Parts Manual BACKHOE Loader 420D CATERPILLAR

SEBP3203 November 2000 Parts Manual See “General Information” for New Parts Manual Features. 420D Backhoe Loader FDP1-Up (Machine) 7BJ19000-Up (Engine) Powered By 3054 Engine

Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number: Dealer Information Name: Branch: Address: D e a l e r C o n t a c t P h o n e N u m b e r H o u r s Sales: Parts: Service:

Informations produit et concessionnaire Nota: Voir l’emplacement de la plaque signalétique du produit au chapitre “Informations produit” du guide d’utilisation et d’entretien. Date de livraison: Informations produit Modèle: Numéro d’identification produit: Numéro de série du moteur: Numéro de série de la boîte de vitesses: Numéro de série de l’alternateur: Numéros de série d’équipement: Informations sur l’équipement: Numéro matériel client: Numéro matériel concessionnaire: Informations concessionnaire Nom: Agence: Adresse: C o n t a c t c o n c e s s i o n n a i r e N u m é r o d e t é l é p h o n e H e u r e s Ventes: Pièces: Service:

Información del Producto/Distribuidor Nota: Para saber la ubicación de las placas de identificación del producto, ver la sección “Información sobre identificación del producto” en el Manual de Operación y Mantenimiento. Fecha de entrega: Información del producto Modelo: Número de identificación del producto: Número de serie del motor: Número de serie de la transmisión: Número de serie del generador: Números de serie de los accesorios: Información sobre los accesorios: Número del equipo del cliente: Número del equipo del distribuidor: Información del distribuidor Nombre: Sucursal: Dirección: C o m u n i c a c i ó n c o n e l d i s t r i b u i d o r N ú m e r o d e t e l é f o n o H o r a s Ventas: Piezas: Servicio:

Informações Sobre Produto e Revendedor Nota: Para localizações da placa de identificação do produto, consulte a seção, “Informações Sobre Identificação do Produto” no Manual de Operação e Manutenção. Data de Entrega: Informações Sobre o Produto Modelo: Número de Identificação do Produto: Número de Série do Motor: Número de Série da Transmissão: Número de Série do Gerador: Números de Série de Acessórios: Informações Sobre Acessórios: Número do Equipamento do Cliente: Número do Equipamento do Revendedor: Informações Sobre o Revendedor Nome: Filial: Endereço: C o n t a t o d o R e v e n d e d o r T e l e f o n e H o r a s Vendas: Peças: Serviço:

Produkt- und Händlerinformation Anmerkung: Für die Lage der Produkt-Identnummer und Seriennummern siehe Abschnitt “Produkt-Identinformation” im Betriebs- und Wartungshandbuch. Lieferdatum: Produkt-Identinformation Modell: Produkt-Identnummer: Seriennummer des Motors: Seriennummer des Getriebes: Seriennummer des Generators: Seriennummern der Arbeitsgeräte: Arbeitsgeräteinformation: Kundennummer: Händlernummer: Händlerinformation Name: Niederlassung: Adresse: K o n t a k t p e r s o n b e i m H ä n d l e r T e l e f o n D i e n s t s t u n d e n Verkauf: Ersatzteile: Service:

MEMORANDA MEMORANDA SEBP3203

TABLE OF CONTENTS Name Page Name Page GENERAL INFORMATION .................. A20 REPAIR ALTERNATIVES .......... .......... A39 SUPPLEMENTAL COOLANT ADDITIVES .............................. A44 MAINTENANCE PARTS ........... ........... A49 INDEX ................... ................... A69 MACHINE ARRANGEMENT ......... ......... 1 BACKHOE AR ............................ 1 BACKHOE AR-EXTENDABLE STICK ...... 7 CHASSIS AR .............. .............. 11 COMMON AR ............................ 12 SUPPRESSION AR-SOUND ....... ....... 13 ENGINE ARRANGEMENT ......... ......... 14 ENGINE AR ............... ............... 14 ENGINE AR-PRIMARY .................... 15 INSTALLATION AR-ENGINE ....... ....... 16 BASIC ENGINE .............. .............. 17 CAMSHAFT GP .......................... 17 COVER GP-FRONT HOUSING ...... ...... 18 COVER GP-VALVE MECHANISM ..... ..... 20 CRANKSHAFT GP ........................ 22 CYLINDER BLOCK GP .................... 23 CYLINDER HEAD GP .......... .......... 26 DRIVE GP-FAN ............. ............. 28 FASTENER GP-CYLINDER HEAD ..... ..... 29 FLYWHEEL GP ............. ............. 30 HOUSING GP-FLYWHEEL ........ ........ 31 HOUSING GP-FRONT .......... .......... 32 LIFTING GP-ENGINE ........... ........... 33 MOUNTING GP-ALTERNATOR ...... ...... 34 MOUNTING GP-ENGINE & TMSN ..... ..... 36 MOUNTING GP-STARTING MOTOR .... .... 38 PAN GP-OIL ............... ............... 40 PISTON & ROD GP ........... ........... 42 PLUG GP-CYLINDER BLOCK ....... ....... 43 PLUG GP-CYLINDER HEAD ....... ....... 44 PLUG GP-ENGINE ............ ............ 45 PULLEY GP-CRANKSHAFT ....... ....... 47 VALVE MECHANISM GP ......... ......... 48 LUBRICATION SYSTEM .......... .......... 50 GAUGE GP-OIL LEVEL & FILLER ..... ..... 50 PUMP GP-GEROTOR .................... 51 COOLING SYSTEM .......................... 52 CONNECTION GP-WATER ........ ........ 52 COOLER GP-FLTR BASE & ENG OIL ... ... 54 COOLING AR ............................ 56 COOLING AR-HIGH AMBIENT TEMP ... ... 57 FAN GP-SUCTION ........................ 59 LINES GP-POWER TRAIN COOLER .... .... 62 PUMP GP-WATER ........................ 66 RADIATOR & HYD OIL COOLER GP .... .... 68 AIR INLET AND EXHAUST SYSTEM .... .... 70 AIR CLEANER GP ........................ 70 INDICATOR GP-AIRFILTER CHANGE ... ... 72 LINES GP-AIR .............. .............. 74 MUFFLER GP .............. .............. 76 TURBOCHARGER GP .......... .......... 78 FUEL SYSTEM ............... ............... 80 CONTROL GP-GOV & ACCELERATOR ... ... 80 FILTER & LINES GP-FUEL ........ ........ 82 FILTER GP-FUEL ............ ............ 84 LEVER GP-GOVERNOR CONTROL .... .... 85 LINES GP-FUEL ............. ............. 86 PUMP GP-FUEL INJECTION ....... ....... 88 SEPARATOR GP-WATER .................. 90 TANK GP-FUEL ............. ............. 94 ELECTRICAL AND STARTING SYSTEM ... ... 98 ALTERNATOR GP-CHARGING ...... ...... 98 BATTERY GP .............. .............. 106 HEATER GP-AIR INLET ......... ......... 110 HEATER GP-JACKET WATER ....... ....... 112 INSTALLATION GP-WARNING BEACON ................................ 114 LAMP GP-WARNING BEACON ...... ...... 115 LIGHTING GP-FLOOD .......... .......... 118 LIGHTING GP-WARNING BEACON .... .... 125 MODULE GP-WARNING INDICATOR ...... 127 STARTING MOTOR GP-ELECTRIC .... .... 129 SWITCH GP-PRESSURE ......... ......... 132 WIRING GP-AIR CONDITIONER ..... ..... 134 WIRING GP-AUTOSHIFT ......... ......... 136 WIRING GP-CAB ............. ............. 140 WIRING GP-CONSOLE .......... .......... 144 WIRING GP-ENGINE ........... ........... 156 WIRING GP-PLATFORM ......... ......... 164 WIRING GP-POWER RECEPTACLE .... .... 172 WIRING GP-REAR ............ ............ 174 WIRING GP-RIDE CONTROL .............. 178 WIRING GP-SENSOR .......... .......... 185 WIRING GP-STABILIZER .................. 186 WIRING GP-STABILIZER ALARM ..... ..... 188 WIRING GP-STEERING .................. 189 POWER TRAIN ............... ............... 190 AXLE & MTG GP-DRIVE & STEERING ... ... 190 AXLE & MTG GP-REAR ......... ......... 191 AXLE GP-DRIVE & STEERING ...... ...... 192 AXLE GP-REAR .......................... 198 SEBP3203 TABLE OF CONTENTS A1

