Field Installation of the 126-5004 Valve Control Group , Excavator Style Controls{5063} Caterpillar

Backhoe Loaders:

416C (PIN: 1WR1-UP; 1XR1-UP; 4ZN1-UP; 5YN1-UP)

426C (PIN: 1CR1-UP; 1ER1-UP; 1MR1-UP; 1NR1-UP; 1YR1-UP; 1ZR1-UP; 6XN1-UP; 7WN1-UP)

436C (PIN: 1FR1-UP; 1GR1-UP; 1PR1-UP; 1RR1-UP; 2AR1-UP; 2BR1-UP; 8TN1-UP; 9JN1-UP)

Introduction

Backhoe Loaders have the ability to accommodate different styles of backhoe hydraulic control groups. These control groups may be customized by using the appropriate kit at any time during the life of the machine. The proper configuration of controls increases operator productivity and operator comfort. This instruction details the following information: parts included in the 126-5004 Valve Control Group , the installation process and proper adjustment procedures.

Consult the Safety Section of your machine's Operation and Maintenance Manual before beginning this procedure. Read the following sections of the Operation and Maintenance Manual before operating the new controls: Operation Section, Machine Controls, Attachments and General Hazard Information.

126-5004 Valve Control Group , Excavator Style Controls Required Parts

Preparation for Installation

Illustration 1	g00355935

1. Remove four knobs (1) from controls. See Illustration 1.

2. Remove eight 9R-9901 Fasteners (2) from plate (3). Remove plate (3). The fasteners (2) and the plate (3) will be used during the assembly procedure. See Illustration 1.

3. Remove four boots (4). Boots (4) will be used during the assembly procedure. See Illustration 1.

4. Remove former instruction plate (30). See Illustration 1.

5. Remove rear console (5). See Illustration 1.

6. Remove two clips (6) and two pins (7). See Illustration 1.

7. Loosen two nuts (8). Remove two rod ends (9). See Illustration 1.

8. Loosen two nuts (10). Remove two rods (11). See Illustration 1.

9. Remove two 6V-7744 Locknuts (36). See Illustration 1.

10. Remove two 8T-4773 Ball Joints (29) and remove two 8T-4121 Washers (19). The 8T-4121 Washers (19) will be used during assembly. See Illustration 1.

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Illustration 2	g00385752

11. Inspect two 8T-4773 Ball Joints (29). The dust cover (A) for the ball stud (B) should be intact. Inspect the ball stud (B) for end play. If the ball joints fail the inspection, order new ball joints. The two 8T-4773 Ball Joints (29) are not included in the kit. See Illustration 2.

Installation of 118-5262 Levers

Illustration 3	g00361032
118-5262 Levers .

1. Install one 136-7440 Shim (26) on the 117-1052 Shaft (13). Start shaft (13) into the end of the first 118-5262 Lever (12). See Illustration 3.

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Illustration 4	g00372784

2. Move shaft (13) through the first lever (12) and install a 136-7440 Shim (26). Install the second 118-5262 Lever (12) on shaft (13). See Illustration 4.

3. Move shaft (13) through the second lever (12) and install a 136-7440 Shim (26). Install one 142-7405 Collar (14). Do not lock the collar at this time. See Illustration 4.

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Illustration 5	g00385861

4. Install the second 142-7405 Collar (14) and install one 136-7440 Shim (26). Continue to insert shaft (13) through the first lever (12). See Illustration 5.

5. Install six 136-7439 Spacers (15) and install two 136-7440 Shims (26). Continue to insert shaft (13) through the second lever (12). See Illustration 5.

6. Install the following parts on the 117-1052 Shaft (13) : 136-7440 Shim (26), 117-1051 Plate (16) and 006-8606 Retaining Ring (17). Hand tighten the two 6V-8932 Socket Setscrews (31). These socket setscrews will be tightened after all the parts are installed. See Illustration 5.

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Illustration 6	g00387737

7. Use spacers (15) and use shims (26) to achieve the correct free play. The correct free play is 1.25 ± .25 mm (0.049 ± 0.010 inch). This may need to be adjusted after all of the parts are installed. See Illustration 6.

8. Adjust collar (C) in order to allow .75 ± .25 mm (0.030 ± 0.010 inch) end play. Hand tighten the socket setscrews for collar (C). This may need to be adjusted after all of the parts are installed.

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Illustration 7	g00376292

9. Install the shaft assembly created during the previous steps into mounting bracket (20). Use four 8T-4196 Bolts (18) and use four 8T-4121 Washers (19). Hand tighten four bolts (18). See Illustration 7.

Installation of the 144-0898 Rods

Illustration 8	g00361172
Installation of the 144-0898 Rods

1. Install one 8T-4133 Nut (22) and install one 8T-4815 Rod End (25) on each of the 144-0898 Rods (23). Do not tighten the nuts at this time. See Illustration 8.

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Illustration 9	g00361652
Dimension (C) is 126.0 mm (4.96 inch).

2. Preset the length of the rod assemblies created in Step 1. Measure in a straight line between the mounting hole centerlines and the centerline of the rod end hole. Dimension (C) is 126.0 mm ( 4.96 inch). Hand tighten the nut (22). See Illustration 9.

