Caterpillar Cat 428D BACKHOE LOADER (Prefix BNS) Service Repair Manual (BNS01118-01851).pdf

Service Repair Manual
Model
428D BACKHOE LOADER

Shutdown SIS
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Product: BACKHOE LOADER
Model: 428D BACKHOE LOADER BNS
Configuration: 428D Backhoe Loader BNS01118-01851 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Power
Train
Media Number -RENR3578-12 Publication Date -01/04/2010 Date Updated -13/04/2010
i01459029
Transmission (Direct Drive) - Install
SMCS - 3030-012-DD
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
8S-7640 Stand 2
8S-7611 Tube 2
8S-7615 Pin 2
B 1U-9760 Jack Stand 2
C 1U-7505 Transmisson Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar Assembly 1
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428D Backhoe Loader BNS01118-01851 (MACHINE) POWERED BY 3054 Engine(...
2019/10/4
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Illustration 1 g00762601
1. Attach tooling (D) to tooling (C) and transmission (10) in order to maintain a good balance.
2. Use tooling (C) in order to position transmission (10). The weight of transmission (10) is
185 kg (408 lb).
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3. Install fourteen bolts (11) .
4. Slide rod assembly (9) on the transmission lever and tighten bolt (8) .
5. Connect three electrical connectors (7) .
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6. Install four bolts (5) .
7. Repeat Step 6 for the opposite side.
8. Install two bolts (6) .
9. Install plug (4) .
10. Remove tooling (E). Install inspection plate (3) .
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11. Remove tooling (B) from front axle (2) .
12. Remove tooling (A) from rear frame (1) .
13. Fill the transmission with oil. Refer to Operation and Maintenance, SEBU7398,
"Capacities" for the proper type and capacity of oil.
,
End By:
a. Install the piston pump. Refer to Disassembly and AssemblyRENR3585, "Piston Pump
(Implement and Steering) - Install".
b. Install the rear drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Rear) -
Remove and Install".
c. Install the front drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Front) -
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Oct 4 13:16:53 UTC+0800 2019
5/5
2019/10/4

Shutdown SIS
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Train
i05395070
Transmission (Power Shift) - Remove
SMCS - 3030-011-PM
Removal Procedure
Table 1
Required Tools
A
8S-7640 Stand 2
8S-7611 Tube 2
8S-7615 Pin 2
B 1U-9760 Jack Stand 2
C 1U-7505 Transmisson Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar Assembly 1
Start By:
A. Remove the front drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Front) -
B. Remove the rear drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Rear) -
C. Remove the piston pump. Refer to Disassembly and Assembly, RENR3585, "Piston Pump
(Implement and Steering) - Remove".
1. Use a suitable lifting device in order to raise the machine to a height of 91.4 mm (36 inch)
between the ground and the side step.
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2. Place tooling (A) under rear frame (1) .
3. Place tooling (B) under front axle (2) .
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4. Remove the inspection cover. Install Tooling (E) in order to support the engine when the
transmission is removed.
5. Disconnect seven electrical connectors (3) . Cut three straps (4) .
6. Cut the strap and disconnect three electrical connectors (5) .
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7. Remove plug (6) and drain the transmission oil into a suitable container. The capacity of the
transmission is 18.5 L (4.9 US gal). Remove two bolts (7) .
8. Disconnect line (8) .
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9. Disconnect line (9) .
10. Disconnect wires (10) and (11) .
11. Remove 12 bolts (12) .
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12. Position tooling (C) under transmission (13) . Attach tooling (D) to each side of
transmission (13) .
13. Remove four bolts (14) . Carefully move transmission (13) away from the engine in order to
clear the torque converter. Lower transmission (13) to the ground. The weight of
transmission (13) is 227 kg (500 lb).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Oct 4 13:17:40 UTC+0800 2019
6/6
2019/10/4

Shutdown SIS
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Train
i02557470
Transmission (Power Shift) - Disassemble
SMCS - 3030-015-PM; 3066-015
Disassembly Procedure
Table 1
Required Tools
A 1U-7502 Repair Stand 1
B
152-7085 (1)
Transmission Shaft Handler 1
189-0409 Shackle As 1
C 1P-0074 Slide Hammer 1
D
8H-0063 Bearing Puller Assembly 1
6V-3010 Puller Group 1
126-7177 Leg 2
E 1U-6405 Puller 1
F 152-7055 Spring Compressor 1
G 1U-6400 Puller 1
H
128-5041 Bearing Puller 1
6V-3010 Puller Group 1
126-7177 Leg 2
I 6V-2157 Link Bracket 1
1/46
2019/10/4

( 1 )
CE Compliant
Start By:
A. Remove the transmission. Refer to Disassembly and Assembly, "Transmission (Powershift)
- Remove".
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 Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
Note: The transmission will be disassembled in major components. The major components will
then be disassembled.
1. Use a suitable lifting device in order to install transmission (1) on tooling (A) . The weight
of transmission (1) is 172 kg (379 lb).
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2. Remove two valve groups (2) .
3. Remove nut (3) , washer (4) , and coil assembly (5) . Remove seal kit (6) from cartridge
(7) .
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4. Remove magnetic sensor (8) .
5. Remove tube assembly (9) .
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6. Remove valve group (10) .
7. Remove O-ring (11) and O-ring (12) .
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9. Remove two O-rings (14) and O-ring (15) .
10. Remove two bolts (16) and plate (17) .
11. Remove O-ring (18) .
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12. Remove screen filter (19) .
13. Remove oil filter (20) .
14. Remove two bolts (21) and elbow assembly (22) .
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15. Remove two O-rings (23) .
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17. Remove ball (25) , spring (26) , and O-ring (27) .
18. Remove pump drive shaft (28) from the transmission.
19. Remove bolt (29) , washer (30) , and yoke assembly (31) from the output shaft.
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20. Remove gasket (32) from yoke (33) .
21. Remove bolt (34) and washer (35) .
22. Remove O-ring (36) and yoke (37) from the output shaft.
10/46
428D Backhoe Loader BNS01118-01851 (MACHINE) POWERED BY 3054 Engin...
2019/10/4

23. Remove four bolts (38) , washers (39) , and pump group (40) .
24. Remove seal (41) .
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428D Backhoe Loader BNS01118-01851 (MACHINE) POWERED BY 3054 Engin...
2019/10/4

Caterpillar Cat 428D BACKHOE LOADER (Prefix BNS) Service Repair Manual (BNS01118-01851).pdf

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