Installation of a Backhoe Control STANDARD/CROSS Pattern Set{5063} Caterpillar

Backhoe Loader:

416D (S/N: BGJ1-UP)

424D (S/N: BGP1-UP; BKR1-UP)

428D (S/N: BLL1-UP; BMT1-UP; BNB1-UP; BNS1-UP)

438D (S/N: BPE1-UP; BPN1-UP)

Introduction

This special instruction outlines the basic procedures in order to install a Hydraulic Hand Control. The 164-1450 Hydraulic Hand Control Group has a standard pattern and a cross pattern. The levers are a good indicator of the pattern. The 190-5131 film explains the difference between control patterns. Refer to Operation and Maintenance Manual, "Machine Controls".

Show/hide table

Make sure the control rods are adjusted properly before proceeding. Severe personal injury or death may result due to improperly adjusted controls. Unexpected boom motion may be caused if controls are not aligned properly and the controls stick.

The Hydraulic Hand Control Group is interchangeable with other kits. 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 164-1450 Hydraulic Hand Control Gp (Kit- Standard Two Lever) is composed of the 164-1440 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 Leicester, England.

Installation of the Standard Pattern

Show/hide table



Illustration 1	g00796865
(1) 8T-4773 Ball Joint (2) 8T-4815 Rod End (3) 9R-9901 Fastener (Clip) (4) 164-1361 Boot (5) 164-1371 Plate (6) 164-1399 Knob (7) 164-1406 Rod (8) 164-1441 Rod (9) 164-1447 Lever (10) 164-1451 Bracket (11) 164-1452 Bracket (12) 164-1455 Lever (13) 164-1565 Tower (14) 167-8248 Rear Console (15) 179-8235 Bearing Lockpin (16) 190-5131 Film (Controls) (17) 190-5134 Film (Pattern) (18) 6V-7744 Locknut (19) 8C-4987 Clevis Pin (20) 8T-4121 Washer (21) 8T-4133 Nut (22) 8T-4195 Bolt (23) 8T-4224 Washer (24) 8T-7547 Bolt (25) 9X-2038 Washer (26) 9X-2045 Screw

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

2. Remove all hydraulic pressure.

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

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

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

   Note: The following steps outline the procedures in order to assemble the right hand control lever assembly. These steps can also be used to assemble the left hand control lever.

6. Assemble the following parts in order to create the right hand control assembly: 164-1447 Lever (12), two 8T-4157 Bolts (24), two 8T-4224 Washers (23), and 164-1451 Bracket (10). See Illustration 1.

7. Secure the bracket (10) of the right hand control lever assembly to the 164-1565 Tower (13) with two 8T-7547 Bolts (24) and two 8T-4224 Hard Washers (23). See Illustration 1.

8. Repeat Steps 1 to 7 in order to install the left hand control assembly.

9. Use the following parts to assemble the four control rods: 8T-4773 Ball Joint (1), 8T-4133 Nut (21), 164-1441 Rod (8), 164-1406 Rod (7), 8T-4815 Rod End (2), 8C-4987 Clevis Pin (19), and 179-8235 Lock Pin (15). See Illustration 1.

   Note: Locate the 164-1441 Rods (8) on the outside. See Illustration 1.

Show/hide table



Illustration 2	g00797137

10. Adjust the control rod assemblies to a length of 370 mm (14.57 inch). See Illustration 2.

    Note: The 8T-4133 Nuts (21) must be tightened to a torque of 20 ± 5 N·m (14.75 ± 3.69 lb ft).

11. Attach the control rod assemblies to the control lever assemblies with locknuts (18) and hard washers (20). See Illustration 1.

    Note: The locknuts (18) must be tightened to a torque of 30 ± 7 N·m (22.13 ± 5.16 lb ft).

12. Use two washers (20) and two 8T-4195 Bolts (22) in order to attach the tower (13) to the machine. See Illustration 1.

13. Attach the control rods to the main hydraulic control valve with the clevis pins (19) and the lock pins (15). See Illustration 1 and Illustration 4.

