Installing the 473-2822 Auxiliary Lines Kit {5057} Caterpillar

Backhoe Loader

432F2 (S/N: LYJ1-UP; HWP1-UP)

444F2 (S/N: LYL1-UP; HWS1-UP)

Introduction

This Special Instruction outlines the parts and procedure for installing the 473-2822 Auxiliary Lines Kit

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Personal injury or death can result without releasing all of the hydraulic pressure. Release all the pressure from the hydraulic system before any lines are disconnected.

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. In order to prevent possible injury, perform the following procedure before testing and adjusting any of the machine hydraulic systems.

Required Parts

Installation Procedure

Installing the Sideshift Gp

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Illustration 1	g06046946
View of the Right Stabilizer from the front of the machine (8) 348-1713 Bracket As

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Illustration 2	g06046942
View of the Right Stabilizer from the rear of the machine (A) Reference point (B) Reference point (C) 80.5 ± 1 mm (3.17 ± 0.04 inch) (8) 348-1713 Bracket As

1. Position Bracket As (8) on the right stabilizer per the dimensions that are specified in Illustration 2. Use a 6 mm (0.24 inch) fillet welds to secure the bracket. Refer to Illustrations 1 and 2.

   Note: The welds in Illustration 2 should be from Point (A) to Point (B). Be sure to clean up the weld and the surrounding surface area. After work is complete, apply paint to the area.

2. Release the pressure from the sideshift locks. To release the locks, turn the ignition key to the RUN position. Do not start the engine. Engage the switch for the sideshift lock. This procedure will release the sideshift lock. Turn off the ignition.

   Note: Refer to Disassembly and Assembly, UENR3749, "System Pressure - Release"

3. Lift the slide frame and support the slide frame. Be sure to use the proper jack and stands. Blocking the machine is also sufficient.

   Note: Refer to Disassembly and Assembly, UENR2309, "Sliding Frame and Bearing - Remove"

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Illustration 3	g06046978
(18) Existing bolts (19) Existing hard washers (20) Existing blocks (21) Existing bars

1. Remove the existing six bolts (18) and existing six hard washers (19) to remove existing blocks (20) and existing bars (21). Discard the six bolts, six washers, two blocks, and two bars. Refer to Illustration 3.
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   Illustration 4	g06046990
   (4) 344-5302 Block (5) 344-5303 Pad (6) 344-5338 Mount As (9) 350-2961 Pad (14) 8T-4196 Bolt (16) 8T-5005 Bolt (17) 8T-5035 Bolt

2. Assemble one Pad (5) to each Block (4). Secure pads to Blocks (4) with two bolts (14). Refer to Illustration 4.

3. Assemble the one Pad (5) on the right side of the swing frame using two bolts (17) to secure the pad. Install pad (9) to the right side of the swing frame using bolt (16). Install another Pad (5) on the left side of the swing frame is to be secured to the swing frame using Bolt (17). The last two Pads (8) need assembled on to Blocks (4) using two Bolts (14) to secure the pad on each block. Torque Bolts (14) to 30 ± 2 N·m (22.1 ± 1.5 lb ft). Refer to Illustration 4.

   Note: Ensure that Blocks (4) are oriented, as shown in Illustration 4

4. Torque Bolts (16) and (17) to 30 ± 2 N·m (22.1 ± 1.5 lb ft).
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   Illustration 5	g06047018
   (1) 106-7994 Bolt (4) 344-5302 Block (6) 344-5338 Mount As (12) 8T-1482 Hard Washer (22) Existing bolts (23) Existing hard washers

5. On the left side of the swing frame, install Mount As (6) and Block (4) with three Bolts (1) and three Hard Washers (12). On the right side of the swing frame, install Block (4) using the existing bolts (22) and hard washers (23). Hand tighten the bolts now. Refer to Illustration 5.

   Note: Ensure that the mount assembly is parallel with the slide frame.

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   Illustration 6	g06047034
   (1) 106-7994 Bolt (4) 344-5302 Block (22) Existing bolts (24) Existing slide rail

6. Lower the slide frame with the jack so that the slide frame is supported on the existing slide rail (24). Make sure that blocks (4) are hooked behind slide rail (24). Refer to Illustration 6.