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Illustration 10	g00362012

3. Install the two lever assemblies created in Step 1 and in Step 2 in Position (A) and Position (B). Use the following parts for each location: two 8T-4121 Washers (19), one 9R-2807 Clip (24) and two 9R-1968 Spacers (33). See Illustration 10.

   Note: Arrange washers and spacers to minimize misalignment between the linkage and the valves.

4. Install the following items with the valve in the centered position: 9R-2806 Pin (21) and 9R-2807 Clip (24). Connect the lever assemblies (23) to the valves. The following information is the proper adjustment procedure for each side:

   1. Remove pin (21) from rod end (25) .

   2. Move the linkage away from the valve.

   3. Loosen nut (22). Turn rod end (25) in order to adjust.

   4. Hand tighten nut (22). See Illustration 10.

Installation of 142-7404 Rods

Illustration 11	g00362313
Installation of 142-7404 Rods .

1. Install one 8T-4133 Nut (22) on each end of the 142-7404 Rods (28). Turn the nut on the rod to the end of the threads. Do not tighten the nuts at this time. See Illustration 11.

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Illustration 12	g00377139
Alignment of 8T-4773 Ball Joint and 8T-6431 Rod End (27) .

2. Install one 8T-4773 Ball Joint (29) on each rod (28). Align ball joint (29). See Illustration 12. Tighten nut (22) for ball joint (29) to a torque of 20 ± 5 N·m (15.0 ± 4.0 lb ft). Do not allow 8T-4773 Ball Joint (29) to move.

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Illustration 13	g00377141
8T-6431 Rod End (27), smooth side (E) .

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Illustration 14	g00377144
8T-6431 Rod End (27), formed side (D) .

4. Determine the smooth side (E) and formed side (D) of the 8T-6431 Rod End (27). See Illustration 13 and Illustration 14.

5. Install an 8T-6431 Rod End (27) on each rod (28). Illustration 12 shows the correct alignment of rod end (27). Tighten nut (22) for rod end (27) to a torque of 20 ± 5 N·m (15.0 ± 4.0 lb ft). Do not allow the 8T-6431 Rod End (27) to move.

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Illustration 15	g00384818

6. Install one 8T-4121 Washer (19) on ball joint (29). Install one rod assembly (28), created during the previous steps, into Position (F) and lever assembly (33). Arrange the following items to minimize misalignment: 8T-4121 Washers (19) and 9R-1968 Spacer (26) . See Illustration 15.

7. Install one 8T-4121 Washer (19) on ball joint (29). Install one rod assembly (28) into Position (G) and lever assembly (34). Arrange the following items to minimize misalignment: 8T-4121 Washers (19) and 9R-1968 Spacer (26) . Install two locknuts (36) removed during the Installation Preparation procedure on ball joint (29). The used locknuts (36) will be replaced after the linkage is aligned correctly. Hand tighten locknuts (36). See Illustration 15.

8. When linkage alignment is correct, install two new 6V-7744 Locknuts (36). See Illustration 15.

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NOTICE
Locknuts should only be used once. Locknuts which are used multiple times may loosen and cause damage to the machine.

9. Tighten two locknuts (36) to a torque of 25 ± 3 N·m (18.0 ± 2.0 lb ft). See Illustration 15.

10. Inspect all linkage for alignment. Move lever (33) and move lever (34). The linkage should not bind during normal operation. Adjust the shims and adjust the spacers if the linkage does not operate properly. See Illustration 15.

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Illustration 16	g00392622

11. Tighten four bolts (18) to a torque of 55 ± 10 N·m (41.0 ± 7.0 lb ft). Do not allow collar (14) to move. Remove one setscrew (30). Use 9S-3263 Thread Lock Compound on setscrew (30). Reinstall setscrew (30) and tighten setscrew (30). Do not allow second collar (14) to move. Remove the second setscrew (30). Apply 9S-3263 Thread Lock Compound to setscrew (30). Reinstall setscrew (30). Tighten setscrew (30). See Illustration 16.

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Illustration 17	g00412240

12. Length (H) of lever assemblies (33) and (34) should be in line with each other and perpendicular to the floorplate. Adjust rod assemblies (23). The correct procedure to adjust the linkage follows:

    1. Remove pin (21) from rod end (25). See Illustration 15.

    2. Move the linkage away from the valve.

    3. Loosen nut (22). Turn rod end (25) in order to adjust. See Illustration 15.

    4. Hand tighten nut (22). See Illustration 15.

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New installation of backhoe controls may cause unexpected movement of the backhoe during the initial testing. Personal injury or death could occur if all persons and obstructions are not removed from the backhoe's range of motion.

13. Read the appropriate Operations and Maintenance Manual, "Operation Section", Attachment Controls, Hydraulic Excavator Controls. Test the installed kit. Make adjustments which are required.

14. Tighten the nuts (22) on both rod assemblies (23) to a torque of 20 ± 5 N·m (15.0 ± 4.0 lb ft). See Illustration 15.

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Illustration 18	g00391557

15. Install the rear console (5) .

16. Use eight 9R-9901 Fasteners (2) to attach cover plate (3) and boots (4). Install the knobs (1). Install 128-6150 Film (35). See Illustration 18.