Show/hide table



Illustration 3	g00797069

14. Adjust the control lever assemblies so a space of 327 ± 2 mm (12.87 ± 0.08 inch) separates the two levers (9) and (12). See Illustration 3.

Show/hide table



Illustration 4	g00797150
(3) 9R-9901 Fastener (Clip) (4) 164-1361 Boot (5) 164-1371 Plate (6) 164-1399 Knob (9) 164-1447 Lever (12) 164-1455 Lever (14) 164-8248 Rear Console (16) 190-5131 Film (Controls) (25) 9X-2038 Washer (26) 9X-2045 Screw

Note: The lever (9) and the lever (12) should be perpendicular to the plane of the machine.

15. Put the 167-8248 Rear Console (14) over the levers (9) and (12) and the tower assembly (13). See Illustration 4.

    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.

Show/hide table

Make sure the control rods are adjusted properly before proceeding. Severe personal injury or death may result due to improperly adjusted controls. Unexpected boom motion may be caused if controls are not aligned properly and the controls stick.

16. Secure the rear console (14) to the machine with four 9X-2045 Screws (26) and four 9X-2038 Washers (25). See Illustration 4.

17. Install the 164-1371 Plate (5) over the boots (4). Secure the plate to the rear console with six 9R-9901 Fasteners (3). See Illustration 4.

18. Apply the 190-5131 Film (16) to the rear console (14). See Illustration 4.

19. Install the 164-1399 Knobs (6) to the levers (9) and (12) .

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

Installation of the Cross Pattern

Illustration 5	g00798869
(1) 8T-4773 Ball Joint (2) 8T-4815 Rod End (3) 9R-9901 Fastener (Clip) (4) 164-1361 Boot (5) 164-1371 Plate (6) 164-1399 Knob (7) 164-1406 Rod (8) 164-1441 Rod (9) 164-1447 Lever (10) 164-1451 Bracket (11) 164-1452 Bracket (12) 164-1455 Lever (13) 164-1565 Tower (14) 167-8248 Rear Console (15) 179-8235 Bearing Lockpin (16) 190-5131 Film (Controls) (17) 190-5134 Film (Pattern) (18) 6V-7744 Locknut (19) 8C-4987 Clevis Pin (20) 8T-4121 Washer (21) 8T-4133 Nut (22) 8T-4195 Bolt (23) 8T-4224 Washer (24) 8T-7547 Bolt (25) 9X-2038 Washer (26) 9X-2045 Screw

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

2. Remove all hydraulic pressure.

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

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

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

   Note: The following steps outline the procedures in order to assemble the right hand control lever assembly. These steps can also be used to assemble the left hand control lever.

6. Assemble the following parts in order to create the right hand control assembly: 164-1455 Lever (9), two 8T-4157 Bolts (24), two 8T-4224 Washers (23), and 164-1451 Bracket (10). See Illustration 5.

7. Secure the bracket (10) of the right hand control lever assembly to the 164-1565 Tower (13) with two 8T-7547 Bolts (24) and two 8T-4224 Hard Washers (23). See Illustration 5.

8. Repeat Steps 1 to 7 in order to install the left hand control assembly.

9. Use the following parts to assemble the four control rods: 8T-4773 Ball Joint (1), 8T-4133 Nut (21), 164-1441 Rod (8), 164-1406 Rod (7), 8T-4815 Rod End (2), 8C-4987 Clevis Pin (19), and 179-8235 Lock Pin (15). See Illustration 1.

   Note: Locate the 164-1441 Rods (8) on the outside. See Illustration 1.

10. Adjust the control rod assemblies to a length of 370 mm (14.57 inch). See Illustration 2.

    Note: The 8T-4133 Nuts (21) must be tightened to a torque of 20 ± 5 N·m (14.75 ± 3.69 lb ft).

11. Attach the control rod assemblies to the control lever assemblies with locknuts (18) and hard washers (20). See Illustration 1.

    Note: The locknuts (18) must be tightened to a torque of 30 ± 7 N·m (22.13 ± 5.16 lb ft).

12. Use two washers (20) and two 8T-4195 Bolts (22) in order to attach the tower (13) to the machine. See Illustration 1.

