Field Installation of the 135-7197 Auxiliary Lines Kit {5057} Caterpillar

Backhoe Loaders:

416C (PIN: 4ZN1-16043; 5YN1-15147; 1WR1-8115; 1XR1-2183)

Introduction

This special instruction outlines the basic steps in order to install a 135-7197 Auxiliary Lines Kit on a backhoe loader with an extendable stick. The 135-7197 Auxiliary Lines Kit is specifically designed for the operation of hydraulic hammers.

The information in this instruction should be read and understood before you proceed with any modifications. Also refer to the Service Manual for the machine.

Required Tools

Required Parts

Preparing the Machine for Servicing

1. Park the machine on a level surface.

2. Apply the service brake in order to stop the machine. Move the transmission control lever to the NEUTRAL position.

3. Move the speed control lever to the LOW IDLE position.

4. Engage the parking brake.

5. Engage the transmission neutral lock.

6. Lower the loader assembly to the ground.

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Illustration 1	g00287246
Put the backhoe loader in the servicing position.

7. Put the backhoe loader in the servicing position. The bucket must rest on the ground. Refer to Illustration 1.

   Note: Support the weight of the boom, stick, and bucket. Use the correct jacks or supports. Total weight of the boom, stick, and bucket is approximately 1815 kg (4001 lb).

8. Stop the engine.

9. Turn the engine start switch key to the OFF position. Remove the key.

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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.

10. Move the hydraulic control levers back and forth in order to relieve the hydraulic pressure in the system.

11. Move the hydraulic control levers to the HOLD position.

    Note: The pressure in the hydraulic system has now been released. Hydraulic lines and components can now be removed.

12. Place chocks in front of the rear wheels and behind the rear wheels.

Gain Access to the Hydraulic Lines

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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 attachments 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.

1. Release the hydraulic pressure. Refer to ""Preparing the Machine for Servicing" ".

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Illustration 2	g00481684
(A) floormat (B) Bolts (C) Rear console

2. Remove the four bolts (B) which secure the floormat (A) to the floor of the cab. Refer to Illustration 2.

3. Remove the rear console (C). Refer to Illustration 2.

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Illustration 3	g00481700
(D) Bolts (E) Floorplate

4. Remove the four bolts (D) which secure the floorplate (E) to the machine.

5. Remove the floorplate (E) .

Installation of the Hydraulic Lines

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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 attachments 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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Illustration 4	g00657435
(F) Connection to the hydraulic filter (G) Hydraulic line (J) Main hydraulic control valve (1) 109-2953 Connector (2) 7M-8485 O-Ring Seal (3) 6V-9854 Swivel Elbow (4) 5K-9090 O-Ring Seal (5) 124-7633 Tube (6) 6V-9746 O-Ring Seal (7) 123-3201 Tube (8) 6V-8714 Seal Connector (9) 3D-2824 O-Ring Seal (10) 106-0405 Hose Assembly (11) 159-1551 Hose Assembly (12) 8T-1891 Clip (13) 8T-1892 Clip (14) 8T-4121 Hard Washer (15) 8T-4137 Bolt (16) 8T-1889 Clip (17) 8T-1890 Clip

1. Connect the 109-2953 Connector (1), a 7M-8485 O-Ring Seal (2), and two 5K-9090 O-Ring Seals (4) between the hydraulic oil filter (F) and the hydraulic hose (G). Refer to Illustration 4.

   Note: Caps and plugs will prevent contamination from entering the hydraulic system. Use the caps and plugs on the following parts: all hydraulic lines, hoses and tubes.

   Note: Caterpillar recommends using the 130-6061 Hose Cleaner Group or the 156-0058 Hose Cleaner Group in order to reduce the risk of contamination to the hydraulic system. The hose cleaner groups clean the inside of hydraulic hoses. Refer to Tool Operating Manual, NEHS0643-01.

2. Connect the 6V-9854 Swivel Elbow (3) and a 5K-9090 O-Ring Seal (4) to the 109-2953 Connector (1). Refer to Illustration 4.

3. Connect the 124-7633 Tube (5) and a 5K-9090 O-Ring Seal (4) to the 6V-9854 Swivel Elbow (3). Refer to Illustration 4.

4. Remove the existing hose and seals from the top port of the seventh valve which is part of the main hydraulic control valve. Install the 6V-9746 O-Ring Seal (6) and a 123-3201 Tube (7). Use a 6V-8714 Seal Connector (8), a 5K-9090 O-Ring Seal (4), and a 3D-2824 O-Ring Seal (9) to secure the tube (7) and O-ring seal (6) to the main hydraulic control valve. Refer to View L-L in Illustration 4.

