Conversion of the Joystick from Fork Control to Bucket Control{5063, 5705, 6107} Caterpillar

Telehandler:

TH62 (S/N: 3LN750-951; 4TM1235-4013)

TH63 (S/N: 3NN784-1067; 5WM1588-6020)

TH82 (S/N: 3JN579-1509; 3KN439-457)

TH83 (S/N: 3RN1072-4014)

Introduction

The following procedure will describe the steps that are required to convert the joystick from a fork control to a bucket control.

Reference: Parts Manual, SEBP2352, "TH62 Telehandler"

Reference: Parts Manual, SEBU3087, "TH63 Telehandler"

Reference: Parts Manual, SEBP3088, "TH82 Telehandler"

Reference: Parts Manual, SEBP3089, "TH83 Telehandler"

Reference: Operators and Maintenance Manual, SEBU7112, "TH62, TH63, TH82 and TH83 Telehandlers"

Parts that are required for the Conversion

Conversion Procedure

1. Park the machine on level ground. Fully retract and fully lower the boom. Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged. Shut off the engine.

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Illustration 1	g00808633

2. Loosen the four screws that secure cover (13). Remove the cover.

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Illustration 2	g00808651

3. Remove the screws that secure floormat (14) on the right side of the cab below cover (13). Pull the floormat away from the right side of the cab in order to gain access to relay box (15) .

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Illustration 3	g00808676

4. Remove the cover from the relay box. Hold the relay box in your right hand with the harness on the right side of the relay box. Install relay as (16) in the top socket on the left side of the relay box. Install the cover on the relay box. Return the relay box to the original position behind the floormat.

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Illustration 4	g00808844

5. Pull link harness (17) for the joystick through the hole in the side panel.

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Illustration 5	g00808824

6. Disconnect link harness (17) and discard the harness. Connect harness (18) and (19) together.

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Illustration 6	g00808846

7. Remove the existing film from the right side panel. Discard the film. Replace the existing film with film (7) .

8. Return the floormat to the original position. Secure the floormat with the existing clips. Install cover (13). Secure the cover with the original screws. Refer to illustration 1.

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Illustration 7	g00809227

9. Remove plate (20) and plate (21) from the underside of the subframe in order to gain access to the valves. Retain the attaching hardware.

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Illustration 8	g00810929
Location of the ports in the Control Valve

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Illustration 9	g00809229

10. Disconnect hose (22) from control valve (25). Plug the hose. Disconnect hoses (23) and (24) from ports "X1" and "X2" on control valve (25). Plug the hoses.

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Illustration 10	g00809369

11. Disconnect pilot line (28) from port "P1" on control valve (25). Loosen the cable ties that secure the pilot line. Disconnect pilot line (29) from port "P2" on control valve (25). Loosen the cable ties that secure the pilot line. Remove the couplings from ports "P1" and "P2" in the control valve. Discard the couplings.

12. Disconnect pilot line (27) from port "A2" on control valve (25). Disconnect pilot line (30) from port "A1" on control valve (25).

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Illustration 11	g00809232

13. Disconnect pilot line (27) with the brown sleeve from the top port on the implement section (coupler tilt forward) of bank valve (26). Discard pilot line (27). Disconnect pilot line (30) with the red sleeve from the bottom port on the implement section (coupler tilt backward) of bank valve (26). Discard pilot line (30). Pilot line (30) is not visible in illustration 11.

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Illustration 12	g00809571

14. Remove the couplings from ports "A1" and "A2" in control valve (25). Discard the couplings. Install hydraulic fittings (6) and O-Rings (1) in ports "A1" and "A2" in control valve (25). Disconnect pilot line (31) from the coupling in port "B2". Disconnect pilot line (32) from the coupling in port "B1". Remove the couplings from ports "B1" and "B2". Discard the couplings.

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Illustration 13	g00809572

15. Install a plug gp (12) in ports "B1" and "B2" in control valve (25). Install two connectors (9) into ports "P1" and "P2" in control valve (25). Connect pilot line (31) with the yellow sleeve onto the hydraulic fitting in port "A2" in control valve (25). Connect pilot line (32) with the blue sleeve onto the hydraulic fitting in port "A1" in control valve (25) .

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Illustration 14	g00810527

16. Disconnect pilot lines (28) and (29) from port "2" and port "4" on joystick control (33). Discard the pilot lines. Cut one length of nylon tubing 2500 mm (98.5 inch) long of nylon tubing (8). Install a ferrule (4) and compression nut (3) on one end of the nylon tubing. Install an additional ferrule (4) on the other end of the new pilot line (35). Install a green sleeve (2) on each end of the new pilot line.

