tube As (17) .

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Illustration 13	g02348097
(18) 290-6711 Hose As (E) Swing Frame

16. Route the 290-6713 Hose As (18) through the swing frame (E) .

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Illustration 14	g02348098
(F) Bolt (G) Boom (18) 290-6713 Hose As (36) 8S-0023 Clip (37) 8S-0024 Clip

17. Use the existing bolt (F), one 8S-0023 Clip (36), and one 8S-0024 Clip (37) in order to attach the 290-6713 Hose As (18) to the boom (G) .

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Illustration 15	g02348099
(G) Boom (H) Bolt (12) 262-3043 Tube As (18) 290-6713 Hose As (28) 5K-9090 O-Ring Seal (40) 8T-1889 Clip (41) 8T-1890 Clip

18. Insert one 5K-9090 O-Ring Seal (28). Connect the 262-3043 Tube As (12) to the 290-6713 Hose As (18). In order to attach the 262-3043 Tube As (12) to the boom (G), use the existing bolt (H), one 8T-1889 Clip (40), and one 8T-1890 Clip (41) .

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Illustration 16	g02318654
(J) Plate

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Illustration 17	g02348116
(12) 262-3043 Tube As (20) 316-6273 Hose As (26) 155-2026 Union As (33) 6V-9172 Nut (J) Plate

19. Insert the 155-2026 Union As (26) into plate (J). Use 6V-9172 Nut (33) to secure the 155-2026 Union As (26) into plate (J) .

20. Tighten the 6V-9172 Nut (33) to a torque of 200 ± 20 N·m (148 ± 15 lb ft).

21. Attach the 262-3043 Tube As (12) to the 155-2026 Union As (26) .

22. Attach the 316-6273 Hose As (20) to the 155-2026 Union As (26) .

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Illustration 18	g02348159
(20) 316-6273 Hose As (M) Grommet

23. Route the 316-6273 Hose As (20) through the bottom hole in existing dual grommet (M) .

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Illustration 19	g02348160
(20) 316-6273 Hose As (J) Plate (M) Grommet (N) Bucket hose assembly

24. Pull the 316-6273 Hose As (20) through the existing dual grommet (M). Pull the hose so that there is minimal slack in the hose between the existing dual grommet (M) and plate (J). The existing bucket hose assembly (N) should be routed to the inside of the 316-6273 Hose As (20) .

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Illustration 20	g02348162
(20) 316-6273 Hose As (30) 5P-7466 Clip (31) 5P-7467 Clip (32) 5P-8112 Grommet (50) 8T-4910 Bolt (AA) Plate

25. Use the following hardware in order to attach the 316-6273 Hose As (20) to plate (AA) :
    • One 8T-4910 Bolt (50)

    • The existing washers and nut

    • One 5P-7466 Clip (30)

    • One 5P-7467 Clip (31)

    • One 5P-8112 Grommet (32)

    Leave the 8T-4910 Bolt (50) loose until adjustment. Hoses and grommets should be orientated so that the 316-6273 Hose As (20) is at a right angle to plate (AA) .

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Illustration 21	g02319074
(Z) Stick

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Illustration 22	g02348163
(23) 148-8449 Swivel Tee (35) 6V-9832 Cap As (1) 106-0401 Fitting (24) 150-3053 Connector As (15) 278-4497 Bracket (42) 8T-4121 Hard Washer (44) 8T-4136 Bolt (6) 241-8448 Film (ANSI) (7) 241-8450 Film (ISO) (27) 2P-1293 Locknut (Z) Stick

26. Attach the 278-4497 Bracket (15) to stick (Z) using two 8T-4136 Bolts (44) and two 8T-4121 Hard Washers (42) .

27. Insert the 150-3053 Connector As (24) to the 278-4497 Bracket (15). Connect the 106-0401 Fitting (1) to the 150-3053 Connector As (24) using 2P-1293 Locknut (27). Tighten to 225 ± 20 N·m (166 ± 15 lb ft). Connect the 148-8449 Swivel Tee (23) to the 150-3053 Connector As (24). Point the tee assembly towards the bottom of the stick (Z). Connect the 6V-9832 Cap As (35) to the 148-8449 Swivel Tee (23) .