   Note: You must remove all of the hose assemblies which lead from the top port of the seventh valve of the main hydraulic control valve (J) to the support plate (U). Support plate (U) is located on top of the boom.

5. Connect the 123-3201 Tube (7) to the 106-0405 Hose Assembly (10). Refer to Illustration 4.

6. Secure the hoses (7,10) to the machine with the following parts: 8T-1891 Clip (12), 8T-1892 Clip (13), 8T-4121 Hard Washer (14) and 8T-4137 Bolt (15) .

7. Connect the 124-7633 Tube (5) to the 159-1551 Hose Assembly (11).

8. Secure the hoses (5,11) to the machine with the following parts: 8T-4121 Hard Washer (14), 8T-4137 Bolt (15), 8T-1889 Clip (16) and 8T-1890 Clip (17) .

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Illustration 5	g00657441
(P) Hose to the E-stick cylinder (head) (Q) Support plate (R) Hose to the bucket cylinder (rod end) (S) Support plate (T) Hose to the bucket cylinder (head) (10) 106-0405 Hose Assembly (11) 159-1551 Hose Assembly (18) 106-0414 Block (19) 106-0415 Block (20) 106-0416 Block (21) 7X-2538 Bolt (22) 8T-4224 Hard Washer (23) 6V-9189 Locknut

9. Remove the existing blocks which support the hoses in View M-M of Illustration 4. Save the support plate (S) which aids in holding the blocks together. Refer to Illustrations 4 and 5.

10. Enlarge the holes which are in the support plates (Q, S) to a diameter of 10 mm (0.40 inch). Use a 1U-8168 Drill Bit to enlarge the holes. Refer to View M-M in Illustrations 4 and 5.

11. Route the hoses through the new blocks according to Illustration 5. Secure the 106-0414 Block (18), the 106-0415 Block (19), and the 106-0415 Block (20) between the two support plates (Q,S) with two 7X-2538 Bolts (21), two 8T-4224 Hard Washers (22), and two 6V-9189 Locknuts (23). Refer to Illustration 5.

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Illustration 6	g00657443
(U) Support plate (Y) Existing clips, bolt, and washer (CC) Hose assembly (3) 6V-9854 Swivel Elbow (4) 5K-9090 O-Ring Seal (6) 6V-9746 O-Ring Seal (10) 106-0405 Hose Assembly (11) 159-1551 Hose Assembly (14) 8T-4121 Hard Washer (15) 8T-4137 Bolt (24) 106-0411 Block (25) 106-0412 Block (26) 106-0413 Block (27) 2P-1293 Bulkhead Locknut (28) 3E-7443 Union Tee (29) 6V-9853 Swivel Elbow (30) 110-7713 Tube (31) 6V-8398 O-Ring Seal (32) 110-7709 Tube (33) 106-0843 Tube (34) 7S-3916 Clip (35) 7S-3919 Clip (36) 8T-4223 Hard Washer (37) 8T-4192 Bolt (38) 8W-5149 Hose Assembly (39) 5P-8112 Grommet (40) 5P-7466 Clip (41) 5P-7467 Clip (42) 8T-4139 Bolt (48) 130-3161 Abrasion Sleeve (49) 096-0061 Cable Strap

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Illustration 7	g00657445
(Z) Hose to the E-stick cylinder (head) (AA) Hose to the bucket cylinder (rod end) (BB) Hose to the bucket cylinder (head) (10) 106-0405 Hose Assembly (11) 159-1551 Hose Assembly (15) 8T-4137 Bolt (24) 106-0411 Block (25) 106-0412 Block (26) 106-0413 Block

12. Install the 160-2247 Abrasion Sleeve (48) over the 159-1551 Hose Assembly (11). Secure the abrasion sleeve to the hose with two 096-0061 Cable Straps (49). Refer to Illustration 6.

13. Route the hydraulic hoses which are on top of the boom through the two sets of 106-0411 Blocks (24), 106-0412 Blocks (25), and 106-0413 Blocks (26). Refer to Illustration 6 and 7.

14. Attach each set of assembled blocks (24), (25), and (26) to the boom. Install each set of blocks with two 8T-4137 Bolts (15). Refer to Illustration 7.

15. Connect the 106-0405 Hose Assembly (10) and a 6V-9746 O-Ring Seal (6) to the 3E-7443 Union Tee (28) which is extending through the support plate (U). Use a 2P-1293 Bulkhead Locknut (27) in order to secure the hose assembly (10) to the union tee (28). Refer to View W-W in Illustration 6.

