SERV1820

J uly 2006
STUDENT HANDOUTS
"E" SERIES BACKHOE LOADERS
MACHINE SYSTEMS
(SECTION 4 OF 4 FOR SERV1820)
Service Training Meeting Guide
(STMG)
GLOBAL SERVICE LEARNING
420E, 430E, 432E, 434E, 442E, AND 444E
IMPLEMENT AND STEERING
HYDRAULIC SYSTEMS
SECTION 3
AUDIENCE
Level II - Service personnel who understand the principles of machine system operation, diag-
nostic equipment, and procedures for testing and adjusting.
CONTENT
The following pages are handouts to support the presentations for the "E" Series Backhoe
Loaders.
OBJECTIVES
After learning the information in this presentation, the technician will be able to:
1. identify the correct operation of the "E" Series Backhoe Loader 420E, 430E, 432E,
434E, 442E, and 444E implement and steering systems; and,
2. diagnose problems in the "E" Series Backhoe Loader 420E, 430E, 432E, 434E, 442E,
and 444E implement and steering systems.
REFERENCES
STMG "D" Series Backhoe Loaders - Introduction SERV1746
NPI "All Wheel Steer System (AWS) for "D" Series Backhoe Loaders
Update" SERV7105-01
PREREQUISITES
"Fundamentals of Mobile Hydraulics Self Study Course" TEMC3002
"Fundamentals of Electrical Systems Self Study Course" TEMC3004
Handouts: 36
Form: SERV1820
Date: 07/06
2006 Caterpillar Inc.
ADDITIONAL REFERENCES
Specalogs - Center Pivot Backhoes:
"416E Backhoe Loader" AEHQ5684
"420E/420E IT Backhoe Loader" AEHQ5685
"430E/430E IT Backhoe Loader" AEHQ5686
416E, 420E/420E IT, 430E/430E IT, 446D Backhoe Loaders Field Reference
Guide Reference Guide AEXQ0072
Specalogs - Side Shift Backhoes:
"422E Backhoe Loader (EAME and LACD only)" HEHB3123
"428E Backhoe Loader (EAME and LACD only)" HEHB3124
"432E Backhoe Loader (EAME and LACD only)" HEHB3125
"442E Backhoe Loader (EAME and LACD only)" HEHB3126
Multimedia:
DVD "Backhoe Loader, E-Series Walkaround" AEVD6065
CD "Backhoe Loader, E-Series Walkaround" AERV6065
CD "416E/420E / 430E Backhoe Loader NPI eLearning - English" TERV9003
SERV1820 - 3 - References
07/06 Section 4
NOTES
SERV1820 - 4 - Notes
07/06 Section 4
SERV1820 - 5 - Handout No. 1
07/06 Section 4
"E" Series Backhoe Loader Walk-around Checklist
Directions: Use this sheet when performing the machine orientation lab exercise.
Machine Sales Model
Machine PIN (S/N)
Transmission S/N Arrangement
Engine S/N Arrangement
Place a check in the blank if the fluid level is acceptable.
Engine oil level Hydraulic system oil level
Fuel level Brake system oil level
Cooling system fluid level Transmission oil level
Place a check in the blank if acceptable or after task was performed.
Drain water separator Check air filter indicator
Check seat belt Cab air filter
Place a check in the blank after locating and reading the following warnings label on the machine.
Before operating Use of ether
Caution high electrical wires Use of J umpers
Boom/stick-worktool area ROPS (no weld/no drill)
Boom/swing area Attachment line high pressure caution
Loader arm brace
Place a check in the blank if the indicator, switch or control is working correctly.