7. Tighten bolts (1) and bolts (22) to standard torque. Refer to Illustrations 5 and 6.
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   Illustration 7	g06047047
   (6) 344-5338 Mount As (7) 347-2223 Sideshift Cylinder Gp (8) 348-1713 Bracket As (10) 351-2210 Pin (11) 6V-7644 Retaining Ring

8. Install the rod end of the cylinder (7A) to previously installed Bracket As (8) that is on the existing right stabilizer . Insert Pin (10) to connect the rod end of cylinder (7A) to the bracket. Secure the pin with two Retaining Rings (11). Refer to Illustration 7.

9. Install the rod end of the cylinder (7B) to Mount As (6). Secure the cylinder with a Retaining Ring (11). Refer to Illustration 7.
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   Illustration 8	g06047202
   Rear View of the Cab (A) 80 mm (3.1 inch) (B) 480 mm (18.9 inch) (C) 880 mm (34.6 inch) (D) 43 mm (1.7 inch) (3) 321-2392 Plate (13) 8T-4189 Bolt (15) 8T-4224 Hard Washer (34) 180-3748 Threaded Insert

10. Use Plate (3) as a template to mark the location of the three holes on the back of the cab. Refer to Illustration 8 for the location of the holes.

11. Drill three holes to 13.5 mm (0.5 inch) diameter. Refer to Illustration 8 for the location of the holes.

12. Install three threaded inserts (34) (part of the 473-2822 Auxiliary Lines Kit). Use the installation procedure that follows. The method that is described in this procedure will work for installing the threaded inserts in the field.

    1. Use a M8 nut, Hard Washer (15), and Bolt (13). Screw Bolt (13) onto threaded insert (34). Screw the Bolt (13) until there are a few threads showing at the bottom of threaded insert (34).

    2. Holding head of bolt, push threaded insert (34) into the hole in the cab.

    3. Secure the nut to 30 N·m (265 lb in). The threaded insert (34) should collapse inside the hole in the cab and lock into place.

    4. Remove Bolt (13), the nut, and Hard Washer (15).
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    Illustration 9	g06047198
    (E) 495 ± 20 mm (19.5 ± 0.8 inch) (F) 10 ± 5 mm (0.4 ± 0.2 inch) (2) 124-2456 Film (3) 321-2392 Plate

13. Apply Film (2) to Plate (3). Refer to Illustration 9.
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    Illustration 10	g06047125
    (3) 321-2392 Plate (13) 8T-4189 Bolt (15) 8T-4224 Hard Washer

14. Install Plate (3) onto the back of the cab. Use Bolts (13) and Hard Washers (15) to secure the plate to the cab. Refer to Illustration 10.

Welding the Bosses

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Illustration 11	g06046502
Right side view for an EST frame (47) 9R-2160 Boss (A) 56.8 mm (2.23 inch) (B) 126.5 mm (4.98 inch) (C) 126.8 mm (4.99 inch)

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Illustration 12	g06046508
Right side view for a Standard frame (47) 9R-2160 Boss (A) 88.5 mm (3.48 inch) (B) 126.5 mm (4.98 inch) (C) 47.6 mm (1.87 inch)

1. Weld two Bosses (47) to the insideofthe left side of the frame. Use a 3 mm (0.12 inch) filet weld around the perimeter of the bosses. Refer to Illustrations 11 and 12 for the proper machine.

Assembling the Main Control Valve Gp

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Illustration 13	g06045992
(5) 319-2155 Main Control Valve Gp (26) 148-8319 Connector As (27) 148-8325 Connector As (29) 148-8345 Connector As (35) 241-6185 Plug As (39) 6V-9830 Cap As

1. Assemble three Connector As (27), two Connector As (29), two Connector As (26), and one Plug As (35) to Main Control Valve Gp (5). Assemble one Cap As to each Connector As (29). Refer to Illustration .
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   Illustration 14	g06046212
   Front view (3) 106-8715 Elbow As (5) 319-2155 Main Control Valve Gp (30) 148-8347 Elbow As (31) 148-8368 Elbow As

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   Illustration 15	g06046216
   Left side view (3) 106-8715 Elbow As (5) 319-2155 Main Control Valve Gp (30) 148-8347 Elbow As (31) 148-8368 Elbow As

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   Illustration 16	g06046224
   Bottom view (3) 106-8715 Elbow As (5) 319-2155 Main Control Valve Gp (30) 148-8347 Elbow As (31) 148-8368 Elbow As

2. Assemble two Elbow As (31), one Elbow As (3), and one Elbow As (30) to Main Control Valve Gp (5). Refer to Illustrations 14,15, and 16 for elbow orientation.

