Field Installation of the 135-7198 Auxiliary Lines Kit {5057, 5057} Caterpillar

Backhoe Loaders:

426C (PIN: 6XN1-3615; 7WN1-938; 1CR1-863; 1ER1-863; 1MR1-955; 1NR1-953; 1YR1-1516; 1ZR1-925)

436C (PIN: 8TN1-924; 9JN1-883; 1FR1-1415; 1GR1-915; 1PR1-1598; 1RR1-997; 2AR1-1603; 2BR1-910)

Introduction

This special instruction outlines the basic steps in order to install a 135-7198 Auxiliary Lines Kit on a backhoe loader which has a six bank main hydraulic control valve. The 135-7198 Auxiliary Lines Kit is specifically designed for the operation of a hydraulic hammer.

Before the 135-7198 Auxiliary Lines Kit is installed on the machine, a seventh control valve must be installed on the main hydraulic control valve. A seventh control valve is required in order to control any attachments which are connected to the auxiliary lines.

The seventh control valve is part of two arrangements which can be used with the auxiliary lines kit. Caterpillar requires installing either a 106-6253 Backhoe Hydraulic Arrangement or a 119-4005 Backhoe Hydraulic Arrangement with the 135-7198 Auxiliary Lines Kit . Both hydraulic arrangements can be installed in the field. Each arrangement contains the following groups: a valve control, a field conversion kit and hydraulic lines.

Installing a new control valve to the six bank main hydraulic control valve requires the main hydraulic control valve to be removed from the machine. See the section ""Installing a New Control Valve on the Main Hydraulic Control Valve" " in this publication. Removal instructions are also found in the Disassembly and Assembly, "Backhoe & Stabilizer Implement Control Valve" of the machine's Service Manual. Also see the Parts Manuals for the 426C and 436C Backhoe Loaders.

See the section ""Installing a Valve Control" " which is in this publication in order to install a valve control. Also refer to the Parts Manuals for the 426C and 436C Backhoe Loaders.

The information in this instruction should be read and understood before you proceed with any modifications.

Required Tools for Installing an Auxiliary Lines Kit

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 1220 kg (2690 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. When the hydraulic oil has cooled, hydraulic lines and components can be removed. Refer to the instructions in the section ""Installation of the Auxiliary Lines Kit" ".

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

Gaining Access to the Main Hydraulic Control Valve

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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 four bolts (B) in order to remove the floormat (A). 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 four bolts (D) in order to remove the floorplate (E) .

Installing a New Control Valve on the Main Hydraulic Control Valve

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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.

As part of the installation of the 135-7198 Auxiliary Lines Kit , you must install a new control valve on the main hydraulic control valve. Caterpillar recommends installing a 119-4003 Control Valve Conversion . The 119-4003 Control Valve Conversion is part of both the 106-6253 Backhoe Hydraulic Arrangement and the 119-4005 Backhoe Hydraulic Arrangement .

Required Parts

Installation Procedures

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Illustration 4	g00661897
(F) Mounting bracket (G) Main hydraulic control valve

1. Remove the main hydraulic control valve (G) according to the instructions in the Disassembly and Assembly, "Backhoe & Stabilizer Implement Control Valve" module. The module is part of the Service Manual which covers the 426C and 436C Backhoe Loaders.

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Illustration 5	g00660086
(1) 6E-6287 Control Valve (2) 4J-5140 O-Ring Seal (3) 4J-5267 O-Ring Seal (4) 116-1315 Stud (5) 9S-8752 Nut (6) 5M-2894 Washer (7) 4T-2723 Shim (8) 4D-9986 O-Ring Seal

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Illustration 6	g00661901
(1) 119-4003 Control Valve Conversion (4) 116-1315 Stud (H) Cover

2. Install the new 119-4003 Control Valve Conversion (1) on the main control valve. Refer to the Disassembly and Assembly, "Backhoe & Stabilizer Implement Control Valve" module which is in the machine's Service Manual for more installation instructions. Also see the Parts Manuals which are developed for the 426C and 436C Backhoe Loaders.