Keystart switch
Immobilizer system (if equipped)
Turn signal
Tachometer
Engine coolant gauge
Power train/converter oil temperature gauge
Fuel level gauge
Parking brake light
Turn Signal
Horn (front console)
Horn (rear joystick-pilot controls)
Running lights
Front work lights
Rear work lights
Windshield wipers
Heating and air conditioner controls (HVAC)
Service hour meter
Start aid/glow plug switch
Backup alarm
SERV1820 - 6 - Handout No. 2
07/06 Section 4
Machine Walk-around Checklist - continued
Place a check in the blank after locating each of the following controls or switches
Engine and Power Train:
Directional or transmission neutral lock
Transmission neutralizer switch (loader control)
Transmission neutralizer switch (directional shifter)
All wheel drive (AWD) switch (if equipped)
Transmission Auto/Manual switch (autoshift only)
Front governor pedal
Steering wheel
Directional shifter
Speed selector or shifter
Differential lock pedal (if equipped)
Brake pedals
Parking brake lever (and release)
Rear governor lever
Hydraulic System:
Stabilizer levers
Sideshift lock switch
Boom lock lever
Mechanical controls (if equipped)
Boom lever (mechanical control)
Swing lever or pedals
Stick lever
Bucket lever
E-stick/attachment pedal
Loader lift and tilt controls
Attachment lever
Pilot controls (if equipped)
Backhoe left and right joysticks
Attachment thumbswitches
Attachment thumbswitch
Attachment buttons
Continous flow switch
Loader joystick
Pattern changer switch (if equipped)
Pilot shutoff/hydraulic lock switch (if equipped)
"E" Series Backhoe Loader Engine Checklist
Directions: Use this sheet to take notes during the presentation. During the engine lab, use this sheet
as a checklist when identifying components.
Fuel filter
Fuel injection pump
Fuel Shutdown Solenoid
Priming (lift) pump )
Primary air filter
Secondary air filter
Oil filter
Water separator w/ fuel filter
Engine oil dipstick
Engine oil pressure test port
Engine oil cooler (turbocharged models only)
Turbocharger (if equipped)
Wastegate (if equipped)
Air filter indicator
Glow plugs
Cold start advance solenoid
Radiator
Water pump
Temperature regulator housing
High idle adjustment screw
Low idle adjustment screw
Engine oil pressure test port
Plug for checking engine boost
Plugs for checking coolant temperatures
SERV1820 - 7 - Handout No. 3
07/06 Section 4
SERV1820 - 8 - Handout No. 4
07/06 Section 4
3054C Engine In Chassis Test Sheet
Machine Model Dealer
Name/Code Customer
Machine PIN (S/N) J ob
Transmission S/N Application
Engine S/N Date
S.M.H. Serviceman
VISUAL CHECKS: Fuel Level EngineOil level
Coolant level Power Train Oil level
Oil/Coolant/Fuel Leaks Air Filters and Precleaner Inspection
TEST SPECS ACTUAL COMMENTS
Engine rpm: High Idle
Low Idle
Full Load Engine rpm (average of five tests)
Torque Converter Stall Check - Full throttle with brakes
applied, and transmission engaged in:
Third Speed - Forward
Third Speed - Reverse
Inlet Manifold Pressure @ Full Load RPM (reference only)
Fuel Transfer Pressure @ Full Load rpm
Engine RPM at Torque Converter Stall [with temperature
regulator (thermostat) fully opened]
Radiator Top Tank Temperature C (F)
[Should be less than 43 C (110F) over ambient]
Water Pump Inlet Temperature - C (F)
[Should be -13C to -6C (8 to 20F) less than Top Tank Temperature.]
Engine Oil Pressure at: 1500 rpm
Idle
Cylinder Compression Checks: No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
Crankcase (Crankshaft Compartment) Pressure
ADD. CHECKS: Fuel Type Engine Oil Type
Antifreeze Protection Temp Coolant Conditioner %
Battery Voltage Alternator Output Voltage
Starter Cold Cranking Amps
NOTE: Make sure the fuel is shut off
when performing compression checks.
SERV1820 - 9 - Handout No. 5
07/06 Section 4
"E" Series Electrical System Checklist
Directions: During a lab exercise, use this sheet as a checklist when identifying components on the
machine and for recording information from the electrical schematic.