28. Clean area on stick (Z). Attach either 241-8448 Film (ANSI) (6) or 241-8450 Film (ISO) (7) .

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Illustration 23	g02348176
(20) 316-6273 Hose As (Z) Stick

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Illustration 24	g02348177
(20) 316-6273 Hose As (23) 148-8449 Swivel Tee

29. Attach 316-6273 Hose As (20) to the 148-8449 Swivel Tee (23). Orientate the 316-6273 Hose As (20) so that the hose assembly is parallel to stick (Z) .

Installation of the Supply Line

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Illustration 25	g02348196
(19) 290-6714 Hose As (21) 148-8327 Connector As

1. Connect the 148-8327 Connector As (21) to the 290-6714 Hose As (19). Then connect the hose assembly to the top port of the Backhoe Loader valve.

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Illustration 26	g02348216
(19) 290-6714 Hose As (E) Swing frame

2. Route the 290-6714 Hose As (19) through the swing frame (E) .

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Illustration 27	g02348237
(19) 290-6714 Hose As (36) 8S-0023 Clip (37) 8S-0024 Clip (F) Bolt (G) Boom

3. Use the existing bolt (F), and one 8S-0023 Clip (36), one 8S-0024 Clip (37) in order to attach the 290-6714 Hose As (19) to the boom (G) .

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Illustration 28	g02348316
(11) 262-3042 Tube As (19) 290-6714 Hose As (28) 5K-9090 O-Ring Seal (40) 8T-1889 Clip (41) 8T-1890 Clip (G) Boom (H) Bolt

4. Insert one 5K-9090 O-Ring Seal (28). Connect the 262-3042 Tube As (11) to the 290-6714 Hose As (19). In order to attach the 262-3042 Tube As (19) to the boom (G), use the existing bolt (H), one 8T-1889 Clip (40), and one 8T-1890 Clip (41) .

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Illustration 29	g02348339
(11) 262-3042 Tube As (20) 316-6273 Hose As (26) 155-2026 Union As (33) 6V-9172 Nut (J) Plate (G) Boom

5. Insert the 155-2026 Union As (26) into the plate (J). Use the 6V-9172 Nut (33) in order to secure the 155-2026 Union As (26) into plate (J) .

6. Tighten the 6V-9172 Nut (33) to a torque of 200 ± 20 N·m (148 ± 15 lb ft).

7. Attach the 262-3042 Tube As (11) to the 155-2026 Union As (26) .

8. Attach the 316-6273 Hose As (20) to the 155-2026 Union As (26) .

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Illustration 30	g02348356
(20) 316-6273 Hose As (M) Grommet

9. Route the 316-6273 Hose As (20) through the bottom hole in existing dual grommet (M) .

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Illustration 31	g02348358
(20) 316-6273 Hose As (J) Plate (M) Grommet (N) Bucket hose assembly

10. Pull the 316-6273 Hose As (20) through the existing dual grommet (M). Pull the hose so that there is minimal slack in the hose between the existing dual grommet (M) and plate (J). The existing bucket hose assembly (N) should be routed to the inside of the 316-6273 Hose As (20) .

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Illustration 32	g02348477
(20) 316-6273 Hose As (30) 5P-7466 Clip (31) 5P-7467 Clip (32) 5P-8112 Grommet (50) 8T-4910 Bolt (AA) Plate

11. In order to attach the 316-6273 Hose As (20) to plate (AA) use the following hardware:
    • One 8T-4910 Bolt (50)

    • The existing washers and nut

    • One 5P-7466 Clip (30)

    • One 5P-7467 Clip (31)

    • One 5P-8112 Grommet (32)

    Hoses and grommets should be orientated so that the 316-6273 Hose As (20) is at a right angle to plate (AA) .