3. Secure the cover (H). Refer to the Disassembly and Assembly, "Backhoe & Stabilizer Implement Control Valve" module for more installation instructions.

4. Assemble the main hydraulic control valve to the mounting bracket and install the configuration to the machine. Refer to the Disassembly and Assembly, "Backhoe & Stabilizer Implement Control Valve" module for more installation instructions.

Installing a Valve Control

Installing a valve control is required when you install a new control valve to the main hydraulic control group. You have a choice of installing either a 106-6373 Valve Control or a 112-1842 Valve Control . A valve control is necessary in order to operate any attachments which are connected to the auxiliary hydraulic lines.

The 106-6373 Valve Control is operated by the operator's foot. The 112-1842 Valve Control is hand operated.

Required Parts

Installation Procedures for the 106-6373 Valve Control

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Illustration 7	g00662025
(J) Support plates (1) 106-6374 Support (2) 8T-4195 Bolt (3) 8T-4121 Hard Washer (4) 8T-4133 Nut

1. Remove the rear console.

2. Locate the support plates (J) which are surrounding the hydraulic control valve for the backhoe. Refer to Illustration 7.

3. Attach the 106-6374 Support (1) to the support plates (J). Use two 8T-4195 Bolts (2), two 8T-4121 Hard Washers (3), and two 8T-4133 Nuts (4) to secure the support (1) to the support plates (J). Refer to Illustration 7.

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Illustration 8	g00647806
(1) 106-6374 Support (3) 8T-4121 Hard Washer (4) 8T-4133 Nut (5) 128-7341 Shaft (6) 9R-2614 Bearing (7) 109-0533 Seal (8) 121-0593 Pedal Assembly (9) 6V-8335 Bolt (10) 8T-4773 Ball Joint (11) 155-6011 Rod (12) 8T-4815 Rod End (13) 9R-2806 Pin (14) 9R-2807 Clip (15) 6V-7744 Locknut

4. Insert the 9R-2614 Bearings (6) in the 106-6374 Support (1). Refer to Illustration 8.

5. Insert the 128-7341 Shaft (5) through the 106-6374 Support (1) and 9R-2614 Bearings (6). Refer to Illustration 8.

6. Slide the 109-0533 Seal (7) over the shaft (5). Refer to Illustration 8.

7. Attach the 121-0593 Pedal Assembly (8) to the shaft (5). Use a 6V-8335 Bolt (9) and 8T-4121 Hard Washer (3) to secure the pedal assembly to the shaft. Refer to Illustration 8.

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Illustration 9	g00647807
(4) 8T-4133 Nut (10) 8T-4773 Ball Joint (11) 155-6011 Rod (12) 8T-4815 Rod End

8. Assemble the following parts according to Illustration 9: two 8T-4133 Nuts (4), 8T-4773 Ball Joint (10), 155-6011 Rod (11) and 8T-4815 Rod End (12) .

   The final assembly must measure 133 ± 2 mm (5.24 ± 0.08 inch). Refer to Illustration 9.

9. Attach the 8T-4773 Ball Joint (10) to the 128-7341 Shaft (5). Use a 6V-7744 Locknut (15) and a 8T-4121 Hard Washer (3) to secure the ball joint to the shaft. Refer to Illustration 8.

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Illustration 10	g00662034
(K) Top of the seventh control valve (12) 8T-4815 Rod End (13) 9R-2806 Pin (14) 9R-2807 Clip

10. Attach the 8T-4815 Rod End (12) to the top of the seventh control valve (K). Use a 9R-2806 Pin (13) and a 9R-2807 Clip (14) to secure the rod end to the hydraulic control valve. Refer to Illustration 10.

