Caterpillar cat 420 e backhoe loader (prefix djl) service repair manual (djl00001 and up)

service repair manual

1. Service Repair Manual
Model
420E BACKHOE LOADER

2. Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 420E BACKHOE LOADER DJL
Configuration: 420E Backhoe Loader Single Tilt DJL00001-UP (MACHINE) POWERED BY C4.4 Engine
Disassembly and Assembly
416E, 420E and 430E Backhoe Loaders Power Train
Media Number -UENR0226-03 Publication Date -01/12/2014 Date Updated -05/12/2014
i04818786
Drive Shaft (Front) - Remove and Install
SMCS - 3253-010-FR
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-7505 Hydraulic Jack 1
Illustration 1 g01116830
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3. 1.Install Tooling (A) under guard (2) . Remove bolts (1) . Repeat for the other side. Use
Tooling (A) in order to lower guard (2) to the ground. The weight of guard (2) is
approximately 38 kg (85 lb).
Illustration 2 g01116832
2.Remove bolts (3) .
Illustration 3 g01116843
3.Remove bolts (5) and remove front drive shaft (4) .
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4. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 1U-7505 Hydraulic Jack 1
Illustration 4 g01116843
1.Install front drive shaft (4) and install new bolts (5) . Tighten bolts (5) to a torque of 28 ± 7
N·m (21 ± 5 lb ft)
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5. Illustration 5 g01116832
2.Install new bolts (3) .
Illustration 6 g01116830
3.Install Tooling (A) under guard (2) . The weight of guard (2) is approximately 38 kg (85 lb).
Use Tooling (A) in order to raise guard (2) into position. Install bolts (1) . Repeat for the
other side.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
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6. Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 420E BACKHOE LOADER DJL
Configuration: 420E Backhoe Loader Single Tilt DJL00001-UP (MACHINE) POWERED BY C4.4 Engine
Disassembly and Assembly
416E, 420E and 430E Backhoe Loaders Power Train
Media Number -UENR0226-03 Publication Date -01/12/2014 Date Updated -05/12/2014
i02990373
Drive and Steering Axle (Front) - Remove
SMCS - 3020-011-FR
S/N - DAN1-UP
S/N - DJL1-UP
S/N - LMS1-UP
S/N - MXB1-UP
S/N - SWC1-UP
Removal Procedure
Table 1
Required Tools
ToolPart Number Part DescriptionQty
A 308-3470 Repair Stand 2
B 308-3471 Repair Stand 2
C 1U-9745 Air/Hydraulic Jack Gp 1
Start By:
a.Remove the front drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Front) -
Remove and Install".
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7. Illustration 1 g01237930
1.Raise the bucket and install lift cylinder brace (1).
Illustration 2 g01515289
2.Use Tooling (C) in order to position Tooling (A) under the rear of the machine.
Illustration 3 g01515297
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8. 3.Use Tooling (C) in order to raise the front of the machine. Position Tooling (B) under the
front of the machine.
4.Remove the front tires and rims. Refer to Disassembly and Assembly, "Tire and Rim (Front)
- Remove and Install".
5.Remove the counterweight. Refer to Disassembly and Assembly, "Counterweight - Remove
and Install".
Illustration 4 g01515414
6.Disconnect hose assembly (2). Repeat for the opposite side of the machine.
7.Remove bolt (3).
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9. Illustration 5 g01515454
8.Attach a suitable lifting device to both sides of front drive and steering axle (4). The weight
of front drive and steering axle (4) is approximately 408 kg (900 lb).
Illustration 6 g01516006
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10. Illustration 7 g01515475
9.Remove pin assembly (5). Remove front drive and steering axle (4). Remove washers (6)
and thrust washers (7) from both sides of front drive and steering axle (4).
Note: The flange of pin assembly (5) must be rotated downward in order to clear the frame.
Illustration 8 g01515522
10.Remove seal (8). Remove bushing (9). Repeat this step for the other side.
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11. Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
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12. Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 420E BACKHOE LOADER DJL
Configuration: 420E Backhoe Loader Single Tilt DJL00001-UP (MACHINE) POWERED BY C4.4 Engine
Disassembly and Assembly
416E, 420E and 430E Backhoe Loaders Power Train
Media Number -UENR0226-03 Publication Date -01/12/2014 Date Updated -05/12/2014
i05437915
Axle Housing and Flange - Remove
SMCS - 4057-011; 4234-011
S/N - DAN1-UP
S/N - DJL1-UP
S/N - LMS1-UP
S/N - MXB1-UP
S/N - SWC1-UP
Removal Procedure
Table 1
Required Tools
ToolPart Number Part Description Qty
A 1P-2320 Combination Puller 1
B 230-7923 Spanner Wrench As 1
C 2P-8312 Retaining Ring Pliers 1
Start By:
A.Remove the final drive planetary. Refer to Disassembly and Assembly, "Final Drive Planetary -
Remove".
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13. Illustration 1 g01047618
1.Loosen nut (2) . Do not remove nut (2) at this time. Install Tooling (A) . Remove tie rod end (1) from
the taper of the knuckle. Remove nut (2) and position tie rod end (1) out of the way.
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14. Illustration 2 g01047569
2.Remove bolts (5) and remove locking plate (4) . Use Tooling (B) in order to remove spanner nut (3) .
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15. Illustration 3 g01023074