Machine Schematic
Location Part No. Location Parts Manual Description Schematic Description
Starter motor
Alternator
Battery
Key start fuse
Engine oil pressure switch
Power train oil temperature
sender (converter)
Hydraulic oil temperature sensor
Fuel level sender
Engine shutdown solenoid
Key start switch
Start relay
Start aid switch
Start aid relay
Glow plugs
Cold start advance solenoid
Auto/Manual switch (if
equipped)
Ride control relay (if equipped)
Torque limiter bypass solenoid
(if equipped)
Hydraulic filter bypass switch
Cat ET Connector (if equipped)
Backhoe shutoff switch (if
equipped)(if equipped)
Machine ECM (if equipped)
SERV1820 - 10 - Handout No. 6
07/06 Section 4
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SERV1820 - 11 - Handout No. 7
07/06 Section 4
Standard Power Train Component Checklist
Directions: Use this sheet to take notes during the presentation (i.e. location, functions). During a lab
exercise, use this sheet as a checklist when identifying components and pressure test locations.
Fill tube
Filter
Suction screen
Torque converter housing
Transmission directional control selector lever
Speed selector
Relief valve
Cold start relief valve
Torque converter inlet relief valve
Transmission control valve (if equipped)
Clutch solenoids for autoshift (if equipped)
AWD solenoid valve (if equipped)
Transmission oil cooler bypass valve
Transmission oil cooler
Test Locations:
Lube pressure
FORWARD clutch pressure
REVERSE clutch pressure
Pump supply pressure
Torque converter outlet pressure
Torque converter inlet pressure
AWD clutch pressure (if equipped)
SERV1820 - 12 - Handout No. 8
07/06 Section 4
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SERV1820 - 13 - Handout No. 9
07/06 Section 4
Backhoe Loader Standard Transmission Test Sheet
Machine Model _____________________________ Dealer ___________________________________
Name/Code ________________________________ Customer _________________________________
Mach. S/N ________________________________ J ob______________________________________
Trans. S/N _________________________________ Application _______________________________
Engine S/N ________________________________ Date ____________________________________
S.M.U. ____________________________________ Serviceman _______________________________
VISUAL CHECKS
Oil Level _______ Suction Screen _______
Oil Type _______ Oil Filter _______
Oil Leaks _______ Abrasives in Oil _______
Air/H2O in Oil _______ Debris in Pan _______
PRESSURE TESTS
PARKING BRAKE - ON
PRESSURE TEST
SHIFT
LEVER
SPEC ACTUAL SPEC ACTUAL
Pump SuppIy
PRESSURES
LOW IDLE HIGH IDLE
Forward CIutch
Reverse CIutch
Lube
T.C. InIet
T.C. OutIet (T.C. StaII)
AWD CIutch Pressure
N
F
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XXXX
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SHIFT
LEVER
SPEC ACTUAL
ENGINE SPEED
4th / FWD
4th / REV
TORQUE CONVERTER STALL TEST
NOTE: Depending on which service publication is used, specifications may not always be provided for both speed ranges.
When testing the transmission pressures, use the stabilizers to raise the rear wheels off the ground. As the machine
attempts to drive through the brakes, the machine will not move.
Comments:
SERV1820 - 14 - Handout No. 10
07/06 Section 4
Autoshift Transmission Component Checklist
Directions: Use this sheet to take notes during the presentation (i.e. location, functions). During a lab,
use this sheet as a checklist when identifying components and pressure test locations.
Solenoid No. 1 - FORWARD HIGH
Solenoid No. 2 - REVERSE
Solenoid No. 3 - FORWARD LOW
Solenoid No. 4 - speed clutch No. 1
Solenoid No. 5 - speed clutch No. 2
Solenoid No. 6 - speed clutch N.o. 3
All wheel drive solenoid (if available)
Pressure regulator valve
Torque converter inlet relief valve
Transmission speed sensor
Electronic Control Module (ECM)
Electronic Technician (ET) connector
Diagnostic indicator lamp
Test Locations:
Pump supply pressure
FORWARD HIGH clutch pressure
FORWARD LOWclutch pressure
Speed clutch No. 1
Speed clutch No. 2
Speed clutch No. 3
REVERSE pressure tap
Lube pressure tap
All-Wheel Drive clutch pressure tap (if available)
SERV1820 - 15 - Handout No. 11
07/06 Section 4
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SERV1820 - 16 - Handout No. 12
07/06 Section 4
Using Cat ET and the Machine ECM
Autoshift Transmission
Directions: Connect Cat ET. Search through the various menus and screens to find engine informa-
tion to answer the questions that follow.