Show/hide table



Illustration 6	g00798891
The rods (8) have the bend in a different position.

13. Attach the control rods to the main hydraulic control valve with the clevis pins (19) and the lock pins (15). See Illustration 5 and 6.

    Note: The lever (9) and the lever (12) should be perpendicular to the plane of the machine.

14. Adjust the control lever assemblies so a space of 327 ± 2 mm (12.87 ± 0.08 inch) separates the two levers (6) and (12). See Illustration 3.

15. Put the 167-8248 Rear Console (14) over the levers (9) and (12) and the tower assembly (13). See Illustration 4.

    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.

Show/hide table

Make sure the control rods are adjusted properly before proceeding. Severe personal injury or death may result due to improperly adjusted controls. Unexpected boom motion may be caused if controls are not aligned properly and the controls stick.

16. Secure the rear console (14) to the machine with four 9X-2045 Screws (26) and four 9X-2038 Washers (25). See Illustration 4.

17. Install the 164-1371 Plate (5) over the boots (4). Secure the plate to the rear console with six 9R-9901 Fasteners (3). See Illustration 4.

18. Apply the 190-5131 Film (16) to the rear console (14). See Illustration 4.

19. Install the 164-1399 Knobs (6) to the levers (9) and (12) .

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

Procedures to Modify the Controls from the Standard Pattern to the Cross Pattern

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

2. Remove all hydraulic pressure.

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

4. Rotate the 164-1452 Left Bracket (11) universal joint. Loosen the bolt under the universal joint. Remove the second bolt. Rotate the bracket clockwise. Line up the next hole. Install the second bolt. Tighten both bolts.

5. Rotate the 164-1451 Right Bracket (10) universal joint. Loosen the bolt under the universal joint. Remove the second bolt. Rotate the bracket counterclockwise. Line up the next hole. Install the second bolt. Tighten both bolts.

6. Switch the right lever and the left lever. Remove the right 164-1455 Lever (12). Attach the lever to the left 164-1452 Bracket (11). Remove the left 164-1447 Lever (9). Attach the lever to the right 164-1451 Bracket (10). Tighten all bolts.

7. Rotate the control rods and check the adjustment of the rods. Adjust the rods so the levers are perpendicular to the plane of the machine. Rotate the 8T-4815 Rod Ends (4) so levers have a full range of movement.

Procedure to Modify the Controls from the Cross Pattern to the Standard Pattern

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

2. Remove all hydraulic pressure.

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

4. Rotate the 164-1451 Right Bracket (10) universal joint. Loosen the bolt under the universal joint. Remove the second bolt. Rotate the bracket clockwise. Line up the next hole. Install the second bolt. Tighten both bolts.

5. Rotate the 164-1452 Left Bracket (11) universal joint. Loosen the bolt under the universal joint. Remove the second bolt. Rotate the bracket counterclockwise. Line up the next hole. Install the second bolt. Tighten both bolts.

6. Switch the right lever and the left lever. Remove the left 164-1455 Lever (12). Attach the lever to the right 164-1451 Bracket (11). Remove the right 164-1447 Lever (9). Attach the lever to the left 164-1452 Bracket (10). Tighten all bolts.

7. Rotate the control rods and check the adjustment of the rods. Adjust the rods so the levers are perpendicular to the plane of the machine. Rotate the 8T-4815 Rod Ends (4) so levers have a full range of movement.

Key Points

• The knobs are located in the same position in both patterns.

• If a X is facing forward on the 190-5134 film (17), the machine has the cross pattern. See Illustration 5.

• If a X is not facing forward on the 190-5134 film (17), the machine has the Standard pattern. See Illustration 1.

• In each pattern, the right lever and the left lever change sides.

• The position of the 164-1451 Bracket (10) and the 164-1452 Bracket (11) is limited to the two patterns. Changing of the pattern is allowed by the two bolt pattern on the bracket and the three bolt pattern on the tower. 164-1565 (13). See Illustration 1 and Illustration 5.

• The 190-5131 film (16) shows the difference between control patterns. See Illustration 4.

• No extra parts are needed for either pattern.