Installation of an Hydraulic Hand Control Conversion (Kit-Excavator Two Lever) for a Backhoe Loader{5063} Caterpillar

Backhoe Loaders:

416D (S/N: BKG; BGJ; BFP)

424D (S/N: BGP; BKR)

428D (S/N: BLL; BNS)

Introduction

This special instruction outlines the basic procedures in order to install an Hydraulic Hand Control Conversion.

The Hydraulic Hand Control Conversion is interchangeable with other kits that are designed for the D-series backhoe loaders. The kits allow the skills of the operator to be matched with the machine controls.

Do not perform any of the procedures until you have read the information in this publication.

Required Parts

The 164-1430 Hydraulic Hand Control Conversion Gp (Kit-Excavator Two Lever) is composed of the 164-1420 Hydraulic Hand Control Gp . The kit and the control group are not serviceable. Many of the parts in the control group are serviceable.

The kit is available from the BCP facility in Clayton, North Carolina.

In addition to the parts in the following table, you will also need to obtain 8T-9021 Adhesive .

Installation Procedures

Show/hide table



Illustration 1	g00762485
(1) 164-1409 Lever (1a) 164-1411 Lever (2) 8T-4172 Bolt (3) 7X-7729 Washer (4) 164-1435 Plate (5) 164-1402 Sleeve (6) 6V-7744 Locknut

1. Prepare the backhoe loader for servicing. Refer to the machine's Service Manual for all safety and operation instructions.

2. Remove the rear console that is on the machine.

3. Remove the existing backhoe controls from the backhoe control valve.

4. Remove the tower assembly and the existing backhoe controls from the machine.

5. Assemble the following parts in order to create the right hand control assembly: 164-1409 Lever (1), 8T-4172 Bolt (2), 7X-7729 Washer (3), 164-1435 Plate (4), 164-1402 Sleeve (5), and 6V-7744 Locknut (6). Refer to Illustration 1.

Show/hide table



Illustration 2	g00762493
(3) 7X-7729 Washer (4) 164-1435 Plate (6) 6V-7744 Locknut (7) 8T-4138 Bolt (8) 9X-8256 Washer (9) 170-6312 Bearing (10) 164-1404 Spacer (11) 164-1560 Tower (12) 8T-6466 Bolt (13) 8T-4121 Hard Washer

6. Attach the bearings (9) and spacer (10) to the 164-1560 Tower (11) with the bolts (7) and washers (8). Refer to Illustration 2.

   Note: Torque bolt (7) through the spacer (10) and bearings (9) before bolting the bearings to the tower (11) .

7. Secure the plate (4) of the control lever assembly to the bearings (9) with a 8T-6466 Bolt (12), a 8T-4121 Hard Washer (13), two washers (3), and a locknut (6). Refer to Illustration 2.

   Note: Repeat steps 5 to 7 in order to assemble the left hand controls.

Show/hide table



Illustration 3	g00762495
(13) 8T-4121 Hard Washer (15) 8T-4133 Nut (21) 164-1422 Shaft As (22) 142-7405 Collar (23) 164-1425 Coupler (24) 164-1429 Coupler (25) 6V-8932 Socket Setscrew (26) 164-1421 Plate (27) 8T-4195 Bolt

8. Assemble the 164-1425 Coupler (23) and 164-1429 Coupler (24). Use the following parts in order to attach the couplers to the tower (11) : 8T-4121 Hard Washers (13), 8T-4133 Nuts (15), 164-1422 Shaft As (21), 142-7405 Collars (22), 6V-8932 Socket Setscrews (25), 164-1421 Plate (26), and a 8T-4195 Bolts (27). Refer to Illustration 3.

Show/hide table



Illustration 4	g00762498
(1) 164-1409 Lever (1a) 164-1411 Lever (4) 164-1435 Plate (6) 6V-7744 Locknut (13) 8T-4121 Hard Washer (14) 8T-4773 Ball Joint (15) 8T-4133 Nut (16) 164-1438 Rod (17) 164-1441 Rod (18) 8T-4815 Rod End (19) 9R-2806 Pin (20) 9R-2807 Clip (23) 164-1425 Coupler (24) 164-1429 Coupler (27) 8T-4195 Bolt (28) 164-1427 Rod

9. Assemble two shorter control rod assemblies from the following parts: two 8T-4773 Ball Joints (14), two 8T-4133 Nuts (15), and 164-1438 Rod (16). Refer to Illustration 4.