Illustration 4 g01023075
3.Use a suitable pry bar and push the double U-joint toward the wheel flange. This will make the
removal of retaining ring (8) easier. Use Tooling (C) and remove retaining ring (8) . Remove thrust
washer (7) and washer (6) .
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16. Illustration 5 g01023088
4.Remove ring gear (9) .
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17. Illustration 6 g01023126
5.Remove wheel flange (10) .
Note: Bearing cone (11) will fall out of wheel flange (10) when wheel flange (10) is removed.
Illustration 7 g01023130
Note: Note the order and orientation of shims (14) for assembly purposes.
6.Remove bolts (12) . Remove pin assembly (13) and shims (14) . Remove bolts (16) and pin assembly
(15) .
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18. Illustration 8 g01023136
7.Use a suitable lifting device in order to remove knuckle (17) . The weight of knuckle (17) is
approximately 50 kg (110 lb).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
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19. Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 420E BACKHOE LOADER DJL
Configuration: 420E Backhoe Loader Single Tilt DJL00001-UP (MACHINE) POWERED BY C4.4 Engine
Disassembly and Assembly
416E, 420E and 430E Backhoe Loaders Power Train
Media Number -UENR0226-03 Publication Date -01/12/2014 Date Updated -05/12/2014
i04790842
Axle Housing and Flange - Disassemble
SMCS - 4057-015; 4234-015
Disassembly Procedure
Table 1
Required Tools
ToolPart NumberPart DescriptionQty
A 1P-0510 Driver Gp 1
B 1P-0520 Driver Gp 1
Start By:
a.Remove the axle housing and the wheel flange.
Illustration 1 g01023873
1.Remove retaining ring (1) and ring gear hub (2) from ring gear (3).
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20. Illustration 2 g01023874
2.Remove seal (4) from wheel flange (7). Use Tooling (B) and a suitable hammer in order to remove
bearing cup (5). Remove spacer (6). Use Tooling (B) and a suitable hammer in order to remove
bearing cup (8).
Illustration 3 g01023875
3.Remove bearing cone (9) and seal (10) from pin assembly (11). Repeat for the other pin assembly.
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21. Illustration 4 g01023881
4.Remove seal (12) from knuckle (13).
Illustration 5 g01038749
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22. 5.Remove bearing cone (14) from knuckle (13).
Illustration 6 g01023876
6.Use Tooling (A) and a suitable hammer in order to remove the bushing from knuckle (13).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
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23. Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 420E BACKHOE LOADER DJL
Configuration: 420E Backhoe Loader Single Tilt DJL00001-UP (MACHINE) POWERED BY C4.4 Engine
Disassembly and Assembly
416E, 420E and 430E Backhoe Loaders Power Train
Media Number -UENR0226-03 Publication Date -01/12/2014 Date Updated -05/12/2014
i04790848
Axle Housing and Flange - Assemble
SMCS - 4057-016; 4234-016
Assembly Procedure
Table 1
Required Tools
ToolPart NumberPart DescriptionQty
A 1P-0510 Driver Gp 1
B 1P-0520 Driver Gp 1
C 2S-3230 Bearing Lubricant 1
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24. Illustration 1 g01038749
1.Install bearing cone (14) onto knuckle (13).
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25. Illustration 2 g01026726
2.Use Tooling (A) and a suitable hammer and install the bushing into knuckle (13).
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27. Illustration 3 g01029981
3.Use Tooling (A) and install seal (12) into knuckle (13).
Illustration 4 g01023875
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28. 4.Install seal (10) onto pin assembly (11). Raise the temperature of bearing cone (9). Install bearing
cone (9) onto pin assembly (11). Repeat for the other pin assembly.
Note: Use Tooling (C) after installing bearing (9) to pack bearing.
Illustration 5 g01023874
5.Use Tooling (B) and a suitable hammer and install bearing cup (8) into wheel flange (7). Install
spacer (6). Use Tooling (B) and a suitable hammer and install bearing cup (5) into wheel flange (7).
Install bearing cup (5). Install seal (4).
Illustration 6 g01023873
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29. 6.Install ring gear hub (2) into ring gear (3). Install retaining ring (1).
End By:
a.Install the axle housing and the wheel flange.
Copyright 1993 - 2019 Caterpillar Inc.
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30. Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 420E BACKHOE LOADER DJL
Configuration: 420E Backhoe Loader Single Tilt DJL00001-UP (MACHINE) POWERED BY C4.4 Engine
Disassembly and Assembly
416E, 420E and 430E Backhoe Loaders Power Train
Media Number -UENR0226-03 Publication Date -01/12/2014 Date Updated -05/12/2014
i05437916
Axle Housing and Flange - Install
SMCS - 4057-012; 4234-012
S/N - DAN1-UP
S/N - DJL1-UP
S/N - LMS1-UP
S/N - MXB1-UP
S/N - SWC1-UP
Installation Procedure
Table 1
Required Tools
ToolPart Number Part Description Qty
B 230-7923 Spanner Wrench As 1
C 2P-8312 Retaining Ring Pliers 1
D 129-1938 Grease Cartridge -
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31. Illustration 1 g01023136
1.Use a suitable lifting device in order to install knuckle (17) . The weight of knuckle (17) is
approximately 50 kg (110 lb).
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