Field Installation of the 264-0187 Ride Control Installation Gp {1408, 5004, 5057, 5077} Caterpillar

Backhoe Loader:

420E (S/N: HLS210-UP; KMW150-UP)

430E (S/N: DDT220-UP; EAT230-UP)

Introduction

This special instruction outlines the basic procedures in order to install a ride control kit on a backhoe loader of the E series.

Ride control is an option on all backhoe loaders in the E series.

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 264-0187 Ride Control Installation Group .

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.

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Illustration 1	g01302286
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.

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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.

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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.

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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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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

Installing the Kit's Hydraulic Lines and Hardware

Illustration 2	g01284624
(1) 7K-1181 Cable Strap (2) 106-8704 Arc Suppressor As (3) 146-9439 Relay As (4) 162-3960 Ride Control Accumulator Gp (6) 214-4710 Rocker Switch (7) 224-7830 Film (Warning) (8) 245-8780 Solenoid Valve Gp (9) 246-8038 Ride Control Harness As (10) 247-0320 Bracket As (11) 252-1221 Hose As (12) 265-0868 Hose As (13) 096-5866 Bolt (14) 109-1633 Clip (15) 109-1634 Clip (17) 148-8318 Connector As (18) 148-8340 Connector As (19) 148-8358 Elbow As (20) 153-6241 Elbow As (23) 3S-2093 Cable Strap (24) 4P-7581 Clip (25) 8T-4121 Hard Washer (26) 8T-4137 Bolt (27) 8T-4139 Bolt (28) 8T-4223 Hard Washer (29) 8T-4224 Hard Washer

Illustration 3	g01277431
(4) 162-3960 Ride Control Accumulator Gp (8) 245-8780 Solenoid Valve Gp (11) 252-1221 Hose As (12) 265-0868 Hose As (16) 131-9203 Pressure Switch (21) 164-5549 Coupling As (22) 3J-1907 O-Ring Seal (25) 8T-4121 Hard Washer (26) 8T-4137 Bolt

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 2 for part numbers.

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Illustration 4	g01278888
(8) 245-8780 Solenoid Valve Gp (16) 131-9203 Pressure Switch (18) 148-8340 Connector As (19) 148-8358 Elbow As (20) 153-6241 Elbow As (22) 3J-1907 O-Ring Seal

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Illustration 5	g01278890
(8) 245-8780 Solenoid Valve Gp (16) 131-9203 Pressure Switch (17) 148-8318 Connector As (18) 148-8340 Connector As (19) 148-8358 Elbow As (20) 153-6241 Elbow As (22) 3J-1907 O-Ring Seal

1. Install the 148-8318 Connector As (17) onto the 245-8780 Solenoid Valve Gp (8). Refer to Illustration 5.

2. Install the two 148-8358 Elbow As (19) onto the 245-8780 Solenoid Valve Gp (8). Refer to Illustrations 4 and 5.

3. Install 148-8340 Connector As (18) and 153-6241 Elbow As (20) onto the 245-8780 Solenoid Valve Gp (8). Refer to Illustrations 4 and 5.

4. Install the 3J-1907 O-Ring Seal (22) onto the 131-9203 Pressure Switch (16). Install the 131-9203 Pressure Switch (16) onto the 245-8780 Solenoid Valve Gp (8). Refer to Illustrations 4 and 5.

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Illustration 6	g01278901
(4) 162-3960 Ride Control Accumulator Gp (21) 164-5549 Coupling As

5. Install the 164-5549 Coupling As (21) onto the 162-3960 Ride Control Accumulator Gp (4). Refer to Illustration 6.

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Illustration 7	g01278891
(7) 224-7830 Film (Warning) (10) 247-0320 Bracket As (30) Mounting holes for the accumulator (31) Bosses for mounting the valve manifold (32) Holes for mounting the ride control assembly to the battery box.

