Field Installation of the 387-6455 Auxiliary Lines Kit , 387-6456 Auxiliary Lines Kit , and 387-6457 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

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 an extendable 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.

Safety

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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.

Reference

ReferenceDisassembly and Assembly, UENR2321, "416F, 420F, and 430F Backhoe Loader Machine Systems"

Installation of the 367-9730 Auxiliary Hydraulic Lines Gp 416F and 420F, and 367-9738 Auxiliary Hydraulic Lines Gp 430F.

Required Parts

Note: 375-6022 Bracket As supplied with in 367-9730 Auxiliary Hydraulic Lines Gp is not required. Replaced with 375-6022 Bracket .

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	g03342185
(16) Tube As (B) Filter housing

2. Attach Tube As (16) to the filter housing (B) .

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Illustration 4	g03596200
(17) Bracket (37) Hard Washer (39) Bolt

3. Attach Bracket (17), two Bolts (39) and two Hard Washers (37) to the frame.

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Illustration 5	g03342193
(20) Tee As

4. Make sure that O-Ring Seals are seated into Tee Assembly (20) .

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Illustration 6	g03342200
(19) Elbow Assembly

5. Make sure that O-Ring Seals are seated into Elbow Assembly (19) .

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Illustration 7	g03342207
(14) Manual Valve Gp (19) Elbow As (20) Tee As

6. Attach Tee As (20) to Manual Valve Gp (14). Attach Elbow As (19) to Manual Valve Gp (14) .

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Illustration 8	g03342216
(17) Bracket (26) Bolt (42) Washer

7. Attach Manual Valve Gp (20) to Bracket (17) using four Bolts (26) and four Washers (42) .

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Illustration 9	g03342224
(12) Hose As (13) Tube As (15) Hose As (19) Elbow As (20) Tee As

8. Attach Hose As (15) to Tee As (20) .

9. Connect Tube As (13) to Tee As (20) .

10. Attach Hose As (12) to Elbow As (19) .

Installation of the Supply Line

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Illustration 10	g03342235

1. Attach Tube As (13) to the implement valve. Attach Hose As (10) to the implement valve.

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Illustration 11	g03342250
(3) Cable Strap (10) Hose (15) Hose (33) Clip (34) Clip (40) Bolt

2. Route hoses (10) and (15) on the boom and attach the hoses with two clips (33), two clips (34), and bolts (40). Secure hoses (10) and (15) with two Cable Straps (3). Refer to Illustration 11.

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Illustration 12	g03342256
(6) Tube As (7) Tube As (10) Tube As (15) Tube As (27) O-Ring Seals (35) Clip (36) Clip (40) Bolt

3. Route tubes (6) and (7) on the boom and attach the tubes with clip (35), clip (36), and bolts (40). Make sure that O-Ring Seals are seated into the fittings at the end of tubes (6) and (7). Attach hoses (10) and (15) to tubes (6) and (7) .

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Illustration 13	g03342273
(6) Tube As (7) Tube As (11) Hose As (24) Union As (27) O-Ring Seal (28) Clip (29) Clip (30) Grommet (31) Nut (41) Bolt

4. Insert O-Ring Seals (27) into the unions (24). Connect the unions (24) to the tubes (6) and (7). Install unions (24) and nuts (31) into the mount on the boom and tighten. Connect hose assemblies (11) to the unions (24). Route the hoses (11) along the boom and clamp in place with clips (28), (29), grommets (30), and bolts (41) .