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Illustration 33	g02348522
(23) 148-8449 Swivel Tee (35) 6V-9832 Cap As (2) 106-0406 Fitting (24) 150-3053 Connector As (27) 2P-1293 Locknut (16) 278-4498 Bracket (42) 8T-4121 Hard Washer (44) 8T-4136 Bolt (6) 241-8448 Film (ANSI) (7) 241-8450 Film (ISO)

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Illustration 34	g02319358
(Z) Stick

12. Attach the 278-4498 Bracket (16) to stick (Z) using two 8T-4136 Bolts (44) and two 8T-4121 Hard Washers (42) .

13. Insert the 150-3053 Connector As (24) to the 278-4498 Bracket (16) using 2P-1293 Locknut (27). Tighten to 225 ± 20 N·m (166 ± 15 lb ft). Connect the 106-0406 Fitting (2) to the 150-3053 Connector As (24). Connect the 148-8449 Swivel Tee (23) to the 150-3053 Connector As (24). Point the tee assembly towards the bottom of the stick (Z). Connect the 6V-9832 Cap As (35) to the 148-8449 Swivel Tee (23) .

14. Clean area on stick (Z). Attach 241-8448 Film (ANSI) (6) or 241-8450 Film (ISO) (7) .

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Illustration 35	g02348578
(20) 316-6273 Hose As (23) 148-8449 Swivel Tee

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Illustration 36	g02348579
(20) 316-6273 Hose As (Z) Stick

15. Attach the 316-6273 Hose As (20) to the 148-8449 Swivel Tee (23). Orientate the 316-6273 Hose As (20) so that the hose assembly is parallel to stick (Z) .

Test and Adjust

Adjustment of Auxiliary Hoses

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Illustration 37	g02348656
(20) 316-6273 Hose As (AB) Bucket cylinder hose

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Illustration 38	g02319958
(AC) Pull (AD) Bucket

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Illustration 39	g02319959
(AE) Bucket hose (AF) Auxiliary hose

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Illustration 40	g02319975
(AE) Bucket hose (AF) Auxiliary hose

1. Pull the 316-6273 Hose As (20) through the existing dual grommet. Pull the hose assembly so there is minimal slack in the hose between the existing dual grommet and bulkhead plate. The existing bucket hose should be routed to the inside of the 316-6273 Hose As (20) .

2. Pull the bucket and auxiliary lines through the grommets until the hose slack is at a minimum and the grommets are not deformed.

3. The bucket hose (AE) should lay slightly above and to the outside of the auxiliary hose (AF) .

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Illustration 41	g02319979
(AG) Spacer (AH) Single grommet (AJ) E-stick cylinder hose

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Illustration 42	g02319982
(AK) Grommets

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Illustration 43	g02319984
(AL) Fitting

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Illustration 44	g02319985
(AM) Band clamp (AK) Grommet

4. The single grommet (AH) for the E-stick cylinder hose (AJ) should be a slight angle relative to the dual grommet.

5. Spacers (AG) under the single grommet (AH) may be necessary to allow the grommet to turn doe to the washer for the dual grommet.

6. The grommets (AK) for the bucket hoses are angled such that the hoses determine the angle.

7. The fitting (AL) for the bucket cylinder hose should be loosened to let the hose determine the fitting angle.

8. Adjust the band clamp (AM) and grommet (AK) on the bucket hose.

Testing

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Illustration 45	g02305476
Horizontal

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Illustration 46	g02305477
Forty-five degree

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Illustration 47	g02305479
Vertical

1. Test the machine in three positions. In each position, run the E-stick through the full range of motion.
   • Horizontal

   • Forty-five degree

   • Vertical

   Follow the acceptance criteria

Acceptance Criteria

Illustration 48	g02305515

Illustration 49	g02305516

Auxiliary hoses should route parallel to E-stick structure without twisting.

Bucket hoses should route slightly above and outside auxiliary hoses without twisting.

There may be slight contact between hoses. This contact is acceptable as long as the hoses do not alter the intended path.

Momentary light contact between hoses and boom structure is acceptable.

Unacceptable Criteria

Illustration 50	g02305554

Illustration 51	g02305555

During operation of E-stick, stick and boom functions:

• Contact with inner E-stick structure (1) is unacceptable

• Contact with outer E-stick structure (2) is unacceptable

• Contact with wear pad hardware (3) is unacceptable

Final Adjustment

If adjustment is needed, loosen both ends of the hose at the coupling and any grommets.

Rotate hose at either end to adjust how the hose will articulate.

Retighten and test again.

Repeat until the hose meets the acceptance criteria.