Procedure to Install the Implement Control Levers on Certain Motor Graders {5051, 5063, 726A, 795C} Caterpillar

Introduction

This Special Instruction provides the necessary information to install the implement control levers on the machines listed above.

The steering wheel-controlled Motor Graders listed above have certain implement control levers disconnected for shipment from factory to dealer to meet the regulatory safety requirements.

The disconnected implement control levers arrive partially installed on the machines to the dealers and must be installed properly before the Motor Graders are fully functional.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference Section

Reference: Specifications, SENR3130, "Torque Specifications"

Reference: Operation and Maintenance Manual, M0082745, "120 and 120 AWD Motor Grader", "Prepare the Machine for Maintenance"

Reference: Operation and Maintenance Manual, SEBU8250, "120K Motor Grader", "Prepare the Machine for Maintenance"

Reference: Operation and Maintenance Manual, SEBU8724, "120K Series 2 Motor Grader", "Prepare the Machine for Maintenance"

Reference: Operation and Maintenance Manual, SEBU8249, "12K140K160K Motor Graders", "Prepare the Machine for Maintenance"

Reference: Operation and Maintenance Manual, M0083397, "140 Motor Grader", "Prepare the Machine for Maintenance"

Reference: Operation and Maintenance Manual, SEBU8725, "140K Series 2 Motor Grader", "Prepare the Machine for Maintenance"

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury or death can result from sudden movement. Prevent possible injury by performing the following procedures before work begins: Move the product or equipment to a smooth, level surface. When applicable, lower equipment/work tools to the ground. Engage the parking brake, system brakes and/or hydraulic lockout control. When applicable, stop the engine and remove the ignition key. Release system pressure from pressurized systems. If applicable, block the wheels/tracks. Turn the battery disconnect switch to the OFF position and if applicable, remove the battery disconnect key. If not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps.  Attach a “Do Not Operate” or similar warning tag at the battery disconnect switch location and as defined by site rules and/or local regulations.

Illustration 1	g06276183

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Access to this service point may require climbing on the equipment. Slipping or falling while climbing on the equipment could result in personal injury or death. Refer to the Operation and Maintenance Manual, Mounting and Dismounting topic for safety information.

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Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Machine Preparation

Refer to Operation and Maintenance Manual, "Prepare the Machine for Maintenance" for your machine.

Location of the Tool Box

Illustration 2	g06614528
(A) Tool box

Note: Tool box (A) contains the access cover group, screws, seals, boots, and plugs that are required for the installation of implement control levers.

To install the implement control levers on the machine, follow the installation procedure given below:

Installation Procedure

For 120K, 120K Series 2, 12K, 140K, 140K Series 2, and 160K Motor Graders

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Illustration 3	g06617114
Some parts are removed for clarity (A) Implement control lever (B) 8T-9043 Bolt (C) 3F-9556 Lockwasher

Note: During shipment, implement control levers (A) are partially installed on the machine.

1. Remove and retain six implement control levers (A), six bolts (B), and six lockwashers (C). Refer to Illustration 3.
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   Illustration 4	g06617159
   Some parts are removed for clarity (A) Implement control lever (D) 112-9164 Boot (E) 437-0690 Access Cover Gp

   Note: Boot (D) and access cover group (E) are stored inside the tool box.

2. Slide six boots (D) and access cover group (E) through six implement control levers (A). Refer to Illustration 4.
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   Illustration 5	g06617140
   Some parts are removed for clarity (A) Implement control lever (B) 8T-9043 Bolt (C) 3F-9556 Lockwasher (D) 112-9164 Boot (E) 437-0690 Access Cover Gp

3. Install six implement control levers (A) to the control valve group using six bolts (B) and six lockwashers (C) that were retained in Step 1. Refer to Illustration 5.

   Note: Tighten six bolts (B) to a torque of 13 ± 3 N·m (115 ± 26 lb in).

