The Instructions for the Field Installation of the New 284-8541 Backhoe Lines Gp (Kit) (Field Conversion){5057} Caterpillar


The Instructions for the Field Installation of the New 284-8541 Backhoe Lines Gp (Kit) (Field Conversion){5057}

Usage:

430D BML
Backhoe Loader:
430D (S/N: BNK2502-UP; BML2281-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 instructions 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

Table 1
Needed Parts for the New Hoses for the New 284-8541 Backhoe Lines Gp (Kit, Field Conversion)    
Item     Quantity     Part Number     Description    
1     1     9R-25878     Hose As    
2     1     149-8718     Hose As    
3     1     172-2251     Hose As    
4     1     199-2567     Hose As    
5     1     249-4816     Hose As    
6     1     265-9416     Hose As    
7     1     276-8151     Hose As    

Preparing the Machine




    Illustration 1g01262257

  1. Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel.

  1. Engage the parking brake.

  1. Lower the work tools to the ground. Stop the engine.

  1. Release hydraulic system pressure.

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

Removal of Parts

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.


Mounting Lines Group




    Illustration 2g01262245

  1. Remove bolt (8), washer (9) and locknut (10) .

  1. Remove bolt (11) and washer (12). The weldnut (13) is part of the bracket (14) .

  1. Remove the three bolts (15) and the three washers (16) .

  1. Discard the parts that are removed in Step 1, Step 2, and Step 3.



    Illustration 3g01262248

  1. Remove the two bolts (17), the four hard washers (18) and the two locknuts (19). Remove the blocks (20).

  1. Remove the four bolts (21) and the four hard washers (22). Remove the blocks (23) .

Routing of the Hydraulic Lines




Illustration 4g01262254

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 235-5850 Backhoe Auxiliary Lines Gp and the 235-5851 Backhoe Auxiliary Lines Gp , this is the position for the return line for the auxiliary circuit. In the 267-3450 Backhoe Auxiliary Lines Gp , this is the position for the line for the flow of oil from the auxiliary valve.

(25) In the 235-5850 Backhoe Auxiliary Lines Gp , this is the position for the line for the flow of oil from the auxiliary valve. In the 202-5948 Backhoe Auxiliary Lines Gp , this is the position for the auxiliary line on the left side of the boom. In the 235-5851 Backhoe Auxiliary Lines Gp , this is the position for the line for the flow of oil from the auxiliary valve or this is the position for the line to the rod end of the extendable stick. In the 202-5940 Stick Lines Gp , this is the rod end for the extendable stick cylinder.

(26) In the 202-5936 Stick Lines Gp , this is the position for the head end of the stick cylinder. In the 267-3450 Backhoe Auxiliary Lines Gp , this is the position for the return line for the auxiliary circuit.

(27) In the 202-5936 Stick Lines Gp ,this is the position for the rod end of the stick cylinder. In the 267-3450 Backhoe Auxiliary Lines Gp , this is the position for the rod end of the stick cylinder.

(28) For the 202-5940 Stick Lines Gp , this is the head end of the extendable stick cylinder. For the 235-5851 Backhoe Auxiliary Lines Gp , this is the head end of the extendable stick cylinder.

(29) The rod end of the boom cylinder

(30) The head end of the bucket cylinder

(31) The head end of the boom cylinder

(32) The rod end of the bucket cylinder

(33) For the 202-5940 Stick Lines Gp , this is the rod end of the extendable stick cylinder. For the 202-5948 Backhoe Auxiliary Lines Gp , this is the auxiliary line for the right side of the boom. For the 235-5851 Backhoe Auxiliary Lines Gp , this is the head end of the extendable stick cylinder.

(34) In the 202-5936 Stick Lines Gp and the 267-3450 Backhoe Auxiliary Lines Gp , this is the rod end of the stick cylinder.

(35) For all lines group, this is the head end of the bucket cylinder.