6. Install the 224-7830 Film (Warning) (7) onto the 247-0320 Bracket As (10). Refer to Illustration 7.

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Illustration 8	g01278893
(8) 245-8780 Solenoid Valve Gp (10) 247-0320 Bracket As (13) 096-5866 Bolt (29) 8T-4224 Hard Washer

7. Install the assembly (8) onto 247-0320 Bracket As (10). Tighten securely with bolts (13) and washers (29). Refer to Illustration 8.

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Illustration 9	g01278895
(4) 162-3960 Ride Control Accumulator Gp (10) 247-0320 Bracket As (14) 109-1633 Clip (15) 109-1634 Clip (17) 148-8318 Connector As (21) 164-5549 Coupling As (27) 8T-4139 Bolt (28) 8T-4223 Hard Washer

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Illustration 10	g01278898
Close up view of the coupling assembly (4) 162-3960 Ride Control Accumulator Gp (17) 148-8318 Connector As (21) 164-5549 Coupling As

8. Use clips (14) and clips (15) in order to install the 162-3960 Ride Control Accumulator Gp (4) onto 247-0320 Bracket As (10). Hand tighten bolts (27) with washers (28). Refer to Illustration 9.

9. Install coupling (21) onto connector (17). Tighten bolts (27). Refer to Illustrations 9 and 10.

Installing the Ride Control Kit onto the Machine

The 264-0187 Ride Control Installation Gp will be mounted onto the right hand side battery box assembly under the frame rail. Hydraulic lines connect the accumulator to the Tee fittings at the bank valve and to the hydraulic return filter.

Note: Check all fittings prior to hose installation in order to ensure that the O-ring seals have been installed. Refer to Table 2 for part numbers.

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Illustration 11	g01278947
Underside view of tractor frame (33) Right side battery box (34) Bosses for mounting the Ride Control Assembly.

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Illustration 12	g01278896
(33) Right side battery box (10) 247-0320 Bracket As (25) 8T-4121 Hard Washer (26) 8T-4137 Bolt

1. Install the ride control assembly (10) onto the three bosses (34) on the right hand side battery box assembly (33). Use bolts (26) and washers (25) to secure the assembly to the battery box. Refer to Illustrations 11 and 12.

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Illustration 13	g01279540
View of lift cylinder lines with the accumulator in place (4) Accumulator assembly (10) 247-0320 Bracket As (33) Battery Box assembly (35) Lines for extending the lift cylinders (36) Lines for retracting the lift cylinders (37) Tee fitting for line (35) (38) Tee fitting for line (36)

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Illustration 14	g01279541
Close up view of the lift cylinder lines Some lines have been removed for clarity. (35) Lines for extending the lift cylinders (36) Lines for retracting the lift cylinders (37) Tee fitting for lines (35) (38) Tee fitting for lines (36) (39) Cap for hose (11) (40) Cap for hose (12) (19A) Fitting (19) that will connect to Tee fitting (37) (19B) Fitting (19) that will connect to Tee fitting (38)

2. Remove cap (39) and cap (40). Refer to Illustrations 13 and 14.

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Illustration 15	g01278899
(11) 252-1221 Hose As (12) 265-0868 Hose As (35) Lines for extending the lift cylinders (37) Tee fitting for lines (35) (38) Tee fitting for lines (36) (19A) Fitting (19) that will connect to Tee fitting (37) (19B) Fitting (19) that will connect to Tee fitting (38)

3. Connect the 252-1221 Hose As (11) to fitting (19A) and fitting (37). Connect the 265-0868 Hose As (12) to fitting (19B) and fitting (38). Refer to Illustrations 13, 14, and 15.

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Illustration 16	g01279584

4. The return oil filter (41) is located on the tractor frame directly across from the bank valve. Hydraulic hose (43) is already connected to oil filter (41). Remove the plug (42) from hydraulic hose (43). Refer to Illustration 16.

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Illustration 17	g01279585

5. Connect the hydraulic hose (43) to fitting (20) on the ride control assembly.

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Illustration 18	g01279867

6. Use two 7K-1181 Cable Straps (1) to secure lines (43), (11), and (12) .

Installing the Kit's Electronic Controls and Wiring

Illustration 19	g01284617
(2) 106-8704 Arc Suppressor As (3) 146-9439 Relay As (6) 214-4710 Rocker Switch (9) 246-8038 Ride Control Harness As (23) 3S-2093 Cable Strap (24) 4P-7581 Clip

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.