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Illustration 11	g00662047
(C) Rear console (16) 133-8916 Film

11. Cut a hole which has a diameter of 60 ± 3 mm (2.40 ± 0.12 inch) through the right side of the rear console. Cut a slot from the bottom of the rear console to the hole. The slot must measure 2 ± 1 mm (0.08 ± 0.04 inch) wide. The hole and the slot will allow the rear console to be installed over the shaft (5). Refer to Illustration 11.

12. Place the 133-8916 Film (16) on the right side of the rear console. Refer to Illustration 11.

13. Adjust the rotational position of the pedal assembly. When the pedal is actuated, the pedal assembly must stop 15 ± 10 mm (0.60 ± 0.40 inch) away from the floormat.

14. Install the rear console when all adjustments are finished.

Installing a 112-1842 Valve Control

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Illustration 12	g00662052
(C) Rear console (M) Knobs (N) Plate (P) Boots (Q) Shaft (R) Retaining ring (S) Support (T) Spacer

1. Remove the rear console (C). The knobs (M) must be removed in order to remove the plate (N) and the boots (P). Discard the plate. Refer to Illustration 12.

2. Loosen the shaft (Q) by removing the retaining ring (R). Keep the retaining ring. Refer to Illustration 12.

3. Remove the shaft from the support (S). Refer to Illustration 12.

4. Remove the spacer (T). Refer to Illustration 12.

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Illustration 13	g00662073
(G) Main hydraulic control (Q) Shaft (R) Retaining ring (1) 136-7440 Shim (2) 116-3016 Lever (3) 136-7439 Spacer (4) 8T-4815 Rod End (5) 8T-4133 Nut (6) 116-3018 Rod (7) 9R-2806 Pin (8) 9R-2807 Clip

5. Slide a 136-7440 Shim (1) on the shaft (Q). More than one shim may be required in order to obtain minimum free play and equal spacing between levers. Refer to Illustration 13.

6. Slide the 116-3016 Lever (2) on the shaft (Q). The 5V-4410 Sleeve Bearing must be installed with the lever (2). The sleeve bearing is part of the lever (2). Refer to Illustration 13.

7. Slide a 136-7439 Spacer (3) on the shaft (Q). More than one spacer may be required in order to obtain minimum free play and equal spacing between levers. Refer to Illustration 13.

8. Secure the shaft (Q) to the support (S). Use the retaining ring (R) which was removed in Step 2 to secure the shaft to the support.

9. Attach two 8T-4815 Rod Ends (4) to the 116-3018 Rod (6). Use two 8T-4133 Nuts (5) in order to attach the rod ends to the rod. Tighten the nuts to a torque of 25 ± 5 N·m (18.44 ± 3.70 lb ft). Refer to Illustration 13.

10. Attach the bottom rod end (4) to the main hydraulic control for backhoe operation (G). Use a 9R-2806 Pin (7) and a 9R-2807 Clip (8) to secure the rod end to the hydraulic control valve. Refer to Illustration 13.

11. Attach the top rod end (4) to the 116-3016 Lever (2) with a 9R-2806 Pin (7) and a 9R-2807 Clip (8). Refer to Illustration 13.

12. Adjust the length of rod (6) so the longest straight portion of lever (2) is perpendicular to the cab floor.

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Illustration 14	g00662078
(P) Boots (2) 116-3016 Lever (9) 117-5672 Boot (10) 123-3119 Plate (11) 8T-9000 Knob (12) 101-2788 Film

13. Install the 117-5672 Boot (9) over the lever (2). Install the boots (P) which were removed in Step 1. Refer to Illustration 14.

14. Install the 123-3119 Plate (10). Refer to Illustration 14.

15. Install the 8T-9000 Knob (11) to the lever (2). Also install the knobs (M) which were removed in Step 1. Refer to Illustration 14.

16. Apply the 101-2788 Film (12) to the rear console. Refer to Illustration 14.

    Note: Use the 101-2788 Film only when the backhoe loader is equipped with an extendable stick.

Installation of the 135-7198 Auxiliary Lines Kit

Required Parts

Installing the Hydraulic Lines

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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.

