Installing the <NOBR>387-6451</NOBR> Ride Control Kit to a Machine That Has an ECM {5004} Caterpillar


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Installing the <NOBR>387-6451</NOBR> Ride Control Kit to a Machine That Has an ECM {5004} [REHS6632]
HYDRAULIC SYSTEM
CONTROL GP-RIDE
Installing the <NOBR>387-6451</NOBR> Ride Control Kit to a Machine That Has an ECM {5004}
1.1. Introduction
2.1. Required Parts
3.1. Preparing the Machine for Servicing
4.1. Installing the Hydraulic Lines and Hardware
5.2. Preassembling the Ride Control Kit
6.2. Installing the Ride Control Kit onto the Machine
7.1. Installing the Electronic Controls and Wiring
8.2. Installing the Console Components
9.2. Installing the Ride Control Harness As
10.1. Installing the Configuration for the Ride Control
11.1. Ride Control Use
12.2. Ride Control Activation
13.2. Ride Control Cancelation
14.1. Testing and Troubleshooting the Ride Control System
Backhoe Loader
420F2 IT (S/N: LYC1-UP; HWD1-UP)
420F2 ST (S/N: LYB1-UP; HWC1-UP)
427F2 (S/N: HWK1-UP)
428F2 (S/N: LYG1-UP; HWN1-UP)
430F2 IT (S/N: LYE1-UP; HWG1-UP)
430F2 ST (S/N: LYD1-UP; HWE1-UP)
432F2 (S/N: LYJ1-UP; HWP1-UP)
434F2 (S/N: LYK1-UP; HWR1-UP)
444F2 (S/N: LYL1-UP; HWS1-UP)

Introduction

This special instruction outlines the basic procedures in order to install a 387-6451 Ride Control Kit on all Series F2 Backhoe Loaders that have an ECM.

Ride control is an option on all Backhoe Loaders in Series F2.

Ride control acts as a shock absorber to stabilize bucket movement as the backhoe loader is maneuvering. By dampening bucket movement, the machine is more stable especially when the bucket is carrying a load. More stability over rough terrain results in faster times. More stability also increases productivity.

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

Also refer to the appropriate Parts Manual, Operation and Maintenance Manual, and Service Manual for your machine.

Required Parts

A machine with pilot operated controls for the backhoe must use the 387-6451 Ride Control Kit.



Illustration 1g06023917
(1) 245-8780 Ride Control Manifold Gp
(2) 361-9950 Hose As
(3) 361-9951 Hose As
(4) 361-9952 Hose As
(5) 363-5880 Hose As
(6) 131-8201 Clip
(7) 131-8202 Clip
(8) 148-8336 Connector As
(9) 148-8340 Connector As
(10) 148-8345 Connector As
(11) 148-8363 Elbow As
(12) 148-8370 Elbow As
(13) 148-8372 Elbow As
(14) 5C-7261 Nut
(15) 8T-4121 Hard Washer
(17) 8T-4182 Bolt
(18) 8T-4224 Hard Washer
(19) 382-8033 Ride Control Accumulator Gp
(20) 140-9378 Relay As
(22) 387-6594 Rocker Switch


Illustration 2g06023934
(16) 8T-4177 Bolt
(18) 8T-4224 Hard Washer
(21) 205-9920 Cable Strap
(23) 344-7391 Pressure Sensor Gp
(24) 357-3216 Ride Control Wiring Gp
(25) 3J-1907 O-Ring Seal
(26) 3S-2093 Cable Strap

Table 1
Required Parts 
Item  Qty  Part Number  Description 
245-8780  Ride Control Manifold Gp 
361-9950  Hose As 
361-9951  Hose As 
361-9952  Hose As 
363-5880  Hose As 
131-8201  Clip 
131-8202  Clip 
148-8336  Connector As 
148-8340  Connector As 
10  148-8345  Connector As 
11  148-8363  Elbow As 
12  148-8370  Elbow As 
13  148-8372  Elbow As 
14  5C-7261  Nut 
15  8T-4121  Hard Washer 
16  8T-4177  Bolt 
17  8T-4182  Bolt 
18  8T-4224  Hard Washer 
19  382-8033  Ride Control Accumulator Gp 
20  140-9378  Relay As 
21  205-9920  Cable Strap 
22  387-6594  Rocker Switch 
23  344-7391  Pressure Sensor Gp 
24  331-5471  Ride Control Harness As 
25  3J-1907  O-Ring Seal 
26  3S-2093  Cable Strap 

Preparing the Machine for Servicing

  1. Park the machine on a level surface.

  2. Apply the service brake in order to stop the machine. Move the transmission control lever to the NEUTRAL position.

  3. Move the speed control lever to the LOW IDLE position.

  4. Engage the parking brake.

  5. Engage the transmission neutral lock.

  6. Lower all the work tools to the ground.

  7. Stop the engine.

  8. Turn the engine start switch key to the ON position but do not start the engine.

  9. Move the hydraulic control levers back and forth in order to relieve hydraulic pressure.

  10. Move the hydraulic control levers to the HOLD position.

  11. Turn the engine start switch key to the OFF position and remove the key.

  12. Disconnect the battery.

  13. Remove the floor mat from the cab.

  14. Remove the floorplate of the machine.


    Illustration 3g03322528
    Remove the right side rear tire.