    Note: Before you install the union tee (28), you must remove the existing tube assembly which leads from the support plate (U) to the hose (CC) .

16. Connect the 6V-9853 Swivel Elbow (29) and a 6V-9746 O-Ring Seal (6) to the 3E-7443 Union Tee (28). Refer to View W-W in Illustration 6.

17. Connect a 110-7713 Tube (30) and a 6V-8398 O-Ring Seal (31) to the 6V-9853 Swivel Elbow (29). Refer to View W-W in Illustration 6.

18. Connect the 110-7713 Tube (30) to the existing hose assembly (CC). Refer to View W-W in Illustration 6.

19. Remove the tube assembly and the seal between hoses (DD) and (EE). Install a 6V-9746 O-Ring Seal (6) and a 106-0843 Tube (33) between hose (DD) and hose (EE).

    Reuse the existing clips, bolts, and washers (Y) in order to secure the tube (33) to the boom. Refer to Illustration 6.

20. Connect an 6V-9854 Swivel Elbow (3) and a 6V-9746 O-Ring Seal (6) to the 3E-7443 Union Tee (28). Refer to Illustration 6.

21. Connect the 110-7709 Tube (32) to the 6V-9854 Swivel Elbow (3). Refer to Illustration 6.

22. Connect the 8W-5149 Hose Assembly (38) to the 110-7709 Tube (32). Refer to Illustration 6.

23. Secure tube (32) and hose (38) to the boom with the following parts: 7S-3916 Clip (34), 7S-3919 Clip (35), 8T-4223 Hard Washer (36) and 8T-4192 Bolt (37). Refer to Illustration 6.

24. Support hose (38) on the stick with the following parts: 8T-4223 Hard Washer (36), 5P-8112 Grommet (39), 5P-7466 Clip (40), 5P-7467 Clip (41) and 8T-4139 Bolt (42). Refer to Illustration 6.

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Illustration 8	g00657446
(2) 7M-8485 O-Ring Seal (6) 6V-9746 O-Ring Seal (14) 8T-4121 Hard Washer (27) 2P-1293 Bulkhead Locknut (38) 8W-5149 Hose Assembly (43) 8T-4136 Bolt (44) 109-1260 Bracket (45) 108-3872 Connector (46) 123-7637 Cap (47) 101-0863 Film

25. Secure the 8W-5149 Hose Assembly (38) to the stick assembly with the following parts: 7M-8485 O-Ring Seal (2), 6V-9746 O-Ring Seal (6), 8T-4121 Hard Washer (14), 2P-1293 Bulkhead Locknut (27), 8T-4136 Bolt (43), 109-1260 Bracket (44) and 108-3872 Connector (45). Refer to View X-X in Illustration 6 and Illustration 8.

    Note: Tighten the 2P-1293 Bulkhead Locknut (28) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).

26. Connect a 123-7637 Cap (46) to the end of the 8W-5149 Hose Assembly (38). Refer to Illustration 8.

    Note: Tighten the 123-7637 Cap (46) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).

27. Attach the 101-0863 Film (47) to the stick in order to indicate the direction of flow toward the work tools. The arrow on the film must be pointing away from the cap (46). Refer to Illustration 8 for placement.

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Illustration 9	g00657447
(U) Support plate (2) 7M-8485 O-Ring Seal (4) 5K-9090 O-Ring Seal (6) 6V-9746 O-Ring Seal (11) 159-1551 Hose Assembly (36) 8T-4223 Hard Washer (37) 8T-4192 Bolt (42) 8T-4139 Bolt (48) 130-3161 Abrasion Sleeve (49) 096-0061 Cable Strap (50) 6V-9172 Nut (51) 3E-7426 Elbow (52) 6V-8400 O-Ring Seal (53) 6V-9855 Elbow (54) 110-7710 Tube (55) 8S-0023 Clip (56) 8S-0024 Clip (57) 106-0409 Hose Assembly (58) 5P-8444 Grommet (59) 5P-7468 Clip (60) 5P-7468 Clip

28. Connect the 159-1551 Hose Assembly (11) to the 3E-7426 Elbow (51), a 6V-8400 O-Ring Seal (52), and a 6V-9746 O-Ring Seal (6) with a 6V-9172 Nut (50). The elbow (51) must be routed through the support plate (U) in order for the nut (50) to secure the connection to the support plate (U). Refer to Illustration 9.