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   Illustration 6	g06617155
   Some parts are removed for clarity (D) 112-9164 Boot (E) 437-0690 Access Cover Gp (F) 8X-8055 Plug (G) 9X-2045 Screw

   Note: Plug (F) and screw (G) are stored inside the tool box.

4. Install access cover group (E) to the cab using two screws (G). Refer to Illustration 5 and Illustration 6.

   Note: Tighten two screws (G) to a torque of 12 ± 3 N·m (106 ± 26 lb in).

5. Install six boots (D) and plug (F) as per Illustration 6.

6. Repeat Step 1 through Step 6 on the other side of the cab.

For 120 and 140 Motor Graders

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Illustration 7	g06616674
Some parts are removed for clarity (A) 492-5291 Floor Mat Assembly

1. Remove and retain floor mat assembly (A) from the cab. Refer to Illustration 7.
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   Illustration 8	g06616679
   Some parts are removed for clarity (B) 492-5319 Insulation (C) 6E-3031 Control Valve Gp

2. Pull insulation (B) backward to access control valve group (C). Refer to Illustration 8.
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   Illustration 9	g06616513
   Some parts are removed for clarity (C) 6E-3031 Control Valve Gp (D) Implement control lever (E) 8T-9043 Bolt (F) 3F-9556 Lockwasher

   Note: During shipment, implement control levers (D) are partially installed on the machine.

3. Remove and retain four implement control levers (D), four bolts (E), and four lockwashers (F) from control valve group (C). Refer to Illustration 9.
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   Illustration 10	g06617161
   (G) 461-3545 Access Cover Gp

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   Illustration 11	g06617164
   (G) 461-3545 Access Cover Gp (H) 5P-3602 Seal

   Note: Access cover group (G) and seal (H) are stored inside the tool box.

4. Install seal (H) to access cover group (G) as per Illustration 11.
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   Illustration 12	g06616560
   Some parts are removed for clarity (D) Implement control lever (G) 461-3545 Access Cover Gp (J) 112-9164 Boot

   Note: Boot (J) is stored inside the tool box.

5. Slide access cover group (G) and four boots (J) though four implement control levers (D). Refer to Illustration 12.
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   Illustration 13	g06616573
   Some parts are removed for clarity (C) 6E-3031 Control Valve Gp (D) Implement control lever (E) 8T-9043 Bolt (F) 3F-9556 Lockwasher (G) 461-3545 Access Cover Gp (J) 112-9164 Boot

6. Install four implement control levers (D) to control valve group (C) using four bolts (E) and four lockwashers (F) that were retained in Step 3. Refer to Illustration 13.

   Note: Tighten four bolts (E) to a torque of 13 ± 3 N·m (115 ± 26 lb in).

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   Illustration 14	g06616617
   Some parts are removed for clarity (G) 461-3545 Access Cover Gp (K) 9X-2045 Screw

   Note: Screw (K) is stored inside the tool box.

7. Install access cover group (G) to the cab using four screws (K). Refer to Illustration 13 and Illustration 14.

   Note: Tighten four screws (K) to a torque of 12 ± 3 N·m (106 ± 26 lb in).

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   Illustration 15	g06616624
   Some parts are removed for clarity (G) 461-3545 Access Cover Gp (J) 112-9164 Boot (L) 8X-8055 Plug

   Note: Plug (L) is stored inside the tool box.

8. Install four boots (J) and three plugs (L) to access cover group (G) as per Illustration 15.
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   Illustration 16	g06617483
   Some parts are removed for clarity (B) 492-5319 Insulation

9. Push insulation (B) back to the original position. Refer to Illustration 16.

10. Repeat Step 1 through Step 9 on the other side of the cab.
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    Illustration 17	g06616674
    Some parts are removed for clarity (A) 492-5291 Floor Mat Assembly

11. Install floor mat assembly (A) that was retained in Step 1 to the cab. Refer to Illustration 17.

Once the levers are properly installed, turn battery disconnect switch to ON position.

Start the machine and work all implements to ensure proper function. Upon confirming proper implement function, Motor Grader is ready to be placed in service.