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Illustration 20	g01282158
The position of the ride control switch (6) on the front console. (44) The top cover on the front console (45) dummy switch in the position for the ride control switch

1. Remove the cover (44) on the top of the front console. See Illustration 20 and Illustration 22.

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Illustration 21	g01282671
(44) Top cover on the front console (45) dummy switch in the position for the ride control switch (46) The end connector on the console harness

2. Unplug the connector (46) from the dummy switch (45). Connector (46) is part of the console harness. See Illustration 21.

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Illustration 22	g01282664
(44) Top cover on the front console (45) Dummy switch in the position for the ride control switch

3. Remove the dummy switch (45) from the slot for the ride control switch. See Illustration 20 and Illustration 22.

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Illustration 23	g01282802
(6) 214-4710 Rocker Switch (44) Top cover on the front console

4. Install the 214-4710 Rocker Switch (6) in the slot for the ride control switch. See Illustration 23.

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Illustration 24	g01282824
(6) 214-4710 Rocker Switch (46) The end connector on the console harness

5. Plug connector (46) into the rocker switch (6) .

6. Install the cover (44) .

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Illustration 25	g01283141
(47) Access cover for the main fuse panel

7. Remove the cover (47) on the front of the right side console in order to access the main fuse panel.

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Illustration 26	g01283266

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Illustration 27	g01283186
(49) The location for the 146-9439 Relay As (3)

8. Locate the fuse panel (48) and install the 146-9439 Relay Assembly (3) into the K7 slot. Refer to Illustration 26 and Illustration 27.

9. Replace the access cover (47).

Installing the Ride Control Harness As

Illustration 28	g01283341
(2) 106-8704 Arc Suppressor As (8) 245-8780 Solenoid Valve Gp (9) 246-8038 Ride Control Harness As (16) 131-9203 Pressure Switch (22) 3J-1907 O-Ring Seal (23) 3S-2093 Cable Strap (24) 4P-7581 Clip (50) Platform Harness Assembly

The 246-8038 Ride Control Harness As (9) connects the ride control valve group to the platform harness. It is necessary to remove the floorplate in the operator station in order to access the connections. Refer to Illustration 28 through Illustration 32.

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Illustration 29	g01283423
(2) 106-8704 Arc Suppressor As (8) 245-8780 Solenoid Valve Gp (9) 246-8038 Ride Control Harness As (16) 131-9203 Pressure Switch (22) 3J-1907 O-Ring Seal (23) 3S-2093 Cable Strap (24) 4P-7581 Clip (50) Platform Harness Assembly

1. Connect the ride control harness (9) into solenoid valve group (8) and the pressure switch (16). Refer to Illustration 28 and Illustration 29.

2. Connect the arc suppressor (2) onto the ride control harness (9). Refer to Illustration 28 and Illustration 29.

3. Fasten the clip (24) to the boss on the clip. Use cable strap (23) to secure the ride control harness to the frame rail. Refer to Illustration 29.

4. Use a cable tie (23) to secure the arc suppressor (2) to the ride control harness. Refer to Illustration 28 and Illustration 29.

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Illustration 30	g01311067
The arrow points to the connection for the ride control harness and the platform harness.

5. The connection is located under the floorplate directly under the foot pedal in the operator station. Remove the front floorplate in the operator station. Refer to the appropriate Parts Manual, Operation and Maintenance Manual, and Service Manual for your machine. Refer to Illustrations 30, 31, and 32.

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Illustration 31	g01282217
(9) 246-8038 Ride Control Harness As (50) The plug connector on the platform harness (51) The shielded cable that hides the plug connector (50) (52) The pedal for the throttle control

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Illustration 32	g01282219
(9) 246-8038 Ride Control Harness As (50) The plug connector on the platform harness (51) The shielded cable that hides the plug connector (50)

6. Locate the plug connector (50) on the platform harness. Connect plug (50) into receptacle (51). Refer to Illustration 31 and Illustration 32.