29. Connect an 6V-9855 Elbow (53) and a 6V-8400 O-Ring Seal (52) to the 3E-7426 Elbow (51). Refer to Illustration 9.

30. Connect a 110-7710 Tube (54) and a 5K-9090 O-Ring Seal (4) to the 6V-9855 Elbow (53). Refer to Illustration 9.

31. Connect the 106-0409 Hose Assembly (57) to the 110-7710 Tube (54). Refer to Illustration 9.

32. Secure tube (54) and hose (57) to the boom with the following parts: 8T-4223 Hard Washer (36), 8T-4192 Bolt (37), 8S-0023 Clip (55) and 8S-0024 Clip (56). Refer to Illustration 9.

33. Support the 106-0409 Hose Assembly (57) on the stick with the following parts: 8T-4223 Hard Washer (36), 8T-4139 Bolt (42), 5P-8444 Grommet (58), 5P-7468 Clip (59) and 5P-7468 Clip (60). Refer to Illustration 9.

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Illustration 10	g00657450
(2) 7M-8485 O-Ring Seal (4) 5K-9090 O-Ring Seal (14) 8T-4121 Hard Washer (43) 8T-4136 Bolt (46) 123-7637 Cap (47) 101-0863 Film (50) 6V-9172 Nut (57) 106-0409 Hose Assembly (61) 107-6709 Connector (62) 107-6708 Bracket

34. Connect the 106-0409 Hose Assembly (57) to the stick with the following parts: 7M-8485 O-Ring Seal (2), 5K-9090 O-Ring Seal (4), 8T-4121 Hard Washer (14), 8T-4136 Bolt (43), 6V-9172 Nut (50), 107-6709 Connector (61) and 107-6708 Bracket (62). Refer to Illustration 10.

    Note: Tighten the 6V-9172 Nut (50) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).

35. Connect a 123-7637 Cap (46) to the end of the 106-0409 Hose Assembly (57). Refer to Illustration 10.

    Note: Tighten the cap (46) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).

36. Attach the 101-0863 Film (47) to the stick in order to indicate the direction of flow. The arrow on the film must be pointing toward the cap (46) in order to indicate return flow. Refer to Illustration 10 for placement of the film.

Testing the Hydraulic System

1. Tighten all of the new hose connections.

2. Fill the hydraulic system oil tank according to the Operation and Maintenance Manual for your machine.

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Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

3. Test and adjust the hydraulic system. Refer to the Test and Adjusting manual for your machine.

4. Secure the floorplate and secure the floormat in the cab when all repairs and tests are finished.

Welding the Plate to the Boom

Welding Specifications

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Welding quality is critical to the success of adding the support plate. Welds must be smooth and continuous. No undercutting is allowed. No overlap is allowed. Grind the ends of the welds to a smooth radius.

Prepare the metal for welding according to the section ""Welding Procedures" ". Refer to the illustrations in this special instruction for welding symbols and specifications.

Use a 1U-5236 Welding Rod or an equivalent electrode to weld the reinforcement plate to the boom. Basic welding wire ESAB OK tubrod 15.00 with a 1.2 mm (0.05 inch) diameter can also be used. The basic welding wire must be the equivalent to AWS A5.20 E71T-1 with positive polarity. The welding wire must be protected with CO2 gas.

All electrodes must be completely dried. The electrodes can be dried by heating the electrodes to 300 °C (572 °F). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16 °C (61 °F).

Penetration characteristics may vary greatly depending on the electrode diameter, shielding gas, welding current, and plate thickness. Geometry of the welded joints, surface conditions, and composition of the base metal and electrode also affect the welds.

For more welding information, consult the Caterpillar Service Welding Guide, SEBD0512.

Welding Procedures

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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NOTICE
Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.

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Illustration 11	g00656976
Weld the 106-0425 Plate (63) to this position on the boom (HH) .

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Illustration 12	g00656979
Prepare the shaded area for welding.

1. Disconnect the battery from the electrical system.

2. Cover the boom and surrounding components in order to protect the parts from welding spatters and paint spatters.

3. Remove all paint, rust, dirt, and scale from the metal. The material can be removed by using a wire brush or by buffing or grinding. Refer to Illustrations 11 and 12.

4. Remove any oil or grease with an approved solvent.

5. Position the plate on the boom. Jacks and other supports can be used to hold the plate in place while the welding procedures are being conducted.

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Illustration 13	g00656982
Weld the plate (63) to the boom (HH). Weld around the plate from point (63A) to point (63B) .

6. Weld the plate (63) to the boom (HH) by using a 1U-5236 Welding Rod . Weld from point (63A) to point (63B) in one continuous weld. Refer to Illustration 13 for more information.

7. Grind the ends of the welds to a smooth finish.

8. Shot blast all the welded areas.

9. Paint the weld, the boom, and the plate. Use an authorized Caterpillar paint.

10. Remove all protective covers from the boom.