Machine Model Date
Transmission Serial Number SMU
a) Record the Cat ET Version:
c) Record the ECM Part Number:
b) Record the ECM Serial Number:
d) Record the Software Group Description:
e) Record the Software Group Part Number:
f) Record the Software Group Release date:
e) Record the Transmission Type:
f) Record the Maximum Forward Gear:
g) List the Transmission Status Groups:
1.
2.
3.
4.
5.
i) List all active transmission diagnostic codes found (up to the first three):
1.
2.
3.
j) List all logged transmission diagnostic codes found (up to the first three) and then clear them:
1.
2.
3.
SERV1820 - 17 - Handout No. 13
07/06 Section 4
Backhoe Loader Autoshift Transmission System Pressure Tests
Machine Model _____________________________ Dealer ___________________________________
Name/Code ________________________________ Customer _________________________________
Mach. S/N ________________________________ J ob______________________________________
Trans. S/N _________________________________ Application _______________________________
Engine S/N ________________________________ Date ____________________________________
S.M.U. ____________________________________ Serviceman _______________________________
VISUAL CHECKS
Oil Level _______ Suction Screen _______
Oil Type _______ Oil Filter _______
Oil Leaks _______ Abrasives in Oil _______
Air/H2O in Oil _______ Debris in Pan _______
PRESSURE TEST
ENGINE SPEED
LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Pressure
Lube Pressure
AII WheeI Drive Pressure
Torque Converter InIet (OptionaI)
Torque Converter OutIet (Not AppIicabIe)
FORWARD HIGH
REVERSE
FORWARD LOW
Speed CIutch 1
Speed CIutch 2
Speed CIutch 3
XXX XXX XXX XXX
Comments:
SERV1820 - 18 - Handout No. 14
07/06 Section 4
Backhoe Loader Autoshift Transmission System Pressure Tests
(continued)
PRESSURE TEST
SPEC ACTUAL SPEC ACTUAL
Pressure difference between Pump and
FORWARD LOW
ENGINE SPEED
LOW IDLE HIGH IDLE
Pressure difference between Pump and
FORWARD HIGH
Pressure difference between Pump and
REVERSE
Pressure difference between Pump and CIutch 1
Pressure difference between Pump and CIutch 2
Pressure difference between Pump and CIutch 3
Pressure difference between Pump and
AII WheeI Drive CIutch
Comments:
SHIFT
LEVER
SPEC ACTUAL
ENGINE SPEED
4th / FWD
4th / REV
TORQUE CONVERTER STALL TEST Comments:
T
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k
4
1
6
E
/
4
2
2
E
/
4
2
8
E

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e
.
SERV1820 - 19 - Handout No. 15
07/06 Section 4
SERV1820 - 20 - Handout No. 16
07/06 Section 4
416E/422E/428E Hydraulic System Component Checklist
Directions: Use this sheet to take notes during the presentation (i.e. location, functions). During a lab
exercise, use this as a checklist when identifying components.
Hydraulic sight gauge
Hydraulic tank
Hydraulic oil filter
Pump
Pump control valve
Loader controls
Loader valve group
Loader signal relief valve
Stabilizer controls
Backhoe controls
Boom lock lever
Backhoe valve group
Backhoe signal relief valve
Hand metering unit (HMU)
Pump supply pressure test port
Signal pressure test port
SERV1820 - 21 - Handout No. 17
07/06 Section 4
A
B
C
D
E
F
G
H
I
416E/422E/428E Control Valve
Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes dur-
ing the slide presentation.
PORT B
From
Pump
PORT A
A
B
C
D
E
From
Previous
VaIve
To Pump
and SignaI ReIief
VaIve
From
Previous
VaIve
F
G
H
I
SERV1820 - 22 - Handout No. 18
07/06 Section 4
F
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.