  15. Remove the right side rear tire and rim assembly from the machine. Refer to the Disassembly and Assembly manual for correct removal procedures and tools.

    ------ WARNING! ------

    Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component.

    Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly.

    Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.


    ------ WARNING! ------

    Personal injury can result from hydraulic oil pressure and hot oil.

    Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

    Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.



    NOTICE

    Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

    Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

    Dispose of all fluids according to local regulations and mandates.


  16. Drain the hydraulic fluid from the system according to the service manual for your machine. Also prepare to contain hydraulic fluid before any hydraulic connections or components are loosened or removed.

Installing the Hydraulic Lines and Hardware

Preassembling the Ride Control Kit

Note: Check all fittings prior to installation in order to ensure that the O-ring seals have been installed. Refer to Table 1 for part numbers.



    Illustration 4g03323095
    (1) 245-8780 Ride Control Manifold Gp
    (9) 148-8340 Connector As
    (10) 148-8345 Connector As
    (11) 148-8363 Elbow As
    (12) 148-8370 Elbow As
    (13) 148-8372 Elbow As
    (23) 344-7391 Pressure Sensor Gp
    (25) 3J-1907 O-Ring Seal

  1. Install elbow assembly (11) onto solenoid valve group (1).

  2. Install elbow assembly (13) onto solenoid valve group (1).

  3. Install connector assembly (9) onto solenoid valve group (1).


    Illustration 5g03323119
    (1) 245-8780 Ride Control Manifold Gp
    (10) 148-8345 Connector As

  4. Install connector assembly (10) onto solenoid valve group (1).


    Illustration 6g03322567
    (A) 20 degrees

  5. Install elbow assembly (12) onto connector assembly (10) at the angle shown in Illustration 6.

  6. Charge accumulator (19). Refer to Testing and Adjusting, "Ride Control Accumulator - Test and Charge" that is applicable to the machine.


    Illustration 7g03322570
    (8) 148-8336 Connector As
    (19) 382-8033 Ride Control Accumulator Gp

  7. Install connector assembly (8) onto ride control accumulator group (19) as shown in Illustration 7.

Installing the Ride Control Kit onto the Machine

The 387-6451 Ride Control Kit will be mounted onto the right-hand side baseframe rail under the cab. Hydraulic lines connect the accumulator to the included solenoid valve group.

Note: Check all fittings prior to hose installation in order to ensure that the O-ring seals have been installed. Refer to Table 1 for part numbers.



    Illustration 8g03322572
    (6) 131-8201 Clip
    (7) 131-8202 Clip
    (8) 148-8336 Connector As
    (15) 8T-4121 Hard Washer
    (17) 8T-4182 Bolt
    (19) 382-8033 Ride Control Accumulator Gp

  1. Install ride control accumulator group (19) onto the underside of tractor frame. Using two clips (6), two clips (7), bolts (16) and washers (15), secure ride control accumulator group (19) onto the underside of the tractor frame. Torque the bolts to 35 ± 5 N·m (25.8 ± 3.7 lb ft). Refer to Illustration 8.


    Illustration 9g06023606
    View of the inside of the frame rail with the accumulator in place
    (1) 245-8780 Ride Control Manifold Gp
    (14) 5C-7261 Nut
    (16) 8T-4177 Bolt
    (18) 8T-4224 Hard Washer

  2. Mount ride control manifold group (1) to the inside of the frame rail. Use four hard washers (18), two bolts (16), and one nut (14). Torque the bolts to 25 ± 5 N·m (18.4 ± 3.7 lb ft). Refer to Illustration 9.


