Installing the <NOBR>387-6450</NOBR> Ride Control Kit to a Machine That Does Not Have an ECM {5004} Caterpillar


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Installing the <NOBR>387-6450</NOBR> Ride Control Kit to a Machine That Does Not Have an ECM {5004} [REHS6633]
HYDRAULIC SYSTEM
CONTROL GP-RIDE
Installing the <NOBR>387-6450</NOBR> Ride Control Kit to a Machine That Does Not Have an ECM {5004}
1.1. Introduction
2.1. Reference
3.1. Required Parts
4.1. Preparing the Machine for Servicing
5.1. Installing the Hydraulic Lines and Hardware
6.2. Preassembling the Ride Control Kit
7.2. Installing the Ride Control Kit onto the Machine
8.1. Installing the Electronic Controls and Wiring
9.2. Installing the Console Components
10.2. Installing the Ride Control Harness As
11.1. Testing and Troubleshooting the Ride Control System
Backhoe Loader
415F2 (S/N: HWA1-UP)
415F2 IL (S/N: PF41-UP)
416F2 (S/N: LYA1-UP; HWB1-UP)
422F2 (S/N: LYF1-UP)
427F2 (S/N: HWK1-UP)
428F2 (S/N: LYG1-UP; HWN1-UP)
434F2 (S/N: LYK1-UP; HWR1-UP)

Introduction

This special instruction outlines the basic procedures to install a 387-6450 Ride Control Kit on all Series F2 Backhoe Loaders that do not 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.

Reference

Reference: Testing and Adjusting, UENR5025, "Ride Control Accumulator - Test and Charge"

Reference: For the 415F2 Industrial Loader, refer to Testing and Adjusting, UENR6827, "Ride Control Accumulator - Test and Charge"

Required Parts



Illustration 1g06022786
(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
(19) 382-8033 Ride Control Accumulator Gp
(20) 140-9378 Relay As
(22) 387-6617 Rocker Switch


Illustration 2g06022801
Right side view of the 387-6450 Ride Control Kit for F2 series machines
(16) 8T-4177 Bolt
(18) 8T-4224 Hard Washer
(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 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  387-6617  Rocker Switch 
23  304-5696  Pressure Switch 
24  357-3217  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 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 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 3g03249458
    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. 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 to ensure that the O-ring seals have been installed. Refer to Table 1 for part numbers.



    Illustration 4g03166836
    (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) 304-5696 Pressure Switch
    (25) 3J-1907 O-Ring Seal

  1. Install elbow assembly (11) onto solenoid valve group (1) as shown in Illustration 4.

  2. Install elbow assembly (13) onto solenoid valve group (1) as shown in Illustration 4.

  3. Install connector assembly (9) onto solenoid valve group (1) as shown in Illustration 4.


    Illustration 5g03169717
    (1) 245-8780 Ride Control Manifold Gp
    (10) 148-8345 Connector As

  4. Install connector assembly (10) onto solenoid valve group (1) as shown in Illustration 4.


    Illustration 6g03169698
    (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, UENR5025, "Ride Control Accumulator - Test and Charge"

    For the 415F2 Industrial Loader, refer to Testing and Adjusting, UENR6827, "Ride Control Accumulator - Test and Charge"



    Illustration 7g03169736
    (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 387-6450 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 to ensure that the O-ring seals have been installed. Refer to Table 1 for part numbers.



    Illustration 8g03171316
    Underside view of tractor frame
    (6) 131-8201 Clip
    (7) 131-8202 Clip
    (8) 148-8336 Connector As
    (15) 8T-4121 Hard Washer
    (16) 8T-4177 Bolt
    (19) 382-8033 Ride Control Accumulator Gp

  1. Install ride control accumulator group (19) onto the underside of the tractor frame. Use two clips (6), two clips (7), bolts (16) and washers (15) to secure ride control accumulator group (19) onto underside of 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) as shown in Illustration 9. Torque the bolts to 25 ± 5 N·m (18.4 ± 3.7 lb ft).


    Illustration 10g03171599
    (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
    (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
    (B) Existing 260-9137 Cross Union As
    (C) Existing adapter
    (D) Existing 353-1441 Oil Filter 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 kit.

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) 214-4719 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) 214-4719 Rocker Switch(
    (J) Platform harness end connector

  5. Plug connector from existing platform harness (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 (J).

Installing the Ride Control Harness As



Illustration 21g06022994
(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.


    Illustration 22g06023236

  3. Secure ride control harness assembly (24) using two cable straps (21) and two cable straps (26). Refer to Illustration 21 and Illustration 22.


    Illustration 23g03249458
    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.

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.


  1. Engage the parking brake.

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

    ------ 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. Raise the loader bucket off the ground.


    Illustration 24g06023253
    (22) 214-4719 Rocker Switch
    (22a) Indicator light on the ride control switch

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

  6. Lower the bucket to the ground. Try to lift the wheels off the ground. If ride control is working properly, the machine will not easily lift the front wheels off the ground.

    If ride control is not properly working, Check the following items:

    • the relay for ride control

    • the fuses

    • the arc suppressor

    • the connections at the switch and at each harness

    • the pressure switch

  7. Lower the stabilizers to raise the rear of the machine to 305 mm to 455 mm (12 inch to 18 inch) off the ground.

  8. Lower the bucket to raise the front of the machine to 305 mm to 455 mm (12 inch to 18 inch).

    Note: Ride control must be turned off to raise the front tires off the ground.

  9. Engage the ride control system.

    Note: For machines with standard transmissions, ride control is turned on by pushing the top of the switch (22). To turn off ride control, push the bottom of the switch (22).

  10. Check the machine for any noticeable drift toward the ground. If the machine rapidly drifts, the pressure switch (23) may not be functioning correctly.

  11. Park the machine according to the Operation and Maintenance Manual for your machine.

  12. 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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