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Illustration 15	g00663160
(G) Main control valve (U) Connection to the hydraulic oil filter (V) Hose to the main 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) 9S-4183 Plug (11) 106-0594 Hose Assembly (12) 159-1550 Hose Assembly (13) 8T-1891 Clip (14) 8T-1892 Clip (15) 8T-4121 Washer (16) 8T-4137 Bolt (17) 8T-1889 Clip (18) 8T-1890 Clip

1. Connect the 109-2953 Connector (1), 7M-8485 O-Ring Seal (2), and a 5K-9090 O-Ring Seal (4) between the oil filter (U) and the hose (V). Refer to Illustration 15.

   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 of most contamination prior to installation. Refer to Tool Operating Manual, NEHS0643-01.

2. Connect a 6V-9854 Swivel Elbow (3) and a 5K-9090 O-Ring Seal (4) to the 109-2953 Connector (1). Refer to Illustration 15.

3. Attach the 124-7633 Tube (5) to the 6V-9854 Swivel Elbow (3). Refer to Illustration 15.

4. Connect the 124-7633 Tube (5) and a 5K-9090 O-Ring Seal (4) to the 159-1550 Hose Assembly (12). Refer to Illustration 15.

5. Connect the 6V-9746 O-Ring Seal (6), 123-3201 Tube (7), 5K-9090 O-Ring Seal (4), 6V-8714 Seal Connector (8), and a 3D-2824 O-Ring Seal (9) to the top port of the seventh control valve of the main control valve (G). Refer to View W-W and View X-X of Illustration 15.

6. Install 3D-2824 O-Ring Seal (9) and 9S-4183 Plug (10) in the bottom port of the seventh control valve. Refer to View X-X of Illustration 15.

7. Connect the 123-3201 Tube (7) and a 6V-9746 O-Ring Seal (6) to the 106-0594 Hose Assembly (11). Refer to View Y-Y of Illustration 15.

8. Use the 8T-4137 Bolt and 8T-4121 Washer from the existing clip assembly to install the 8T-1891 Clip (13) and the 8T-1892 Clip (14). Refer to View Y-Y of Illustration 15.

9. Attach tube (5) and hose (12) to the machine with the following parts: 8T-4121 Washer (15), 8T-4137 Bolt (16), 8T-1889 Clip (17) and 8T-1890 Clip (18). Refer to View Y-Y in Illustration 15.

10. Remove the existing blocks and screws in View Z-Z. Save the support plates. Refer to Illustration 15.

11. Drill out the 8 mm (0.32 inch) threaded holes in the swing casting. Enlarge the holes to 10 mm (0.40 inch). Refer to View Z-Z in Illustration 15.

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Illustration 16	g00663161
(AA) Support plate (BB) Support plate (CC) Hose to the boom cylinder (head) (DD) Hose to the boom cylinder (rod end) (EE) Hose to the bucket cylinder (head) (FF) Hose to the bucket cylinder (rod end) (GG) Hose to the stick cylinder (head) (HH) Hose to the stick cylinder (rod end) (11) 106-0594 Hose Assembly for auxiliary supply (12) 159-1550 Hose Assembly for auxiliary return (19) 106-0414 Block (20) 106-0415 Block (21) 106-0416 Block (22) 7X-2538 Bolt (23) 8T-4224 Hard Washer (24) 6V-9189 Locknut

12. Enlarge the holes which are in the support plates (AA,BB) to a diameter of 10 mm (0.40 inch). Use a 1U-8168 Drill Bit to enlarge the holes. Refer to View Z-Z in Illustrations 15 and 16.

13. Route the hoses through the new blocks according to Illustration 16. Secure the 106-0414 Block (19), the 106-0415 Block (20), and the 106-0415 Block (21) between the two support plates (AA,BB) with two 7X-2538 Bolts (22), four 8T-4224 Hard Washers (23), and two 6V-9189 Locknuts (24). Refer to Illustration 16.