TABLE OF CONTENTS Name Page Name Page CHART-WHEEL & TIRE ......... ......... 203 CONTROL GP-DIFFERENTIAL LOCK ... ... 204 CONTROL GP-TRANSMISSION ...... ...... 206 DRIVE AR ................ ................ 208 DRIVE GP-FLEXIBLE COUPLING ..... ..... 210 FILLER GP-POWER TRAIN OIL ............ 212 POWER TRAIN AR ............ ............ 218 SHAFT GP-DRIVE ........................ 228 TRANSMISSION AR-DIRECT DRIVE ...... 231 TRANSMISSION AR-POWER SHIFT ...... 233 TRANSMISSION GP-DIRECT DRIVE ...... 234 TRANSMISSION GP-POWER SHIFT ...... 246 VALVE GP-RELIEF ............ ............ 252 VALVE GP-SOLENOID .......... .......... 253 BRAKING SYSTEM .......................... 258 BRAKE GP-PARKING .......... .......... 258 CONTROL GP-PARKING BRAKE ..... ..... 259 CONTROL GP-SERVICE BRAKE ..... ..... 262 LEVER GP-HAND CONTROL .............. 265 RESERVOIR GP-BRAKE ......... ......... 266 STEERING SYSTEM ........................ 268 AXLE GP-FRONT ............ ............ 268 CONTROL GP-STEERING ........ ........ 270 CYLINDER GP-STEERING ........ ........ 273 KIT-STEERING KNOB .......... .......... 274 LINES GP-STEERING .......... .......... 276 LOCK GP-STEERING CYLINDER ..... ..... 280 PUMP GP-METERING .......... .......... 282 STEERING GP-HYDRAULIC ....... ....... 284 VALVE GP-PRIORITY .......... .......... 285 FRAME AND BODY ............ ............ 286 BATTERY BOX GP ........................ 286 BUMPER GP-FRONT ........... ........... 288 COUNTERWEIGHT GP .......... .......... 289 DOOR GP-BATTERY ........... ........... 294 FENDER GP-REAR ........... ........... 295 FLOORPLATE GP ............ ............ 296 FRAME AS-LOADER ........... ........... 298 FRAME GP-LOADER ........... ........... 299 FRAME GP-SWING ........... ........... 300 GUARD GP-DRIVE SHAFT ........ ........ 302 HOOD & GUARD GP ........... ........... 304 HOOD GP-ENGINE ........... ........... 306 HYDRAULIC SYSTEM ........... ........... 309 ACCUMULATOR GP-STABILIZER ..... ..... 309 CONNECTOR GP-VALVE ......... ......... 310 CONTROL AR-HYDRAULIC ........ ........ 312 CONTROL AR-RIDE ...................... 314 CONTROL GP-HYDRAULIC HAND .... .... 318 CONTROL GP-VALVE .......... .......... 322 CONVERSION GP-CONTROL VALVE ... ... 326 COUPLING GP ............. ............. 327 COVER GP-PROTECTIVE ................ 