(36) For all lines groups except the 267-3450 Backhoe Auxiliary Lines Gp , this is the rod end of the bucket cylinder. For the 267-3450 Backhoe Auxiliary Lines Gp , this is the head end of the stick cylinder.

(37) For the 202-5940 Stick Lines Gp , this is the head end for the extendable stick cylinder. For the 202-5948 Backhoe Auxiliary Lines Gp , this is the position for the auxiliary line for the left side of the boom. For the 267-3450 Backhoe Auxiliary Lines Gp , this is the rod end of the bucket cylinder.

(38) For the 235-5851 Backhoe Auxiliary Lines Gp , this is the rod end of the extendable stick cylinder, or the line for the flow of oil from the auxiliary valve. For the 235-5850 Backhoe Auxiliary Lines Gp , this is the position for the line for the flow of oil from the auxiliary valve.

(39) For all lines groups, this is the rod end of the boom cylinder.

(40) In the 202-5936 Stick Lines Gp , this is the head end of the stick cylinder. In the 267-3450 Backhoe Auxiliary Lines Gp , this is the head end of the boom cylinder.

(41) For the 202-5932 Boom Lines Gp , this is the head end of the boom cylinder. For the 235-5850 Backhoe Auxiliary Lines Gp , the 235-5851 Backhoe Auxiliary Lines Gp and the 267-3450 Backhoe Auxiliary Lines Gp , this is the return line for the auxiliary circuit.




Illustration 5g01262259



Illustration 6g01262260

View A-A

Refer to Illustration 6 for the correct location for the hoses on the bank valve.

(42) For the 235-5851 Backhoe Auxiliary Lines Gp , this is the auxiliary line or the rod end to the extendable stick. For the 235-5850 Backhoe Auxiliary Lines Gp and the 267-3450 Backhoe Auxiliary Lines Gp , this is the auxiliary line. For the 202-5940 Stick Lines Gp , this is the rod end to the extendable stick.

(43) The head end of the stick cylinder

(44) The head end of the bucket cylinder

(45) The rod end of the boom cylinder

(46) The head end of the boom cylinder

(47) The rod end of the bucket cylinder

(48) The rod end of the stick cylinder

(49) For the 235-5851 Backhoe Auxiliary Lines Gp and the 202-5940 Stick Lines Gp , this is the head end to the extendable stick. For the 202-5948 Backhoe Auxiliary Lines Gp , this is the auxiliary line.

The Boom Cylinder Lines

Table 2
Boom Cylinder Lines for the Backhoe    
Former Part Number     Description     New Part Number    
202-1059     Hose As     149-8718    
201-3645     Hose As     265-9416    

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 6 for the positions of the hoses.




    Illustration 7g01262465

  1. Disconnect the hydraulic hose (50) from the head end of the boom cylinder. Disconnect the hydraulic hose (51) from the rod end of the boom cylinder.

  1. Remove the other end of hose (50) from the machine at port (46) for the head end of the boom cylinder. Remove the other end of hose (51) from the machine at port (45) for the rod end of the boom cylinder.



    Illustration 8g01262497

  1. Install one end of the new 149-8718 Hose As (2) at port (45) for the rod end of the boom cylinder.

  1. Route the hose through the lines mounting groups. Install the other end of the new 149-8718 Hose As (2) to the rod end of the boom cylinder.

  1. Install one end of the new 265-9416 Hose As (6) on the machine at port (46) for the head end of the boom cylinder.

  1. Route the hose through the lines mounting groups. Install the other end of the new 265-9416 Hose As (6) to the head end of the boom cylinder.

Stick Cylinder Line

Table 3
Stick Cylinder Lines for the Backhoe    
Former Part Number     Description     New Part Number    
201-3643     Hose As     249-4816    

The following procedure is used in order to replace the former boom cylinder lines with the new boom cylinder lines. Table 3 lists the former part numbers and the new part numbers. Refer to Illustration 4 and Illustration 6 for the positions of the hoses.