Assembly of Pilot Valve Gp

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Illustration 17	g06046280
Front view (9) 373-7028 Pilot Valve Gp (25) 148-8316 Connector As (27) 148-8325 Connector As (31) 148-8368 Elbow As

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Illustration 18	g06046284
Left side view (9) 373-7028 Pilot Valve Gp (25) 148-8316 Connector As (27) 148-8325 Connector As (31) 148-8368 Elbow As

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Illustration 19	g06046291
Bottom view (9) 373-7028 Pilot Valve Gp (25) 148-8316 Connector As (27) 148-8325 Connector As (31) 148-8368 Elbow As

1. Assemble four Connector As (25), one Connector As (27), and one Elbow As (31) to Pilot Valve Gp (9). Refer to Illustrations 17,18, and 19 for elbow orientation.
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   Illustration 20	g06046328
   View of the machine frame (5) 319-2155 Main Control Valve Gp (9) 373-7028 Pilot Valve Gp (24) 107-0269 Bolt (36) 246-7854 Special Nut (40) 8T-4121 Hard Washer (44) 8T-4196 Bolt (47) 9R-2160 Boss

2. Assemble Main Control Valve Gp (5) to the inside face of the left-hand side of the machine frame. Use three Special Nuts (36), Hard Washers (40), and Bolts (44). Torque Bolts (44) and Special Nuts (36) to 35 ± 5 N·m (25.8 ± 3.7 lb ft). Refer to Illustration 20.

3. Assemble Pilot Valve Gp (9) to the inside face of the left-hand side of the machine frame. Use two Bolts (24) to attach Pilot Valve Gp (9) to two Bosses (47). Refer to Illustration 20.
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   Illustration 21	g06047462
   (5) 319-2155 Main Control Valve Gp (9) 373-7028 Pilot Valve Gp (14) 380-5749 Hose As (15) 381-0226 Hose As (16) 381-0227 Hose As (17) 381-0228 Hose As

4. Assemble Hose As (17) to the lower fitting on the left side of Main Control Valve Gp (5). Assemble the other end of Hose As (17) to the "B" port of Pilot Valve Gp (9). Refer to Illustration 21.

5. Assemble Hose As (14) to the upper fitting on the left side Main Control Valve Gp (5). Assemble the other end of Hose As (14) to the "A" port of Pilot Valve Gp (9). Refer to Illustration 21.

6. Assemble Hose As (16) to the upper fitting on the right side Main Control Valve Gp (5). Assemble the other end of Hose As (16) to the "C" port of Pilot Valve Gp (9). Refer to Illustration 21.

7. Assemble Hose As (15) to the lower fitting on the right side Main Control Valve Gp (5). Assemble the other end of Hose As (15) to the "D" port of Pilot Valve Gp (9). Refer to Illustration 21.
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   Illustration 22	g06047507
   (7) 352-5462 Hose As (7A) 347-2223 Sideshift Cylinder Gp (part of 351-1639 Sideshift Gp) (8) 352-5463 Hose As (27) 148-8325 Connector As

8. Assemble two Connector As (27) to Sideshift Cylinder Gp (7A). Assemble Hose As (7) and Hose As (8) to Sideshift Cylinder Gp (7A). Refer to Illustration 22.
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   Illustration 23	g06047561
   (2) 9R-6247 Cable Strap (5) 319-2155 Main Control Valve Gp (7) 352-5462 Hose As (8) 352-5463 Hose As (22) 392-1953 Plate (37) 4D-6988 Clip (40) 8T-4121 Hard Washer (41) 8T-4133 Nut (42) 8T-4192 Bolt (43) 8T-4195 Bolt (45) 8T-4223 Hard Washer (46) 8T-4244 Nut (48) 091-8487 Trim Channel

9. Assemble Hose (7) and Hose (8) to Main Control Valve Gp (5). Refer to Illustration 23.

10. Secure Hose (7) and Hose (8) using 20 Cable Straps (2) (two at each location). Refer to Illustration 23.

11. Secure Hose (7) and Hose (8) to the frame. Use one Clip (37), one Hard Washer (40), one Nut (41), and one Bolt (43). Refer to Illustration 23.