ABCDEFGH
IJ
K
SERV1820 - 23 - Handout No. 19
07/06 Section 4
L
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r

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s
B
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k
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p
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ABCDEFGH
IJ
K
SERV1820 - 24 - Handout No. 20
07/06 Section 4
F
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ABCDEFGH
IJ
SERV1820 - 25 - Handout No. 21
07/06 Section 4
416E/422E/428E BACKHOE LOADER HYDRAULIC TESTS
TEST
4TH AVG.
CYCLE TIMES
SPEC 1ST 2ND 3RD
L
O
A
D
E
R
Bucket Dump
TiIt Back
Dump
Raise
B
A
C
K
H
O
E
Bucket Dump
Bucket Load (CurI)
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
E-Stick Extend
E-Stick Retract
Left StabiIizer Up
Left StabiIizer Down
Right StabiIizer Up
Right StabiIizer Down
Boom Lower
Boom Pause
Boom Raise
(to snubber)
FIoat
Boom Raise
(to stop)
AuxiIiary 1
AuxiIiary 2
RUN ALL TESTS AT MAXI-
MUM RPM
MACHINE AT NORMAL
OPERATINGTEMPERA-
TURES
PRESSURE TEST SPEC ACTUAL ADJUSTED
Low Pressure Standby
Margin Pressure
Loader Signal Relief Pressure
Steering Signal Relief Pressure
Backhoe Signal Relief Pressure
T
a
n
k
P
u
m
p



SERV1820 - 26 - Handout No. 22
07/06 Section 4
4
2
0
E
/
4
3
0
E


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T
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SERV1820 - 27 - Handout No. 23
07/06 Section 4
4
3
2
E
/
4
3
4
E
/
4
4
2
E
/
4
4
4
E

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.
SERV1820 - 28 - Handout No. 24
07/06 Section 4
Hydraulic sight gauge
Hydraulic tank
Hydraulic oil filter
Pump
Pump control valve
Torque limiter (if equipped)
Torque control solenoid (if
equipped)
Loader controls
Continuous flow switch
Loader valve group
Loader signal relief valve
Ride control accumulator (if
equipped)
Hand metering unit (HMU)
Stabilizer controls
Backhoe controls
Boom lock lever
Pattern changing switch (if
equipped)
Backhoe valve group
Backhoe signal relief valve
Pilot accumulator
Pilot lockout switch
Machine ECM (if equipped)
Swing cushion valve (if equipped)
Pump supply pressure test port
Signal pressure test port
420E/430E/432E/434E/442E & 444E Hydraulic System Component Checklist
Directions: Use this sheet to take notes during the presentation (i.e. location, functions). During a lab
exercise, use this as a checklist when identifying components.
SERV1820 - 29 - Handout No. 25
07/06 Section 4
A
B
C
D
E
F
G
"E" Series Hydraulic Pump Components Checklist
420E/430E/432E/434E/442E & 444E Backhoe Loaders
Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes dur-
ing the presentation.
Pump
Output LS SignaI
Backhoe
InIet ManifoId
A
B
C
D
E
F G
H
I
J
L
K
H
I
J
K
L
SERV1820 - 30 - Handout No.261
07/06 Section 4
A
B
C
D
E
F
G
H
420E/430E/432E/434E/442E/444E Control Valve
Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes dur-
ing the presentation.
To Port A To Port B
From
Pump
A
B
C
D
E
F
G
G
SERV1820 - 31 - Handout No. 27
07/06 Section 4
O
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ABCDEFGH
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SERV1820 - 32 - Handout No. 28
07/06 Section 4
P
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ABCDEF
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NO
SERV1820 - 33 - Handout No. 29
07/06 Section 4
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SERV1820 - 34 - Handout No. 30
07/06 Section 4
F
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P
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M
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f
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d
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SERV1820 - 35 - Handout No. 31
07/06 Section 4
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SERV1820 - 36 - Handout No. 32
07/06 Section 4
Using Cat ET and the Machine ECM
Solenoid Controlled Implement Circuits
Directions: Connect Cat ET. Search through the various menus and screens to find engine informa-
tion to answer the questions that follow.