    Illustration 9g01262514

  1. Disconnect the hydraulic hose (52) from the rod end of the stick cylinder.

  1. Remove the other end of hose (52) from port (48) for the rod end of the stick cylinder.

  1. Install one end of the new 249-4816 Hose As (5) on the machine in port (48) for the rod end of the stick cylinder.

  1. Route the hose through the lines mounting groups. Install the other end of the new 249-4816 Hose As (5) to the rod end of the stick cylinder.

The Line to the Head End of the Extendable Stick Cylinder or the Auxiliary Line

Table 4
Auxiliary Line or Line to the Head End of the Extendable Stick Cylinder for the Backhoe    
Former Part Number     Description     New Part Number    
201-3639     Hose As     9R-2587    

The following procedure is used in order to replace the former line to the head end of the extendable stick cylinder (if equipped) or the auxiliary line (if equipped) with the new line to the head end of the extendable stick cylinder (if equipped) or the auxiliary line (if equipped).

Table 4 lists the former part number and the new part number. Refer to Illustration 4 and Illustration 6 for the positions of the hoses.




    Illustration 10g01262575

  1. Disconnect the hydraulic hose (53) from the port (49) at connection (A) .

  1. Remove the other end of hose (53) from the bottom of the boom at connection (B) .

  1. Install one end of the new 9R-2587 Hose As (1) into port (49) at connection (A) .

  1. Install one end of the new 9R-2587 Hose As (1) to the bottom of the boom at connection (B) .

The Line to the Rod End of the Extendable Stick Cylinder or the Auxiliary Line

Table 5
Auxiliary Line or the Line to the Rod End of the Extendable Stick Cylinder for the Backhoe    
Former Part Number     Description     New Part Number    
203-4698     Hose As     276-8151    

The following procedure is used in order to replace the former line to the rod end of the extendable stick cylinder (if equipped) or the auxiliary line (if equipped) with the new line to the rod end of the extendable stick cylinder (if equipped) or the auxiliary line (if equipped).

Table 5 lists the former part number and the new part number. Refer to Illustration 4 and Illustration 6 for the positions of the hoses.




    Illustration 11g01262893

  1. Disconnect the hydraulic hose (54) from the port (42) .

  1. Remove the other end of hose (54) from the tee on the boom at connection (C) .

  1. Install one end of the new 276-8151 Hose As (7) into port (42) .

  1. Install one end of the new 276-8151 Hose As (7) to the tee on the boom at connection (C) .

The Lines to the Bucket Cylinder

Table 6
Lines for the Bucket Cylinder for the Backhoe    
Former Part Number     Description     New Part Number    
201-3641     Hose As     172-2251    
201-3646     Hose As     199-2567    

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 6 for the positions of the hoses.

  1. Disconnect the hydraulic hose (55) from port (44) for the head end of the bucket cylinder. Disconnect the hydraulic hose (56) from port (47) for the rod end of the bucket cylinder.



    Illustration 12g01262792

  1. Remove the other end of hose (55) from the boom. Remove the other end of hose (56) from the boom.

  1. Install one end of the new 172-2251 Hose As (3) on the machine in port (44) for the head end of the bucket cylinder.

  1. Route the hose through the lines mounting groups. Install the other end of the new 172-2251 Hose As (3) on the boom in the position for hose (55) .

  1. Install one end of the new 192-2567 Hose As (4) on the machine in port (47) for the rod end of the bucket cylinder.

  1. Route the hose through the lines mounting groups. Install the other end of the new 192-2567 Hose As (4) on the boom in the position for hose (56) .

  1. Refer to Illustration 3. Install the lines mounting group to the boom.

  1. Fill the hydraulic system. Refer to Operation and Maintenance Manual, SEBU7399, "420D and 430D Backhoe Loaders", "Hydraulic System Oil - Check".

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