328 CYLINDER GP-BACKHOE BUCKET .... .... 330 CYLINDER GP-BOOM .......... .......... 334 CYLINDER GP-EXTENDABLE STICK ... ... 336 CYLINDER GP-LIFT ........... ........... 338 CYLINDER GP-MULTIPURPOSE BUKT .................. .................. 339 CYLINDER GP-STABILIZER ....... ....... 340 CYLINDER GP-STICK .......... .......... 342 CYLINDER GP-SWING .......... .......... 344 CYLINDER GP-TILT ........... ........... 346 DRAIN GP-HYDRAULIC ......... ......... 347 FILTER GP-OIL ............. ............. 348 GUARD GP-STABILIZER CYLINDER ...... 349 HYDRAULIC AR .......................... 352 HYDRAULIC AR-AUXILIARY ....... ....... 357 INSTALLATION AR-BANK VALVE ..... ..... 361 KICKOUT & POSITIONER GP ....... ....... 364 KIT-RIDE CONTROL ...................... 366 LINES GP-BACKHOE AUXILIARY ..... ..... 368 LINES GP-BOOM ............ ............ 390 LINES GP-BUCKET CYLINDER ...... ...... 392 LINES GP-EXTENDABLE STICK ..... ..... 394 LINES GP-LIFT CYLINDER ........ ........ 396 LINES GP-LOAD CONTROL VALVE .... .... 400 LINES GP-LOADER AUXILIARY ...... ...... 406 LINES GP-MULTIPURPOSE BUCKET ... ... 408 LINES GP-PILOT ............. ............. 412 LINES GP-PUMP ............. ............. 424 LINES GP-RETURN ........... ........... 432 LINES GP-RIDE CONTROL ........ ........ 436 LINES GP-STABILIZER .......... .......... 444 LINES GP-STICK ............ ............ 446 LINES GP-SWING ........................ 450 LINES GP-TILT CYLINDER ........ ........ 452 LOCK GP-HYDRAULIC HAND CONTROL ................ ................ 454 MOUNTING GP-BANK VALVE ....... ....... 455 MOUNTING GP-CYLINDER ........ ........ 457 MOUNTING GP-HYDRAULIC CONTROL ................ ................ 458 MOUNTING GP-HYDRAULIC PUMP ........ 461 MOUNTING GP-LINES .................... 462 PUMP GP-PISTON ............ ............ 464 ROTATING GP-PUMP .................... 466 SHAFT GP-POWER TAKE-OFF ...... ...... 467 STABILIZER AR .......................... 468 SUPPORT GP-COVER .................... 471 TANK & MTG GP-HYDRAULIC ...... ...... 472 VALVE & MTG GP-BANK ......... ......... 474 VALVE & MTG GP-SOLENOID ...... ...... 475 VALVE GP-BANK 2 ............ ............ 478 VALVE GP-BANK 3 ............ ............ 481 VALVE GP-BANK 4 ............ ............ 482 A2 TABLE OF CONTENTS SEBP3203