    Illustration 10g03322579
    (1) 245-8780 Ride Control Manifold Gp
    (2) 361-9950 Hose As
    (3) 361-9951 Hose As
    (4) 361-9952 Hose As
    (5) 363-5880 Hose As
    (9) 148-8340 Connector As
    (10) 148-8345 Connector As
    (11) 148-8363 Elbow As
    (13) 148-8372 Elbow As
    (19) 382-8033 Ride Control Accumulator Gp


    Illustration 11g06022808
    (B) Existing 260-9137 Cross Union As
    (C) Existing adapter
    (D) Existing 353-1441 Oil Filter Gp
    (1) 245-8780 Ride Control Manifold Gp
    (2) 361-9950 Hose As
    (3) 361-9951 Hose As
    (4) 361-9952 Hose As
    (5) 363-5880 Hose As
    (8) 148-8336 Connector As
    (10) 148-8345 Connector As
    (11) 148-8363 Elbow As
    (13) 148-8372 Elbow As
    (19) 382-8033 Ride Control Accumulator Gp

  3. Connect the straight end of hose assembly (2) to elbow assembly (11). Connect the angled end of hose assembly (2) to connector assembly (8). Refer to Illustrations 10 and 11.

  4. Connect the straight end of hose assembly (4) to elbow assembly (13). Connect the angled end of hose assembly (4) to the top of existing cross union assembly (B). Refer to Illustrations 10 and 11.

  5. Connect the straight end of hose assembly (5) to connector assembly (10). Connect the angled end of hose assembly (5) to existing adapter (C). Refer to Illustrations 10 and 11.

  6. Connect the straight end of hose assembly (3) to connector assembly (9). Connect the angled end of hose assembly (3) to the top of existing oil filter group (D). Refer to Illustrations 10 and 11.

Installing the Electronic Controls and Wiring

This section will outline the procedure to install the electrical components of the ride control.

Installing the Console Components

A rocker switch must be installed in the front console and a relay assembly must be installed in the fuse block on the side console.



    Illustration 12g06024711
    (E) Steering column covers

  1. Remove steering column covers (E).


    Illustration 13g06024638
    (F) Cover on the front console
    (G) Location G

  2. Remove cover (F) from the front console by prying back at locations (G) and lifting up and back on the cover.


    Illustration 14g06023642
    (H) Cover plate (location for the ride control switch)

  3. Remove cover plate (H) from the slot for the ride control switch.


    Illustration 15g06023638
    (22) 387-6594 Rocker Switch

  4. Install rocker switch (22) in the slot for the ride control switch. See Illustration 15.


    Illustration 16g06023043
    (J) Platform harness end connector


    Illustration 17g06023653
    Front view
    (22) 387-6594 Rocker Switch(
    (J) Platform harness end connector

  5. Plug connector from existing platform harness end connector (J) into rocker switch (22).

    Note: Platform harness connector (J) may be tied to the frame of the front console harness.

  6. Install front cover (F) and steering column cover (E).


    Illustration 18g06023061
    (K) Main fuse panel access cover

  7. Remove access cover (K) on the front of the right side console to access the main fuse panel.


    Illustration 19g06023065
    View of fuse panel with access cover (K) removed
    (L) Fuse panel


    Illustration 20g06023073
    (M) Location for ride control relay (K26 slot)

  8. Locate fuse panel (L) and install relay (20) into location (M).

  9. Replace access cover (K).

Installing the Ride Control Harness As



Illustration 21g06023985
(1) 245-8780 Ride Control Manifold Gp
(21) 205-9920 Cable Strap
(23) 304-5696 Pressure Switch
(24) 357-3217 Ride Control Harness As
(25) 3J-1907 O-Ring Seal
(26) 3S-2093 Cable Straps

One end of ride control harness assembly (24) connects to ride control manifold group (1). The other end of ride control harness assembly (24) connects to the existing platform harness assembly.

  1. Assemble pressure switch (23) with O-ring seal (25) to ride control manifold group (1). Torque the pressure switch to 25 ± 5 N·m (18.43 ± 3.7 lb ft).

  2. Connect ride control harness assembly (24) into ride control manifold group (1) and pressure switch (23). Refer to Illustration 21.

  3. Secure ride control harness assembly (24) using two cable straps (21) and one cable strap (26).


    Illustration 22g03249458
    Install the right side rear tire.

  4. Install the right side rear tire and rim assembly on the machine. Refer to the Disassembly and Assembly manual for the correct installation procedures and tools.

  5. Connect the battery.

Installing the Configuration for the Ride Control



    Illustration 23g01310510

  1. Click the icon that is shown in Illustration 23 to activate the configuration. The icon is located on the tool bar at the top of the Cat Electronic Technician ET screen.


