Field Installation of the 387-6452 Auxiliary Lines Kit , 387-6453 Auxiliary Lines Kit , and 387-6454 Auxiliary Lines Kit {5057} Caterpillar

Backhoe Loader:

416F (S/N: KSF1-UP; LWT1-UP)

420F (S/N: LTG1-UP; LKH1-UP; JWJ1-UP; SKR1-UP)

430F (S/N: RDF1-UP; LNH1-UP; RGS1-UP; LDY1-UP)

Introduction

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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.

ReferenceDisassembly and Assembly, UENR2321, "416F, 420F, and 430FBackhoe 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 hydraulic lines onto 416F, 420F, and 430F Backhoe Loaders that are equipped with a standard stick assembly.

The auxiliary lines power 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.

Installation of the 369-1491 Auxiliary Hydraulic Lines Gp 416F, 387-6453 Auxiliary Lines Kit 420F, and 367-9734 Auxiliary Hydraulic Lines Gp 430F.

Required Parts

Preparing the Machine

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Illustration 1	g01284389

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 the Disassembly and Assembly, "Hydraulic System Pressure - Release" manual for your machine.

Routing of the Hydraulic Lines

Installation of the Return Line

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Illustration 2	g03260679
(A) Cap (B) Filter housing

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

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Illustration 3	g03260837
(22) 368-4842 Tube As (B) Filter housing

2. Attach the 368-4842 Tube As (22) to the filter housing (B) .

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Illustration 4	g03261356
(24) 396-8840 Bracket (39) 8T-4192 Bolt (46) 8T-4223 Hard Washer

3. Attach the 396-8840 Bracket (24), two 8T-4192 Bolts (39) and two 8T-4223 Hard Washer (46) to the frame.

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Illustration 5	g03266596
(5) 148-8442 Tee As (43) 6V-9746 O-Ring Seal (44) 7M-8485 O-Ring Seal

4. Insert O-Ring Seals (43) and (44) into Tee Assembly (5) .

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Illustration 6	g03266597
(43) 6V-9746 O-Ring Seal (44) 5K-9090 O-Ring Seal

5. Insert O-Ring Seals (44) and (45) into Tee Assembly (4) .

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Illustration 7	g03262296
(4) 148-8357 Elbow As (5) 148-8442 Tee As (20) 365-2875 Manual Valve Gp

6. Attach the 148-8442 Tee As (5) to the 365-2875 Manual Valve Gp (20). Attach the 148-8357 Elbow As (4) to the 365-2875 Manual Valve Gp (20) .

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Illustration 8	g03266496
(24) 396-8840 Bracket (26) 5C-9553 Bolt (42) 9X-8256 Washer

7. Attach the 365-2875 Manual Valve Gp (20) to the 396-8840 Bracket (24) using four 5C-9553 Bolts and four 9X-8256 Washers .

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Illustration 9	g03266936

8. Attach the 368-3051 Hose As (21) to the 148-8442 Tee As (5) .

9. Connect the 377-5996 Tube As (25) to the 148-8442 Tee As (5) .

10. Attach the 365-2867 Hose As (19) to the 148-8357 Elbow As (4) .

Installation of the Supply Line

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Illustration 10	g03266963

1. Attach 377-5996 Tube As (25) to the implement valve. Attach 290-6712 Hose As (17) to the implement valve.

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Illustration 11	g03312398

2. Install relief valve (23) into the implement valve.

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Illustration 12	g03266982
(33) 8S-0023 Clip (34) 8S-0024 Clip (40) 8T-4196 Bolt

3. Route hoses (17) and (21) on the boom and attach the hoses with clips (33), (34), and bolts (40) .

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Illustration 13	g03267158
(12) 251-9360 Tube As (14) 262-4217 Tube As (35) 8T-1889 Clip (36) 8T-1890 Clip (40) 8T-4196 Bolt

4. Route tubes (12) and (14) on the boom and attach the tubes with clips (35), (36), and bolts (40). Insert 5K-9090 O-Ring Seals (45) into the fittings at the end of tubes (12) and (14). Attach hoses (17) and (21) to tubes (12) and (14) .

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Illustration 14	g03267302
(8) 155-2026 Union As (13) 262-4203 Hose As (28) 5P-7466 Clip (29) 5P-7467 Clip (30) 5P-8112 Grommet (31) 6V-9172 Nut (41) 8T-4910 Bolt (45) 5K-9090 O-Ring Seal

5. Insert O-Ring Seals (45) into the unions (8). Connect the unions (8) to the tubes (12) and (14). Install unions (8) and nuts (31) into the mount on the boom and tighten. Connect hose assemblies (13) to the unions (8). Route the hoses (13) along the boom and clamp in place with clips (28), (29), grommets (30), and bolts (41) .

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Illustration 15	g03267758
(15) 278-4497 Bracket (16) 278-4498 Bracket (37) 8T-4121 Hard Washer (38) 8T-4136 Bolt

6. Install brackets (15) and (16) with bolts (38) and washers (37) to both sides of the stick.

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Illustration 16	g03267820
(1) 106-0401 Fitting (2) 106-0406 Fitting (6) 148-8449 Swivel Tee (7) 150-3053 Connector As (18) 2P-1293 Locknut (32) 6V-9832 Cap As

7. Install connector assembly (7) in to the brackets (15) and (16) and install o-ring seal into connector assembly (7). Install swivel tee (6) onto connector assembly (7) and install o-ring seals into the two open ports of swivel tee (6). Connect hose assembly (13) to swivel tee (6). Install cap (32) onto swivel tee (6). Install coupler fittings (1) and (2) into the connector assemblies (7) .

