Field Installation of 284-8542 Backhoe Lines Gp (Kit, Field Conversion){5057} Caterpillar

Backhoe Loader:

420D (S/N: BLN2319-UP; FDP7199-UP)

Introduction

ReferenceDisassembly and Assembly, RENR3585, "416D, 420D, 428D, 430D, 432D, 438D and 442D Backhoe Loader Machine Systems", "Hydraulic System Pressure - Release"

ReferenceDisassembly and Assembly, RENR3585, "416D, 420D, 428D, 430D, 432D, 438D and 442D Backhoe Loader Machine Systems", "Boom Cylinder - Remove"

ReferenceDisassembly and Assembly, RENR3585, "416D, 420D, 428D, 430D, 432D, 438D and 442D Backhoe Loader Machine Systems", "Stick Cylinder - Remove"

ReferenceDisassembly and Assembly, RENR3585, "416D, 420D, 428D, 430D, 432D, 438D and 442D Backhoe Loader Machine Systems", "Backhoe Bucket Cylinder - Remove"

ReferenceOperation and Maintenance Manual, SEBU7399, "420D and 430D Backhoe Loaders", "Hydraulic System Oil - Check"

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.

Needed Parts

The required parts for the field installation of the new hoses for the backhoe are listed in Table 1.

Preparing the Machine

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Illustration 1	g01256584

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 "Hydraulic System Pressure - Release" in the Disassembly and Assembly manual for your machine.

Removal of Parts

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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.

Lines Mounting Group

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Illustration 2	g01280982

1. Remove 108-2989 Bolt (8), two 8T-4224 Hard Washers (9) and 6V-9189 Locknut (10) .

2. Remove 099-3649 Bolt (11) and 8T-4224 Hard Washer (12). Weldnut (13) is part of 202-2565 Plate As (14) .

3. Remove three 8T-4136 Bolts (15) and three 8T-4121 Hard Washers (16) .

4. Discard the parts that were removed in Step 1 through Step 3.

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Illustration 3	g01281001

5. Remove two 7X-2539 Bolts (17), four 8T-4224 Hard Washers (18) and two 6V-9189 Locknuts (19). Remove blocks (20).

6. Remove four 8T-4136 Bolts (21) and four 8T-4121 Hard Washers (22). Remove blocks (23) .

Routing of the Hydraulic Lines

Illustration 4	g01281038

For some lines groups, the hydraulic lines can be in different positions in the mounting lines groups. Refer to Illustration 4 for the proper location of the hoses.

(24) In the 202-5939 Extendable Stick Lines Gp , this is the rod end for the extendable stick.

(25) In the 202-5935 Stick Lines Gp , this is the head end for the stick cylinder.

(26) In the 202-5935 Stick Lines Gp , this is the rod end for the stick cylinder.

(27) In the 202-5939 Extendable Stick Lines Gp , this is the head end for the extendable stick.

(28) In the 202-5931 Boom Lines Gp , this is the rod end for the boom cylinder.

(29) In the 202-5939 Extendable Stick Lines Gp , this is the head end for the bucket cylinder.

(30) In the 202-5931 Boom Lines Gp , this is the head end for the boom cylinder.

(31) In the 202-5939 Extendable Stick Lines Gp , this is the rod end for the bucket cylinder.

(32) In the 202-5939 Extendable Stick Lines Gp , this is the head end for the extendable stick.

(33) In the 202-5935 Stick Lines Gp , this is the rod end for the stick cylinder.

(34) In the 202-5939 Extendable Stick Lines Gp , this is the head end for the bucket cylinder.

(35) In the 202-5939 Extendable Stick Lines Gp , this is the rod end for the bucket cylinder.

(36) In the 202-5939 Extendable Stick Lines Gp , this is the rod end for the extendable stick.

(37) In the 202-5931 Boom Lines Gp , this is the rod end for the boom cylinder.

(38) In the 202-5935 Stick Lines Gp , this is the head end for the stick cylinder.

(39) In the 202-5931 Boom Lines Gp , this is the head end for the boom cylinder.

Illustration 5	g01281501

Refer to Illustration 5 for the correct location for the hoses on the bank valve.

(40) The rod end to the extendable stick

(41) The head end of the stick cylinder

(42) The head end of the bucket cylinder

(43) The rod end of the boom cylinder

(44) The head end of the boom cylinder

(45) The rod end of the bucket cylinder

(46) The rod end of the stick cylinder

(47) The head end to the extendable stick

The Boom Cylinder Lines

The following procedure is used in order to replace the former boom cylinder lines with the new boom cylinder lines. Table 2 lists the former part numbers and the new part numbers. Refer to Illustration 4 and Illustration 5 for the positions of the hoses.