12. Secure Hose (7) and Hose (8) to the frame. Use one Plate (22), one Clip (37), Bolt (42), two Hard Washers (45), and one Nut (46). Refer to Illustration 23.
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    Illustration 24	g06047598
    Existing bank valve (32) 148-8445 Tee As (33) 150-5968 Tee As

13. Assemble Tee As (33) to the load sense port of the Existing bank valve. Refer to Illustration 24.

14. Assemble Tee As (32) to the tank port of the Existing bank valve. Refer to Illustration 24.
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    Illustration 25	g06048974
    (AA) Inlet cover (13) 380-5747 Hose As (19) 381-0346 Hose As (28) 148-8335 Connector As (32) 148-8445 Tee As

15. Assemble Connector As (28) and Tee As (32) to the Tank port on Inlet cover (AA). Refer to Illustration 25.

16. Assemble the straight end of Hose As (13) to Tee As (32). Refer to Illustration 25.

17. Assemble the 45° end of Hose As (19) to Tee As (32). Refer to Illustration 25.
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    Illustration 26	g06047678
    (3) 106-8715 Elbow As (5) 319-2155 Main Control Valve Gp (12) 375-6288 Hose As (19) 381-0346 Hose As (32) 148-8445 Tee As (33) 150-5968 Tee As

18. Assemble Hose As (12) to Tee As (33). Assemble the other end to Main Control Valve Gp (5). Assemble the straight end of Hose As (19) to Elbow As (3) .Refer to Illustration 26.
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    Illustration 27	g06048918
    (10) 375-6285 Hose As (30) 148-8347 Elbow As (38) 241-6209 Cross Union As

19. Remove the existing Cross Union As. Install Cross Union As (38). Assemble straight end of Hose As (10) to Cross Union As (38). Refer to Illustration 27.

20. Assemble the 90° end of Hose As (10) to Elbow As (30). Refer to Illustration 27.

21. Assemble Hose As (19) to Tee As (32). Assemble the other end to Elbow As (3) on Main Control Valve Gp (5). Refer to Illustration 26.
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    Illustration 28	g06047696
    (A) Fitting on the filter assembly (13) 380-5747 Hose As (32) 148-8445 Tee As

22. Assemble Hose As (13) between Tee As (32) and Fitting on the filter assembly (A). Refer to Illustration 28.
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    Illustration 29	g06047716
    (9) 373-7028 Pilot Valve Gp (11) 375-6287 Hose As (18) 381-0230 Hose As (27) 148-8325 Connector As (31) 148-8368 Elbow As (33) 150-5968 Tee As

23. Assemble the 90° end of Hose As (18) to Elbow As (31) on Pilot Valve Gp (9). Refer to Illustration 29.

24. Assemble the straight end of Hose As (18) to Tee As (33) on the existing valve assembly. Refer to Illustration 29.

25. Assemble the 90° end of Hose As (11) to Connector As (27) on Pilot Valve Gp (9). Refer to Illustration 29.

26. Assemble the straight end of Hose As (11) to Tee As (33) on the existing valve assembly. Refer to Illustration 29.
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    Illustration 30	g06048203
    View from inside the operator station facing the rear of the machine (20) 387-6564 Joystick Control Gp

27. Replace the left joystick control with the new Joystick Control Gp (20). Refer to Illustration 30.
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    Illustration 31	g06048298
    (9) 373-7028 Pilot Valve Gp (20) 387-6564 Joystick Control Gp (21) 387-6638 Sideshift Wiring Gp (23) 451-9658 Auxiliary Wiring

28. Connect Auxiliary Wiring (23) by making the connections that are specified in Table 3. Refer to Illustration 31.
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    Table 3

    451-9658 Auxiliary Wiring
    Harness Connector	Description	Connection
    AA	"A" X800–OR	Connect to machine right handle
    	"B" J764–BR
    AB	"A" 200–BK	Connect to platform harness
    	"B" M719–GN

29. Connect Auxiliary Wiring (21) by making the connections that are specified in Table 4. Refer to Illustration 31.
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    Table 4