TABLE OF CONTENTS Name Page Name Page VALVE GP-BANK 5 ............ ............ 483 VALVE GP-BANK 6 ............ ............ 484 VALVE GP-CHECK ........................ 485 VALVE GP-CONTROL .......... .......... 488 VALVE GP-LOAD CONTROL ....... ....... 508 VALVE GP-PILOT ............ ............ 511 VALVE GP-POWER COMPENSATOR ...... 520 VALVE GP-PRESS & FLOW CMPNSTR ... ... 521 VALVE GP-SOLENOID .......... .......... 522 IMPLEMENTS .............................. 524 ARM GP-LIFT ............................ 524 BOOM GP ................ ................ 526 BRACE GP-LIFT CYLINDER ....... ....... 528 HOUSING AS-EXTENDABLE STICK .... .... 529 LINKAGE GP-BACKHOE BUCKET ........ 530 LINKAGE GP-LOADER BUCKET ..... ..... 532 LOADER AR ............... ............... 534 LOCK GP-TRANSPORT .................. 535 MOUNTING GP-STICK .................... 539 PAD & GUARD GP-STABILIZER ...... ...... 540 PAD & MTG GP-STABILIZER ....... ....... 543 PAD GP-STABILIZER ........... ........... 546 STABILIZER GP-BACKHOE ........ ........ 548 STICK GP-EXTENDABLE ......... ......... 550 STICK GP-HOE ............. ............. 552 WORK TOOLS ............... ............... 553 BUCKET AR ............... ............... 553 BUCKET AR-MULTIPURPOSE ...... ...... 558 BUCKET AS ............... ............... 566 BUCKET AS-GENERAL PURPOSE .... .... 568 BUCKET AS-LOADER .......... .......... 569 BUCKET GP-HOE ........................ 570 BUCKET GP-MULTIPURPOSE ...... ...... 578 CHART-HOE BUCKET .......... .......... 582 COUPLER GP-QUICK .......... .......... 585 EDGE GP-CUTTING ...................... 589 FORK AR ................................ 591 FORK GP ................ ................ 592 MOUNTING GP-BUCKET ......... ......... 593 MOUNTING GP-FORK .................... 595 OPTION AR-FRONT BUCKET GUARD ... ... 596 STOP GP-BUCKET ............ ............ 598 TOOTH GP-UNI ............. ............. 599 OPERATOR STATION ........................ 600 AIR CONDITIONER & MOUNTING GP ... ... 600 AIR CONDITIONER AR .......... .......... 602 AIR CONDITIONER GP .......... .......... 604 CAB AR .................................. 606 CAB AS ................. ................. 608 CAB GP ................. ................. 612 CANOPY AR ............... ............... 614 CANOPY AS ............... ............... 615 CANOPY GP-OPEN ROPS ........ ........ 619 COMPRESSOR & MTG GP-REFRIG ...... 620 COMPRESSOR GP-REFRIGERANT .... .... 622 CONDENSER & MTG GP- REFRIGERANT ............. ............. 623 CONSOLE GP-FRONT .................... 624 CONSOLE GP-OPERATOR ................ 626 CONSOLE GP-SIDE ...................... 628 COVER GP-CONSOLE .................... 634 COVER GP-FIREWALL .......... .......... 637 COVER GP-POST ........................ 639 DOOR GP-LH ............................ 640 DOOR GP-RH ............................ 642 DUCT GP-AIR ............................ 644 FLOOR MAT GP .......................... 648 LATCH GP-CONSOLE .......... .......... 650 LINES GP-HEATER & AIR COND ..... ..... 652 MIRROR GP-REAR VIEW ........ ........ 654 MOTOR GP-WINDOW WIPER ...... ...... 655 MOUNTING GP-INSTRUMENT PANEL ... ... 656 PEDAL GP-GOVERNOR ......... ......... 659 SEAT BELT GP ............................ 660 SEAT GP-SUSPENSION ......... ......... 666 SUPPRESSION GP-SOUND ....... ....... 674 SUSPENSION GP-SEAT ......... ......... 676 TRIM GP-CAB .............. .............. 678 VISOR GP-CAB .......................... 679 WASHER GP-WINDOW ......... ......... 680 WINDOW GP-CAB ............ ............ 682 WINDOW GP-DOOR ...................... 688 WIPER GP-WINDOW ........... ........... 692 SERVICE EQUIPMENT AND SUPPLIES ... ... 694 FILM GP .................................. 694 INSTALLATION AR-WHEEL CHOCK .... .... 695 LOCK GP-VANDALISM .......... .......... 696 PLATE & FILM GP ........................ 697 PART NUMBER INDEX ...................... B1 SEBP3203 TABLE OF CONTENTS A3

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Parts Manual BACKHOE Loader 420D CATERPILLAR

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