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Illustration 6	g01281509

1. Disconnect 202-1037 Hose As (48) from the head end of the boom cylinder. Disconnect 201-3629 Hose As (49) from the rod end of the boom cylinder.

2. Remove the other end of hose (48) from the machine at port (44) for the head end of the boom cylinder. Remove the other end of hose (49) from the machine at port (43) for the rod end of the boom cylinder.

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Illustration 7	g01281068

3. Install one end of the new 8E-5283 Hose As (1) at port (43) for the rod end of the boom cylinder.

4. Route the hose through the lines mounting groups. Install the other end of the new 8E-5283 Hose As (1) to the rod end of the boom cylinder.

5. Install one end of the new 172-3820 Hose As (7) on the machine at port (44) for the head end of the boom cylinder.

6. Route the hose through the lines mounting groups. Install the other end of the new 172-3820 Hose As (7) to the head end of the boom cylinder.

Stick Cylinder Line

The following procedure is used in order to replace the former line to the rod end of the stick cylinder with the new line to the rod end of the stick cylinder. Table 3 lists the former part number and the new part number. Refer to Illustration 4 and Illustration 5 for the positions of the hoses.

Note: The line to the head end of the stick cylinder is not replaced during this procedure. Do not remove the line to the head end of the stick cylinder.

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Illustration 8	g01281510

1. Disconnect 201-3627 Hose As (50) from the rod end of the stick cylinder.

2. Remove the other end of hose (50) from port (46) for the rod end of the stick cylinder.

3. Install one end of the new 169-2980 Hose As (5) on the machine in port (46) for the rod end of the stick cylinder.

4. Route the hose through the lines mounting groups. Install the other end of the new 169-2980 Hose As (5) to the rod end of the stick cylinder.

The Line to the Head End of the Extendable Stick Cylinder

The following procedure is used in order to replace the former line to the head end of the extendable stick cylinder with the new line to the head end of the extendable stick cylinder.

Table 4 lists the former part number and the new part number. Refer to Illustration 4 and Illustration 5 for the positions of the hoses.

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Illustration 9	g01281512

1. Disconnect 201-3636 Hose As (51) from the port (47) at connection (A) .

2. Remove the other end of hose (51) from the bottom of the boom at connection (B) .

3. Install one end of the new 169-2935 Hose As (4) into port (47) at connection (A) .

4. Install one end of the new 169-2935 Hose As (4) to the bottom of the boom at connection (B) .

The Line to the Rod End of the Extendable Stick Cylinder

The following procedure is used in order to replace the former line to the rod end of the extendable stick cylinder with the new line to the rod end of the extendable stick cylinder.

Table 5 lists the former part number and the new part number. Refer to Illustration 4 and Illustration 5 for the positions of the hoses.

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Illustration 10	g01281514

1. Disconnect 201-3633 Hose As (52) from the port (40) at connection (C) .

2. Remove the other end of hose (52) from the bottom of the boom at connection (D) .

3. Install one end of the new 9R-2587 Hose As (2) into port (40) at connection (C) .

4. Install one end of the new 9R-2587 Hose As (2) to the bottom of the boom at connection (D) .

The Lines to the Bucket Cylinder

The following procedure is used in order to replace the former lines to the bucket cylinder with the new lines to the bucket cylinder. Table 6 lists the former part number and the new part number. Refer to Illustration 4 and Illustration 5 for the positions of the hoses.

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Illustration 11	g01281424

1. Disconnect 201-3630 Hose As (54) from port (42) for the head end of the bucket cylinder. Disconnect 201-3631 Hose As (53) from port (45) for the rod end of the bucket cylinder.

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Illustration 12	g01281440

2. Remove the other end of hose (53) from the boom. Remove the other end of hose (54) from the boom. Refer to Illustration 12.

3. Install one end of the new 169-2983 Hose As (6) on the machine in port (42) for the head end of the bucket cylinder.

4. Route the hose through the lines mounting groups. Install the other end of the new 169-2983 Hose As (5) on the boom in the position for hose (54) .

5. Install one end of the new 160-6026 Hose As (3) on the machine in port (45) for the rod end of the bucket cylinder.

6. Route the hose through the lines mounting groups. Install the other end of the new 160-6026 Hose As (3) on the boom in the position for hose (53) .