    Note: If the sleeve will not pass over the coupling it may be necessary to install the sleeves onto the pilot lines before you install the coupling onto the pilot lines.

17. Cut one length of nylon tubing 2500 mm (98.5 inch) long of nylon tubing (8). Install a ferrule (4) and compression nut (3) on one end of the nylon tubing. Install an additional ferrule (4) and an additional compression nut on the other end of the new pilot line (34).

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Illustration 15	g00811411

18. Connect pilot line (34) onto the coupling in port "2" on the joystick control. Route the pilot line (34) to the bank valve (26). Connect pilot line (35) onto the coupling in port "4" on the joystick control. Route the pilot line (35) to the bank valve. Secure the pilot lines with suitable cable straps. Ensure that the pilot lines are not in contact with any moving parts.

19. Connect pilot line (35) to the port for the coupler tilt backward on the implement section of the bank valve (26). Connect pilot line (34) to the port for the coupler tilt forward on the implement section of the bank valve. Refer to illustrations 23 and 24.

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Illustration 16	g00809574

20. Install two tee's (11) in ports "X1" and "X2". Install connectors (10) into tee's (11). Install two hoses (5) between connector (10) and the couplings in ports "P1" and "P2". Connect one hose (5) between port "X1" and "P1". Connect one hose (5) between port "X2" and "P2".

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Illustration 17	g00809577

21. Remove the plugs from the ends of hoses (22), (23) and (24). Connect hose (22) to the bottom port on the end of control valve (25). Connect hose (23) to the tee in port "X2". Connect hose (24) to the tee in port "X1".

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Illustration 18	g00809624

22. Disconnect harness (36) from the second solenoid from left side of the control valve. The solenoid is adjacent to port "P1" on the control valve.

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Illustration 19	g00809911

23. Locate connector (37) with brown wire in the chassis harness. Remove blanking plug (38) from connector (37) .

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Illustration 20	g00809931

24. Connect harness (36) to connector (37). Install blanking plug (38) onto the connector on the white wire and the black wire. Secure the wires and the connectors to the chassis harness with suitable cable straps.

25. Secure the hoses and the pilot lines with suitable cable straps. Ensure that the hoses and the pilot lines are not in contact with any moving parts.

26. Install panel (20) and panel (21) on the underside of the subframe. Refer to Illustration 7. Secure the access panel with the existing hardware.

Validating

1. Ensure that the parking brake is engaged. Start the engine. Ensure that you are clear of the machine and look for oil leaks. If necessary, shut off the engine and tighten the hydraulic connections.

2. Check the operation of the following functions:
   • Boom raise

   • Boom lower

   • Boom extend

   • Boom retract

   • Fork up

   • Fork down

   • Quick Coupler

   Refer to the Operators and Maintenance Manual for further information.

3. Shut off the engine. Check the new hydraulic connections for oil leaks. If necessary, tighten the connection and repeat Steps 1 and 2.

Hydraulic Schematics

Illustration 21	g00824230
Schematic for Fork Controls on early machines (22) Hose Assembly (23) Hose Assembly (24) Hose Assembly (25) Control Valve (26) Bank Valve (27) Pilot Line (28) Pilot Line (29) Pilot Line (30) Pilot Line (31) Pilot Line (32) Pilot Line (33) Joystick Control

Illustration 22	g00836792
Schematic for Fork Controls on later machines (22) Hose Assembly (23) Hose Assembly (24) Hose Assembly (25) Control Valve (26) Bank Valve (27) Pilot Line (28) Pilot Line (29) Pilot Line (30) Pilot Line (31) Pilot Line (32) Pilot Line (33) Joystick Control

Illustration 23	g00824231
Schematic for Bucket Controls on early machines (5) Hose Assembly (11) Tee (12) Plug Gp (22) Hose Assembly (23) Hose Assembly (24) Hose Assembly (25) Control Valve (26) Bank Valve (31) Pilot Line (32) Pilot Line (33) Joystick Control (34) Pilot Line (35) Pilot Line

Illustration 24	g00836789
Schematic for Bucket Controls on later machines (5) Hose Assembly (11) Tee (12) Plug Gp (22) Hose Assembly (23) Hose Assembly (24) Hose Assembly (25) Control Valve (26) Bank Valve (31) Pilot Line (32) Pilot Line (33) Joystick Control (34) Pilot Line (35) Pilot Line