    387-6638 Sideshift Wiring Gp
    Harness Connector	Description	Connection
    AC	"1" X800–OR	Connect to platform harness
    	"2" J764–BR
    AD	"1" M721–WH	Connect to side shift right suppressor
    	"2" 200–BK
    AE	"1" M719–GN	Connect to side shift left suppressor
    	"2" 200–BK
    AF	"1" M720–BU	Connect to lockout solenoid suppressor
    	"2" 200–BK
    AG	"1" M720–BU	Connect to diode 1
    	"2" M721–WH
    AH	"1" M720–BU	Connect to diode 12
    	"2" M719–GN
    AJ	"1" M720–BU	Connect to lockout solenoid
    	"2" 200–BK

30. Make harness connections at Pilot Valve Gp (9) by making the connections that are specified in Table 5. Refer to Illustration 31.
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    Table 5

    373-7028 Pilot Valve Gp
    Harness Connector	Description	Connection
    AK	"1" T970–GY	Connect to hoe aux valve 2 solenoid 1
    	"2" H802–GY
    AL	"1" M719–GN	Connect to sideshift left solenoid
    	"2" 200–BK
    AM	"1" T972–GY	Connect to hoe aux valve 2 solenoid 12
    	"2" H802–GY
    AN	"1" M721–WH	Connect to sideshift right solenoid
    	"2" 200–BK

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    Illustration 32	g06048392
    (1) 7K-1181 Cable Strap (4) 206-2423 Saddle

31. Secure harnesses using three Cable Straps (1) and Saddle (4). Refer to Illustration 32.
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    Illustration 33	g06048377
    Switch location for the power sideshift function

32. Install the Rocker Switch. The switch connector (A) will connect to the existing side console wiring harness. Refer to Illustration 33 and Table 6.
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    Table 6

    Rocker Switch connections
    Harness Connector	Description	Connection
    AP	"1" H771–BR	Connect to side console harness power sideshift connector
    	"2" R912–OR

ET Configuration

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Illustration 34	g01789793

1. From the Hydraulics Configuration screen, highlight "Hoe Auxiliary Valve #2 Installation Status" and click "Change".

   Note: "Hoe Auxiliary Valve #2" is the eighth function thumb wheel on the left joystick control.

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   Illustration 35	g01789815

2. In the Change Parameter Value screen, highlight "Installed" and click "OK".
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   Illustration 36	g01789836

3. Verify that the "Hoe Auxiliary Valve #2 Installation Status" now shows "Installed".

   There are four options for adjusting the flow for the eighth function auxiliary control valve:

   • Hoe Auxiliary Valve #2-Port A Solenoid Minimum Current — This option adjusts the minimum flow from the circuit on Port A. The setting will affect the feel of the thumb wheel control for Port A. The recommended setting is 0.6 mA. Higher settings will give a harsher start of the work tool.

   • Hoe Auxiliary Valve #2-Port A Solenoid Maximum Current — This option adjusts the maximum flow from the circuit on Port A. This adjustment is factory set at 1.8 mA for maximum flow. This setting can be adjusted with the aid of a flow meter for the required flow for the work tool that is used. Lower settings will yield lower flow. Higher settings will give a harsher start of the work tool.

   • Hoe Auxiliary Valve #2-Port B Solenoid Minimum Current — This option adjusts the minimum flow from the circuit on Port B. This option will adjust the feel of the thumb wheel control for Port B. The recommended setting is 0.6 mA. Higher settings will give a harsher start of the work tool.

   • Hoe Auxiliary Valve #2-Port B Solenoid Maximum Current — This option adjusts the maximum flow from the circuit on Port B. This adjustment is factory set at 1.8 mA for maximum flow. This setting can be adjusted with the aid of a flow meter for the required flow for the work tool that is used. Lower settings will yield lower flow.

   Use the procedure that is provided below to change the settings of the solenoids for the auxiliary valve #2.

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Illustration 37	g01789873

1. From the Valve Calibrations Currents screen, highlight the item that you want to change and click "Change".
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   Illustration 38	g01789924

2. Acknowledge the change by clicking "Yes".
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   Illustration 39	g01789935

3. Enter the new value of "1.4" and click "OK".

4. Observe that the value has been changed to "1.4 Amps". Exit the ET Configuration program.

5. Repeat the procedure for each setting, as needed.

Reference Section

Special Instruction, REHS1841, "General Welding Procedures"

Operation and Maintenance Manual, SEBU9217, "428F2, 432F2, 434F2, and 444F2 Backhoe Loaders"

Disassembly and Assembly, UENR3749, "422F2, 427F2, 428F2, 432F2, 434F2, and 444F2 Backhoe Loaders Machine Systems"