Installation of the 353-1388 Hydraulic Pedal Control Gp for the 416F

Note: The following procedure is for mechanically operated machines.

Required Parts

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Illustration 17	g03320776

1. Remove four bolts (28) and four washers (29) from the rear console (30). Retain four bolts (28) and four washers (29) .

2. Remove and retain decal (31) .

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Illustration 18	g03320777

3. Remove two screws (32) from rear console (30) .

4. Remove rear console (30) from the machine.

5. Refer to Disassembly and Assembly, UENR2321, "416F Backhoe Loaders Machine Systems", "Bank Valve (Backhoe) - Remove".

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Illustration 19	g03320778
(30) rear console

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Illustration 20	g02038862
(J) 45 ± 1.5 mm (1.772 ± 0.059 inch) (K) 144 ± 3 mm (5.669 ± 0.118 inch) (L) Diameter of 60 ± 3 mm (2.362 ± 0.118 inch)

6. Cut a slot in rear console (30) to the dimensions that are shown in Illustration 20.

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Illustration 21	g03320774

7. Secure 8T-6431 Rod End (19) to control valve (33) with 398-8245 Pin (26) and 399-2810 Clip (27) .

8. Secure 366-5461 Rod (21) to 8T-6431 Rod End (19) with 8T-4133 Nut (14). Tighten 8T-4133 Nut (14) to a torque of 20 ± 5 N·m (15 ± 4 lb ft).

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Illustration 22	g03320801

9. Install 8T-4133 Nut (14) and 8T-4773 Ball Joint (20) onto 366-5461 Rod (21). Tighten 8T-4133 Nut (14) to a torque of 20 ± 5 N·m (15 ± 4 lb ft).

10. Assemble 389-2016 Plate As (12) to Plate (34). Use two 8T-4195 Bolts (4), four 8T-4121 Hard Washers (3), and two 8T-4133 Nuts (14) .

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Illustration 23	g03320836

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Illustration 24	g03320837

11. Assemble 8T-4121 Hard Washer (3) to 8T-4773 Ball Joint (20). Assemble 036-4453 Retaining Ring (25) to 389-2016 Plate As (12) .

12. Assemble 8T-4186 Bolt (17) and 8T-4121 Hard Washer (3) to 366-5457 Plate As (15). Assemble 366-5457 Plate As (15) and 036-4453 Retaining Ring (25) to 389-2016 Plate As (12) and 8T-4773 Ball Joint (1). Install and tighten 6V-7744 Locknut .

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Illustration 25	g03320845

13. Assemble 231-2875 Support As (1) to Plate (35). Use two 8T-4195 Bolts (4) and two 8T-4121 Hard Washers (3). Assemble 232-1540 Seal (10) to 231-2875 Support As (1) .

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Illustration 26	g03320847

14. Insert 353-3433 Shaft As (2) into 231-2875 Support As (1) .

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Illustration 27	g03320851

15. Assemble two 8T-4133 Nuts (14) to 366-5460 Rod (24). Assemble 8T-6431 Rod End (22) to one end of the rod assembly. Assemble one 8T-4773 Ball Joint (22) to the other end of the rod assembly.

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Illustration 28	g03320854

16. Assemble one 8T-4121 Hard Washer (3) to 8T-4773 Ball Joint (20). Assemble one 8M-3175 Hard Washer (18) on to 8T-4186 Bolt (17). Assemble the 8T-6431 Rod End (19) to 8T-4186 Bolt (17). Secure rod end (19) with one 6V-7744 Locknut (23). Assemble 8T-4773 Ball Joint (20) to 353-3433 Shaft As (2). Secure with one 6V-7744 Locknut (23) .

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Illustration 29	g03312518
(M) 145 ± 2 mm (5.71 ± 0.08 inch) (N) 97 ± 2 mm (3.82 ± 0.08 inch)

17. Make sure that the setting for the rod is the same dimension that is shown in Illustration 29.

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Illustration 30	g03321003

18. Secure 231-2876 Pedal As (5) to 353-3433 Shaft As (2) with 6V-8335 Self-Locking Bolt (7) and 8T-4121 Hard Washer (3) .

    Note: Make sure that 353-3433 Shaft As (2) can move freely through 231-2875 Support As (1) and 231-2876 Pedal As (5). Also make sure that the side to side movement of the pedal is minimized. Assemble 231-2876 Pedal As (5) so that there is 0.5 mm (0.020 inch) to 1.0 mm (0.039 inch) of side play in 231-2876 Pedal As (5) .

19. Refer to Disassembly and Assembly, UENR2321, "416F Backhoe Loaders Machine Systems", "Bank Valve (Backhoe) - Install".

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Illustration 31	g03321034

20. Install console (30) with two screws (32) .

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Illustration 32	g03321036

21. Install console (30) onto the machine with four bolts (28) and four washers (29). Place decal (31) onto the machine.

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Illustration 33	g03316782

22. Place 133-8916 Film (8) and 198-0098 Film (9) onto console (30) .