   Note: The connector (50) on the platform harness is secured behind the wire harness (51) below the foot pedal (52). Refer to Illustration 31 and Illustration 32.

7. Use a cable tie (23) to secure the connection to the platform harness. Refer to Illustration 28 and Illustration 29.

8. Replace the floorplate that was removed in Step 5.

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Illustration 33	g01302286
Install the right side rear tire.

9. 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.

10. Connect the battery.

Installing the Configuration for the Ride Control

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Illustration 34	g01310510

1. Click on the icon that is shown in illustration 34 in order to activate the configuration. The icon is located on the tool bar at the top of the Caterpillar Electronic Technician ET screen.

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Illustration 35	g01310530

2. The screen will be split into two sides. Click on hydraulic configurations on the left side of the screen.

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Illustration 36	g01310553

3. Click on ride control on the right side.

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Illustration 37	g01310570

4. At the bottom of the Caterpillar Electronic Technician ET screen, click on the "change" button.

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Illustration 38	g01310581

5. Click on the arrow button in order to reveal the parameter values. Click on standard 1 valve. Then click OK.

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Illustration 39	g01310596

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Illustration 40	g01310605

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Illustration 41	g01310614

6. Click on Yes in the window. See Illustration 39.

   The value of the ride control should change. The ride control activation speed will automatically be set to 5.6 (mph). See Illustration 40.

   Ride control turned on in Caterpillar Electronic Technician (ET). See Illustration 41.

Testing and Troubleshooting the Ride Control System

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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.

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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 machine's engine. Release the pressure in the hydraulic system according to the machine's Service Manual.

   Fix any leaks. Check for hydraulic fluid leaks.

4. Raise the loader bucket off the ground.

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Illustration 42	g01284760
The ride control switch on a machine with a standard transmission (6) 214-4710 Rocker Switch (44) Top cover on the front console (53) Indicator light on the ride control switch

5. Turn the switch for the ride control system (6) to the ON position. The indicator (53) should appear. See Illustration 42.

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 suppressors

   • the connections at the switch and at each harness

   • the pressure switch

7. Lower the stabilizers in order 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 in order 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 in order to raise the front tires off the ground.

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Illustration 43	g01284762
The ride control switch on a machine with a standard transmission (6) 214-4710 Rocker Switch (44) Top cover on the front console (53) Indicator light on the ride control switch

9. Engage the ride control system.

10. Check the machine for any noticeable drift toward the ground. If the machine rapidly drifts, the pressure switch (30) may not be functioning correctly.

11. Park the machine according to the machine's Operation and Maintenance Manual.

12. Stop the engine.

Testing the Ride Control System on an Integrated Toolcarrier

1. Turn the key to the ON position.

2. The quick coupler switch should be OFF.

3. Turn the ride control to the ON position. The indicator for ride control should illuminate.

4. Turn the quick coupler switch to the ON position.

5. The circuits of quick coupler and ride control are properly connected, if the indicator for ride control turns OFF. The ride control switch is still in the ON position. If the indicator for ride control remains illuminated, then check the following conditions:
   • The circuit for the ride control and for the quick coupler may not be wired properly.

   • The ride control switch may not be operating properly.

Testing the Ride Control System on Machines With Autoshift Transmissions

1. Engage the parking brake.

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

3. Install the electronic technician to the machine.

4. Select the automatic mode (52) for ride control on the ride control switch.

5. Check the electronic technician. The display should indicate AUTOMATIC for the ride control. If the display does not indicate AUTOMATIC, then one of the following conditions is a possible cause:
   • The ride control switch may not be operating properly.

   • The transmission speed sensor may not be operating properly.

   • The pressure switch may not be operating properly.

6. Park the machine according to the machine's Operation and Maintenance Manual.

7. Stop the engine.

Serviced Parts

Table 2 lists the serviced parts for some of the components in Table 1.