   Note: The 8T-4133 Nuts (15) must be tightened to a torque of 20 ± 5 N·m (14.75 ± 3.69 lb ft).

10. Assemble each of two medium sized rod assemblies with the following parts: two 8T-4773 Ball Joints (14), two 8T-4133 Nuts (15), and a 164-1427 Rod (28). Refer to Illustration 4.

    Note: The 8T-4133 Nuts (15) must be tightened to a torque of 20 ± 5 N·m (14.75 ± 3.69 lb ft).

Show/hide table



Illustration 5	g00762497
(28) 164-1427 Rod

11. The length of the two control rod assemblies (28) must measure 245 mm (9.65 inch). Refer to Illustration 5.

12. Assemble each of the two longer control rod assemblies with the following parts: a 8T-4773 Ball Joint (14), two 8T-4133 Nuts (15), a 164-1441 Rod (17), a 8T-4815 Rod End (18), a 9R-2806 Pin (19), and a 9R-2807 Clip (20). Refer to Illustration 4.

    Note: The 8T-4133 Nuts (15) must be tightened to a torque of 20 ± 5 N·m (14.75 ± 3.69 lb ft).

13. Attach each control rod to the correct lever assembly or coupler assembly for each control rod. Use a 6V-7744 Locknut (6) and a 8T-4121 Hard Washer (13) in order to attach the control rods to the lever assemblies and coupler assemblies. Refer to Illustration 4.

    Note: The locknuts (6) must be tightened to a torque of 30 ± 7 N·m (22.13 ± 5.16 lb ft).

14. Secure the tower (11) and the parts which are attached to the tower to the machine with two hard washers (13) and two bolts (27). Refer to Illustration 4.

15. Attach each of the two control rod assemblies (16) to the main hydraulic control valve for backhoe operations with a locknut (6). Refer to Illustration 4.

16. Attach each of the two control rod assemblies (17) to the main hydraulic control valve for backhoe operations with a 9R-2806 Pin and a 9R-2807 Clip . Refer to Illustration 4.

    Note: Adjust the position of the coupler. Make sure that the linkage rods are vertical. The rods must not bind. There should be no more than 0.5 mm (0.0197 inch) to 1 mm (0.0394 inch) of side play.

Show/hide table



Illustration 6	g00762522
The lever assemblies (1a) and (1) must be separated by the distance in the illustration.

17. Adjust the control lever assemblies so a space of 281 ± 2 mm (11.06 ± 0.09 inch) separates the two levers (1) and (1a). Refer to Illustration 6.

18. Secure the collars (22) with the 6V-8932 Socket Setscrews (25) in order to anchor the couplers (23) and (24) on the shaft assembly (21) .

    Apply 8T-9021 Adhesive to both socket setscrews before securing the collars (25) to the lever shaft (24) .

Show/hide table



Illustration 7	g00762500
(11) 164-1560 Tower (29) 167-8248 Rear Console (30) 9X-2045 Screw (31) 9X-2038 Washer (32) 164-1361 Boot (33) 164-1371 Plate (34) 9R-9901 Fastener (35) 190-5128 Film (36) 164-1399 Knob

19. Put the 167-8248 Rear Console (29) over the control lever assemblies and tower (11). Refer to Illustration 7.

    Note: The levers must have full range of movement when the rear console is installed. Adjust the levers when any problems occur with movement of the levers.

20. Secure the rear console to the floor of the cab with four 9X-2045 Screws (30) and four 9X-2038 Washers (31). Refer to Illustration 7.

21. Slide the 164-1361 Boots (32) over the levers (1) and (1a). The boots must be moved down the levers in order to touch the rear console. Refer to Illustration 7.

22. Place the 164-1371 Plate (33) over the boots and levers. Refer to Illustration 7.

    Note: The levers must have full range of movement when the rear console is installed. Adjust the levers when any problems occur with movement of the levers.

23. Secure the plate (33) to the rear console with six 9R-9901 Fasteners (34). Refer to Illustration 7.

24. Apply the 190-5128 Film (35) to the rear console. Refer to Illustration 7.

25. Put the 164-1399 Knobs (36) on the levers (1) and (1a). Refer to Illustration 7.

26. Check the functioning of the backhoe. Adjust the control rods if any problems occur with the functioning of the backhoe.