    Illustration 24g01310530

  2. The screen will be split into two sides. Click "Hydraulic Configurations" on the left side of the screen.


    Illustration 25g01310553

  3. Click "Ride Control Configuration" on the right side.


    Illustration 26g01310570

  4. At the bottom of the Cat Electronic Technician ET screen, click "Change" button.


    Illustration 27g01310581

  5. Click the arrow button to reveal the parameter values. Click "Standard (1 valve)". Then click "OK".


    Illustration 28g01310596


    Illustration 29g01310605


    Illustration 30g01310614

  6. Click "Yes" in the window shown in Illustration 28.

    The value of the ride control should change. The ride control activation speed will automatically be set to 5.6 (mph). See Illustration 29.

    Ride control turned on in Cat Electronic Technician (ET). See Illustration 30.

Ride Control Use

Ride Control will energize the ride control relay based on the ride control mode, machine ground speed and lift cylinder rod end pressure. The ride control feature will either be in the OFF, AUTOMATIC, or ON modes and controlled through a three position switch connected to the Machine ECM. The switch provides two Switch-to-Ground (SWG) ECM inputs.

When ride control is in the OFF mode, the ride control enable relay will not be energized and the path from the accumulator to the head end of the lift cylinder will remain closed, except for a charging orifice to the accumulator head.

In both the ON and AUTOMATIC modes, ride control will only be on when the lift cylinder rod end pressure is less than 3137 kPa (455 psi). The Machine ECM will activate the ride control relay in response to these modes. Ride control will not be on when the lift cylinder rod end pressure is greater than 3500 kPa (508 psi). If load check is installed, the load check enable relay will be energized when the ride control relay is energized.

Ride Control Activation

Ride control will be active and the ride control relay energized if any of the following are true:

  • Ride control switch is in the ON position and the lift cylinder rod end pressure is less than 3137 kPa (455 psi).

  • Ride control switch is in the AUTOMATIC position, lift cylinder rod end pressure is less than 3137 kPa (455 psi) and ground speed is greater than 9 km/h (5.6 mph).

Ride Control Cancelation

Ride control will be inactive and the ride control relay de-energized if any of the following are true:

  • Ride control switch is in the OFF position.

  • Ride control switch is in the ON or AUTOMATIC position and the lift cylinder rod end pressure is greater than 3500 kPa (507.64 psi).

  • Ride control switch is in the AUTOMATIC position and the ground speed is more than 1 km/h less than 9 km/h (5.59 mph).

  • Quick coupler switch has been actuated to the engage or disengage position within a configurable Ride Control Activation Delay Time. This delay is to allow the accumulator pressure to adjust to changes in work tool mass.

  • There is an active fault on the ride control switch or the lift cylinder rod end pressure sensor.

Note: Ride Control Switch. The Ride Control Switch Input provides the operator with single switch input interface to set ride control to the ON, OFF, or AUTOMATIC mode. If there is an active diagnostic on the ride control switch, ride control will be disabled and the ride control relay de-energized. Ride control will not be enabled until the switch has been seen in a valid state.

Note: Lift Cylinder Rod End Pressure Sensor. If there is an active diagnostic on the lift cylinder rod end pressure sensor, ride control will be disabled and the ride control relay de-energized. Ride control will not be enabled until the lift cylinder pressure sensor has been seen in a valid state.

Testing and Troubleshooting the Ride Control System

------ WARNING! ------

To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area.


Note: Stay clear of the machine when you are performing this test.

  1. Engage the parking brake.

  2. Start the engine. Keep the direction control lever in the NEUTRAL position. Keep the parking brake engaged.

    ------ WARNING! ------

    Personal injury or death can result from escaping fluid under pressure.

    Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

    Always use a board or cardboard when checking for a leak.


  3. Check for hydraulic fluid leaks.

    If leaks are discovered, stop the engine. Release the pressure in the hydraulic system according to the Service Manual for your machine.

    Fix any leaks. Check for hydraulic fluid leaks.

  4. Lower the stabilizers in order to raise the machine to 305 mm to 455 mm (12 inch to 18 inch).

  5. Lower the bucket in order to raise the machine to 305 mm to 455 mm (12 inch to 18 inch).


    Illustration 31g06023253
    (22) 214-4719 Rocker Switch
    (22a) Indicator light on the ride control switch

  6. Turn the switch for the ride control system (22) to the ON position. Indicator (22a) will illuminate.

  7. For machines with the autoshift transmission, select the manual mode.

  8. The machine must not lower to the ground. If the machine lowers to the ground, then the following condition is a possible cause:

    • The pressure switch is faulty.

    • The ride control switch may be faulty.

    • The ride control relay may be faulty.

    • The solenoid valve spool may be stuck.

    • The plug for the solenoid valve may be broken.

    • The solenoid valve may need to be replaced.

  9. Stop the engine.

    Note: After checking the operation, check the hydraulic oil level. Use the procedure shown in the Operation and Maintenance Manual for the machine.

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