Procedure to Unload the 416F2 and 420F2 Backhoe Loader Machine Container {7000} Caterpillar

Backhoe Loader

416F2 (S/N: LBF1-UP)

420F2 (S/N: LBS1-UP)

Reference: Specification , UENR5024 , "Bucket Positioner and Lift Kickout"

Introduction

This Special Instruction covers the procedure for unloading the container with the 416F2 and 420F2 Backhoe Loader machines.

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

To unload two machines out of the container will take approximately three hours. Two persons are required to perform this task safely.

Safety Section

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Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Cat dealer for replacement manuals. Proper care is your responsibility.

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Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

Procedure # 1 - Unload Process for the First Machine

1. Work Level and Container Floor Protection
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   Illustration 1	g06234113
   Dock leveler

   1. Before starting the unload process, the floor of the container needs to be level with the ground outside the container. Damage may occur to the underside of the machine if the ground is not the same level as the container. Refer to Illustration 1 for the recommended dock leveler.

      Note: Be careful while opening the container, the items may have come loose during transportation. Ensure to remove all the wood blocks, straps, and nails before operating the machines.

      Note: If at any time during the unloading operation any transport damage is found, or any straps are loose or broken, take a picture of the problem. Report to your local Caterpillar representative as soon as possible.

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      Illustration 2	g06234117
      Wood shims in the pathway

   2. Place the wood shims in the pathway of the unloading machine. Refer to Illustration 2.

      Minimum recognized wood shim size:

      • Thickness- 20 mm (0.8 inch)

      • Width- 250 mm (9.8 inch)

      • Length- 1000 mm (39.4 inch)

2. Bucket and Tire Removal
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   Illustration 3	g06239937
   (1) Bucket (First machine) (2) Straps (3) Wooden shim

   1. Remove the two straps (2) around the bucket (1) and the wooden shim (3) beside the pallet.

   2. Remove the front bucket positioned in front of the container.
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      Illustration 4	g06239951
      (4) Straps (5) Tire (First machine) (6) Wooden batten

   3. Remove the wooden batten (6) in front of the counterweight.

   4. Remove the two straps (4) around the tires (5).
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      Illustration 5	g06239378
      Safe removal of the wheel

   5. Remove the two tires from both the sides of the container.

      Note: Two people are necessary to remove the wheels safely.

      Note: Be careful when removing straps from around the wheels. The wheels may move. Ensure that the second person is holding the wheel to prevent the wheel from moving or contacting the machine. Refer to Illustration 5.

3. Unload Process for the First Machine
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   Illustration 6	g06239957
   (7) Strap (8) Arm

   1. Remove the two straps (7) from the arm (8).
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      Illustration 7	g06239963
      (9) Wooden shim

   2. Remove the wooden shim (9) in front of the steel wheels.
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      Illustration 8	g06239964
      (10) Strap

   3. Remove the four straps (10) around the machine (fixed at front side and rear side).
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      Illustration 9	g06239969
      (11) Strap (12) Boom

   4. Remove the two straps (11) on the boom (12) from both the machines.
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      Illustration 10	g06234189
      (13) Strap

   5. Remove two straps (13) that are fixing the front tires behind the first machine and second machine.
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      Illustration 11	g06239978
      (14) General power switch (15) Wooden support

   6. Turn ON the master key switch (14), then turn ON the ignition key. Slowly raise the boom to remove the wooden support (15).

      Note: Repeat the same for the second machine.

   7. Lower the arm and remove the machine carefully in a low speed. Refer to Procedure # 5- Attachments.

4. Pads and Front Tires Removal
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   Illustration 12	g06239984
   (16) Pallet (17) Wooden shim

   1. Remove the wooden shims (17) around the pallet (16), then remove the pallet with the pads.

   2. Turn ON the second machine ignition key and move the boom to the center of the container such that the tires are accessible. Roll out both the tires.

Procedure # 2 – Machine Assembly Process

Note: Assemble the first machine before starting the second machine removal to avoid any damage or potential failure. Always check the part side identification (left / right).