Machine Model Date
SMU
a) Record the Cat ET Version:
c) Record the ECM Part Number:
b) Record the ECM Serial Number:
d) Record the Software Group Description:
e) Record the Software Group Part Number:
f) Record the Software Group Release date:
g) List the Hydraulic Status Groups:
1.
2.
3.
4.
5.
6.
i) List all active transmission diagnostic codes found (up to the first three):
1.
2.
3.
j) List all logged transmission diagnostic codes found (up to the first three) and then clear them:
1.
2.
3.
SERV1820 - 37 - Handout No. 33
07/06 Section 4
420E/430E/432E/434E/442E/444E BACKHOE LOADER HYDRAULIC TESTS
TEST
4TH AVG.
CYCLE TIMES
SPEC 1ST 2ND 3RD
L
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Raise
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Bucket Load (CurI)
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Stick Out
Swing
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E-Stick Extend
E-Stick Retract
Left StabiIizer Up
Left StabiIizer Down
Right StabiIizer Up
Right StabiIizer Down
Boom Lower
Boom Pause
Boom Raise
(to snubber)
FIoat
Boom Raise
(to stop)
AuxiIiary 1
AuxiIiary 2
RUN ALL TESTS AT MAXI-
MUM RPM
MACHINE AT NORMAL
OPERATINGTEMPERA-
TURES
PRESSURE TEST SPEC ACTUAL ADJUSTED
Low Pressure Standby XXXX
Margin Pressure
Pilot System Pressure
Loader Signal Relief Pressure
Steering Signal Relief Pressure
Backhoe Signal Relief Pressure
SERV1820 - 38 - Handout No. 34
07/06 Section 4
420E
430E
432E
434E
442E
444E
1600 rpm
1600 rpm
1600 rpm
1600 rpm
1600 rpm
1600 rpm
High Torque
SOLENOID ENERGIZED
1200 rpm
1200 rpm
1200 rpm
1200 rpm
1200 rpm
1200 rpm
High Torque
SOLENOID ENERGIZED
SOLENOID DE-ENERGIZED
Low Torque
1300 rpm
1200 rpm
1300 rpm
1300 rpm
1200 rpm
1200 rpm
1100 rpm
1100 rpm
1100 rpm
1100 rpm
1100 rpm
1100 rpm
SOLENOID DE-ENERGIZED
Low Torque
(FORWARD - OR - REVERSE)
DIRECTIONAL MODE ENABLED
DIRECTIONAL MODE DISABLED
(NEUTRAL)
434E
420E
430E
432E
434E
444E
PUMP SOLENOID TORQUE PARAMETERS
SERV1820 - 39 - Handout No. 35
07/06 Section 4
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6
SERV1820 - 40 - Handout No. 36
07/06 Section 4
Objectives/Student Evaluation
Student Name: Instructor(s):
Course Name: Course Number:
Pretest Score: Posttest Score:
1. The student demonstrated through involvement in lab activities
recommended safety practices.
2. Using an "E" Series backhoe loader complete all assigned activi-
ties and tasks related to the Machine Orientation Module.
3. Using an "E" Series backhoe loader complete all assigned activi-
ties and tasks related to the Engine and Electrical System
Module.
4. Using an "E" Series backhoe loader complete all assigned activi-
ties and tasks related to the Standard Power Train Module.
5. Using an "E" Series backhoe loader complete all assigned activi-
ties and tasks related to the Autoshift Power Train Module.
6. Using an "E" Series backhoe loader complete all assigned activi-
ties and tasks related to the Axles and Brake System Module.
7. Using an "E" Series backhoe loader complete all assigned activi-
ties and tasks related to the 416E, 422E, and 428E Mechanically
Controlled Implement and Steering System Module.
8. Using an "E" Series backhoe loader complete all assigned activi-
ties and tasks related to the 420E, 430E, 432E, 434E, 442E, and
444E Pilot Controlled Implement and Steering System Module.
Did student accomplish the following objectives?
Instructor
Yes No
Additional remarks
Instructor(s):
Training Manager:
Student Average Good Excellent
Student met prerequisites
Class Participation
Desire to Learn