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Illustration 14	g03816187

5. Remove straight fitting (23A) from 266-4570 Hose As .

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Illustration 15	g03816238

6. Install elbow fitting (23) in place of the straight fitting. Reconnect 266-4570 Hose As to the new elbow fitting.

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Illustration 16	g03342277
(8) Bracket (9) Bracket (11) Tube As (37) Hard Washer (38) Bolt

7. Install brackets (9) and (8) with bolts (38) and washers (37) to both sides of the stick.

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Illustration 17	g03587432
(1) Fitting (2) Fitting (6) Swivel Tee (8) Bracket (9) Bracket (11) Tube As (22) Connector As (25) Locknut (32) Cap As

8. Install connector assembly (22) in to the brackets (8) and (9) using Locknut (25). 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 (11) to swivel tee (6). Install cap (32) onto swivel tee (6). Install coupler fittings (1) and (2) into the connector assemblies (7) .

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Illustration 18	g03342321
View of the left side of the Stick

9. Install Film (4) and Film (5) to the right side of the Stick. Repeat this step on the right side of the Stick.

Installation of the 361-9738 Control Valve Gp for the 416F

Note: The following procedure is for mechanically operated machines.

Required Parts

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Illustration 19	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 20	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 21	g03340332
(30) rear console

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Illustration 22	g03340552
(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) (M) 55 ± 3 mm (2.165 ± 0.1181 inch)

6. Cut a slot in rear console (30) to the dimensions that are shown in Illustration 22.

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Illustration 23	g03341187
(1) Ball Joint (8) Plate (9) Rod (10) Plate As (13) Shaft (14) Spring Pin (17) Retaining Ring (18) Hard Washer (19) Nut (20) Bolt (21) Pin (22) Rod End (33) Plate As

7. Secure Plate As (10) with two Hard Washers (18) and two Bolts (20) .

8. Push Shaft (13) through Plate As (10), Plate (8), Plate As (33), and Plate (8). Secure each end of Shaft (13) with one Retaining Ring (17) .

9. Secure two Plates (8) to Shaft (13) with two Spring Pins (17) .

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Illustration 24	g03341194
(1) Ball Joint (8) Plate (9) Rod (10) Plate As (15) Locknut (18) Hard Washer (19) Nut (21) Pin (22) Rod End (34) Valve Section

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Illustration 25	g03340589
(N) 148 ± 2 mm (5.83 ± 0.08 inch)

10. Assemble Rod (9), Rod End (22), Ball Joint (1), and two Nuts (19). Make sure that the setting for the rod is the same dimension that is shown in Illustration 25. Torque Nuts (19) to 20 ± 5 N·m (14.8 ± 3.7 lb ft).

11. Assemble Rod assembly to Valve section (34), using Pin (21) .

12. Assemble Ball Joint (1) to Plate (8) using one Locknut (15) and one Hard Washer (18) .

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Illustration 26	g03341348
(5) Support As (18) Hard Washer (19) Nut (20) Bolt

13. Assemble Support As (5) with one Bolt (20), two Hard Washers (18), and one Nut (19) .

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Illustration 27	g03341391
(1) Ball Joint (7) Rod (19) Nut

14. Assemble Rod (7), two Ball Joints (1), and two Nuts (19). Refer to Illustration 27.

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Illustration 28	g03341398
(5) Support As (8) Plate (11) Spacer (12) Shaft As (15) Locknut (18) Hard Washer

15. Assemble Shaft As (12) and Spacer (11) to Support As (5) .

16. Connect rod assembly to Support As (5) and Plate (8). Use two Hard Washers (18) and two Locknuts (15) .

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Illustration 29	g03341445
(2) Lock Pin (3) Pin (4) Pedal As (6) Seal

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Illustration 30	g03341410
(3) Pin (4) Pedal As (12) Shaft As (16) Self-Locking Bolt (18) Hard Washer

17. Slide Seal (6) onto Shaft (12) .

18. Assemble Pedal As (4) to Shaft (12). Use one Hard Washer (18) and Self-Locking Bolt one (16). Assemble Pedal (4) to allow −.75 ± 0.25 mm (0.03 ± 0.01 inch) of side play. Install Pin (3) and Lock Pin (2) if necessary.

    Note: Pin (3) is used to lock out the eighth function hydraulic operation.

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.