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Illustration 17	g00663168
(EE) Hose to the bucket cylinder (head) (FF) Hose to the bucket cylinder (rod end) (JJ) Support plate (2) 7M-8485 O-Ring Seal (3) 6V-9854 Swivel Elbow (4) 5K-9090 O-Ring Seal (6) 6V-9746 O-Ring Seal (11) 106-0594 Hose Assembly (12) 159-1550 Hose Assembly (15) 8T-4121 Washer (16) 8T-4137 Bolt (25) 160-2247 Abrasion Sleeve (26) 096-0061 Cable Strap (27) 106-0411 Block (28) 106-0412 Block (29) 106-0413 Block (30) 2P-1293 Bulkhead Locknut (31) 3E-7443 Union Tee (32) 6V-9832 Cap Assembly (33) 110-7709 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 (43) 8T-4136 Bolt (44) 109-1260 Bracket (45) 108-3872 Connector (46) 123-7637 Cap

14. Apply a 68 cm (27.0 inch) length of 160-2247 Abrasion Sleeve (25) to the 159-1550 Hose Assembly (12). Secure the abrasion sleeve to the hose with two 096-0061 Cable Straps (26). Refer to Illustration 17.

15. Route the hydraulic hoses which are on top of the boom through the two sets of 106-0411 Blocks (27), 106-0412 Blocks (28), and 106-0413 Blocks (29). Refer to Illustration 17.

16. Attach each set of assembled blocks (27), (28), and (29) to the boom. Install each set of blocks with two 8T-4137 Bolts (16). Refer to Illustration 17.

17. Connect 106-0594 Hose Assembly (11) and a 6V-9746 O-Ring Seal to the 3E-7443 Union Tee (31). Use a 2P-1293 Bulkhead Locknut (30) to secure the connection of the hose (11) and union tee (31) to the support plate (JJ). Refer to Illustration 17.

18. Close off one end of the union tee (31) with a 6V-9832 Cap Assembly (32). Refer to Illustration 35.

19. Connect a 6V-9854 Swivel Elbow (3) and a 5K-9090 O-Ring Seal (4) to the 3E-7443 Union Tee (31). Refer to Illustration 17.

20. Connect the 6V-9854 Swivel Elbow (3) and a 6V-9746 O-Ring Seal (6) to the 110-7709 Tube (33). Refer to Illustration 17.

21. Connect the tube (33) to the 8W-5149 Hose Assembly (38). Refer to Illustration 17.

22. Secure the tube (33) and the hose (38) to the right side of 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 17.

23. Secure the end of the hose (38) to the stick by using the following parts: 7M-8485 O-Ring Seal (2), 6V-9746 O-Ring Seal (6), 8T-4121 Washer (15), 2P-1293 Bulkhead Locknut (30), 8T-4136 Bolt (43), 109-1260 Bracket (44) and 108-3872 Connector (45). Refer to Illustration 17.

    Tighten the bulkhead locknut (30) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).

24. Protect against contamination by capping hose (38) with a 123-7637 Cap (46). Refer to Illustration 17.

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

25. Support the hose (38) by attaching the hose to 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 17.

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Illustration 18	g00663171
(JJ) Support plate (2) 7M-8485 O-Ring Seal (4) 5K-9090 O-Ring Seal (12) 159-1550 Hose Assembly (15) 8T-4121 Washer (36) 8T-4223 Hard Washer (37) 8T-4192 Bolt (42) 8T-4139 Bolt (43) 8T-4136 Bolt (45) 108-3872 Connector (46) 123-7637 Cap (48) 6V-9172 Nut (49) 3E-7426 Elbow (50) 6V-8400 O-Ring Seal (51) 6V-9855 Elbow (52) 110-7710 Tube (53) 8S-0023 Clip (54) 8S-0024 Clip (55) 106-0409 Hose Assembly (56) 5P-8444 Grommet (57) 5P-7468 Clip (58) 5P-7469 Clip (59) 107-6709 Connector (60) 107-6708 Bracket

26. Connect 159-1550 Hose Assembly (12) and 5K-9090 O-Ring Seal (4) to the 3E-7426 Elbow (49) with the 6V-9172 Nut (48). The hose (12) and elbow (49) is secured to the support plate (JJ) with the nut (48). Refer to Illustration 18.