1. Pad Group Assembly
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   Illustration 13	g06241338
   (18) Straps (19) Pin (20) Pad assembly

   1. Remove the straps (18) that are fixing the stabilizers.

   2. Turn ON the ignition key.

   3. Lower the stabilizers carefully until 100 mm (4.0 inch) above the ground.

   4. Remove the pin and shims assembled in the stabilizer.

   5. Assemble the pins (19), shims, and retaining ring as available for each pad.

   6. Repeat the operation for the other side.

2. Bucket Group Assembly
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   Illustration 14	g06241410
   (21) Lift device (22) Pin (23) Shim (24) Retaining ring (25) Link (26) Cylinder head

   1. Put the bucket as near as possible of the front arm and both in the ground level. The loader bucket weighs approximately 476 kg (1049 lb).

   2. Use adequate devices to lift the front tilt cylinder and remove the bar to install the bucket.
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      Illustration 15	g06252217
      (A) Nylon spacer (B) No shim area

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      Illustration 16	g06252220
      Detailed view (B) ( C) Shims (D) Washers (E) Retaining ring

   3. Install the nylon spacers (A) between the bucket and the loader arm as required to maintain a 1.0 mm (0.04 inch) maximum gap between the bucket and the outside of the lift arms. No shims should be fitted between the inside face (B) of the loader arms and the bucket. Refer to Illustration 15.

      Equalize the shims to center the bucket on the lift arms. The metal washers go between the loader arm and the retaining ring. Ensure that the larger 3.0 mm (0.12 inch) washer (D) is put on the pin last, next to the retaining ring (E). Refer to Illustration 16.

   4. Repeat the operation for the other side.
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      Illustration 17	g06251540
      (F) No shim area (G) Washer (H) Tube (J) Washer (K) Washer (L) Link (M) Bucket

   5. Install the metal washers (K) between the links (L) and the tube (H) as required to maintain a 1.0 mm (0.04 inch) maximum gap between the tube and the inside links. The larger 3.0 mm (0.12 inch) should be used until the gaps prevent the fitment, 1.0 mm (0.04 inch) should then be used to reduce the gaps.

      Ensure that the larger 3.0 mm (0.12 inch) washer (J) is put between the bucket (M) and the pin.

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      Illustration 18	g06251555
      (N) Tilt cylinder (P) No shim area (R) Bucket (S) Washer

   6. Install the tilt cylinder on the bucket. No shims should be fitted between the inside face (P) of the bucket (R) and the tilt cylinder (N).

      Ensure that the larger 3.0 mm (0.12 inch) washer (S) is put between the bucket (R) and the pin.

   7. Assemble the pins, shims, and retaining ring as available on the bucket.

3. Wheel Group Assembly

   1. Rear Wheel Installation
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      Table 1

      Required Tools
      Tool	Qty	Part Number	Part Description	Illustration (Substep) Location
      A	2	422-2352	Jack Stand Gp	Illustration 2 (2)
      B	1	444-0526	Air/Hydraulic Jack Gp	Illustration 2 (1)

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      Illustration 19	g06174445

   2. Use Tooling (B) to raise the machine. Position Tooling (A) under the frame of the machine. Use Tooling (B) to lower the machine onto Tooling (A).
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      Illustration 20	g06174510

   3. Loosen rear wheel nuts and remove the slave wheels. Do not damage the paint on the final drive hubs.

      Use a suitable power truck to install each rear wheel assembly.

      Note: Install each wheel nut by hand to ensure that the threads are not damaged.

   4. Apply one drop of clean lubrication oil to the threads, and torque each wheel nut to a pre-torque of 55 N·m (41 lb ft).