27. Connect the 3E-7426 Elbow (49) and a 6V-8400 O-Ring Seal (50) to the 6V-9855 Elbow (51). Refer to Illustration 18.

28. Connect the 6V-9855 Elbow (51) and a 6V-8400 O-Ring Seal (50) to the 110-7710 Tube (52). Refer to Illustration 18.

29. Connect the 110-7710 Tube (52) and a 5K-9090 O-Ring Seal (4) to the 106-0409 Hose Assembly (55). Refer to Illustration 18.

30. Secure tube (52) and hose (55) to the boom with the following parts: 8T-4192 Bolt (37), 8T-4223 Hard Washer (36), 8S-0023 Clip (53) and 8S-0024 Clip (54). Refer to Illustration 18.

31. Secure the 106-0409 Hose Assembly (55) to the stick with the following parts: 8T-4223 Hard Washer (36), 8T-4139 Bolt (42), 5P-7468 Clip (57), 5P-7469 Clip (58) and 5P-8444 Grommet (56). Refer to Illustration 18.

32. Secure the end of hose (55) to the stick with the following parts: 7M-8485 O-Ring Seal (2), 5K-9090 O-Ring Seal (4), 8T-4121 Washer (15), 8T-4136 Bolt (43), 6V-9172 Nut (48), 107-6709 Connector (59) and 107-6708 Bracket (60). Refer to Illustration 18.

    Tighten the nut (48) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).

33. Protect against contamination by capping hose (55) with a 123-7637 Cap (46). Tighten the cap (46) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft). Refer to Illustration 18.

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Illustration 19	g00663173
(LL) View of the stick from the left side of the machine (MM) View of the stick from the right side of the machine

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Illustration 20	g00663175
(LL) View of the stick from the left side of the machine (MM) View of the stick from the right side of the machine (38) 8W-5149 Hose Assembly (46) 123-7637 Cap (47) 101-0863 Film (55) 106-0409 Hose Assembly

34. Apply a 101-0863 Film (47) to the left side of the stick (LL). The film must indicate the flow of the hydraulic oil to the hydraulic work tools. Place the film 330 mm (13 inch) from the cap (46) on the end of hose (38). Refer to Illustrations 19 and 20.

35. Apply a 101-0863 Film (47) to the right side of the stick (MM). The film must indicate the flow of the hydraulic oil from the hydraulic work tools. Place the film 330 mm (13 inch) from the cap (46) on the end of hose (55). Refer to Illustration 20.

36. Install the floorplate in the cab.

37. Install the rear console cover.

38. Test the hydraulic system according to the ""Testing the Hydraulic System" " section in this publication.

Testing the Hydraulic System

1. Tighten all of the new hose connections.

2. If you have not installed either a 106-6373 Valve Control or a 112-1842 Valve Control , see the section ""Installing a Valve Control" " before you proceed with the testing procedures.

3. 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.

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

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

Welding the 106-0425 Plate to the Boom

Welding Requirements

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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 the reinforcement procedures. Welds must be smooth and continuous. No undercutting is allowed. No overlap is allowed. Grind the ends of the welds to a smooth radius.

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.

Illustration 21	g00663745
Weld the 106-0425 Plate (61) to this position on the boom (NN) .

Illustration 22	g00663746
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. Remove the material by buffing, grinding, or brushing with a wire brush. Refer to Illustrations 21 and 22.

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 23	g00663748
Place the plate (61) according to the dimensions which are in the illustration. Weld the plate (61) to the boom (NN). Weld around the plate from point (61A) to point (61B) .

6. Weld the plate (61) to the boom (NN) by using the 1U-5236 Welding Rods . Weld from point (61A) to point (61B) in one continuous weld. Refer to Illustration 23 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.