   5. Use Tooling (B) to raise the machine off Tooling (A) and lower the rear of the machine onto the ground.

   6. Finally, torque each nut to the specifications in Table 2.
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      Table 2

      Specification for the Tire and Rim (Rear)
      Part Name	Step	Sub Step	Specification
      Nut	3	2	Apply one drop of clean lubrication oil to the threads of the nuts.
      			Torque to 460 ± 60 N.m (339 ± 44 lb ft)

4. Front Wheel Installation
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   Illustration 21	g06170783

   1. Raise the bucket and install the cylinder lock (not shown) to lock the lift cylinder in position.
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      Illustration 22	g06171868

   2. Use Tooling (B) to raise the machine. Position Tooling (A) under the frame of the machine. Use Tooling (B) to lower the machine onto Tooling (A).
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      Illustration 23	g06171926

      Note: Install each wheel nut by hand to ensure that the threads are not damaged.

   3. Apply one drop of clean lubrication oil to the threads, and torque each wheel nut to a pre-torque of 55 N·m (41 lb ft).

      Use Tooling (B) to raise the machine off Tooling (A) and lower the rear of the machine onto the ground.

      Finally, torque each nut to the specifications in Table 3.

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      Table 3

      Specification for the Tire and Rim
      Part Name	Step	Sub Step	Specification
      Nut	5	2	Apply one drop of clean lubrication oil to the threads of the nuts.
      			Torque to 460 ± 60 N.m (339 ± 44 lb ft)

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      Illustration 24	g06170783

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      Illustration 25	g06239710
      Wheels installed

   4. Remove the loader cylinder lock from the machine. Put the loader cylinder lock back into the storage place on the machine.

5. Adjust the bucket positioner control. Refer to Specifications, "Bucket Positioner and Lift Kickout" which is available on SIS web.

6. Antenna, Product Link, and Fenders Assembly (If Requested)
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   Illustration 26	g06243328
   (27) Antenna (28) Roof

   1. Pass the antenna (27) through the roof (28) and tightening by hand only.
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      Illustration 27	g06243363
      Product link assembly (29) Harness

   2. Connect the product link to the harness (29) available in the roof. Place the product link in the plate existing in the roof.
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      Illustration 28	g06243697
      (30) Fender (31) Rear bucket (32) Bolt

   3. Remove the fenders (30) from the rear bucket (31). Remove the bolts (32) from the axel. Place the fender in the right position as shown in Illustration 28. Tighten the bolts to 100 ± 20 N·m (74 ± 15 lb ft).

Procedure # 3- Unload Process for the Second Machine

1. Wood Plates and Shims Removal

   1. Before starting the unload process of the second machine, remove all the wood remaining from the first machine.

2. Second Machine Removal
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   Illustration 29	g06243708
   (33) Strap (34) Arm

   1. Remove the two straps (33) from the arm (34).
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      Illustration 30	g06243712
      (35) Wooden shim

   2. Remove the wooden shim (35) in front of the steel wheels.
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      Illustration 31	g06243715
      (36) Strap

   3. Remove the four straps (36) around the machine (fixed at front side and rear side).
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      Illustration 32	g06243980
      Rear tire (Second machine) (37) Strap

   4. Remove the strap (37) of the rear tires.
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      Illustration 33	g06243988
      Rear tire removal (Second machine) (38) Rear tire

   5. Drive the machine carefully backwards enough to roll off both rear tires (38) from the axle.

      Note: Two people are necessary to remove the rear tires safely.

   6. Remove the machine carefully in a low speed. Refer to Procedure # 5- Attachments

3. Bucket, Rear Tires, and Front Tires Removal
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   Illustration 34	g06244014
   (39) Front tires (40) Strap

   1. Roll off both the rear tires.

   2. Remove the straps (40) and both the front tires (39) located above the bucket. Roll off the front tires.

   3. Remove the front bucket positioned in the end of the container. Remove all the wood remaining in the container from the second machine.

Procedure # 4- Second Machine Assembly Process

Repeat the Procedure # 2 - Machine Assembly Process

Procedure # 5- Attachments

If the machine is equipped with extendible stick and there is no counterweight installed, you must use the equipment below during the machine removal:

• First Machine -Small cart under the stick and bucket (Refer to Illustration 35)

• Second Machine -Counterweight fixed in the arm (Refer to Illustration 36)

Illustration 35	g06244324
First machine (41) Cart under the stick and bucket

Illustration 36	g06244327
Second machine (42) Counterweight fixed in the arm