A

February 2006
GLOBAL SERVICE LEARNING
TECHNICAL PRESENTATION
"E" SERIES BACKHOE LOADERS

INTRODUCTION
PRELIMINARY
Service Training Meeting Guide
(STMG)
INTRODUCTION
AUDIENCE
Level II - Service personnel who understand the principles of machine system operation,
diagnostic equipment, and procedures for testing and adjusting.
CONTENT
This presentation provides an introduction and describes the components and systems operation
of the electrical system, power train, and implement and steering systems for the "E" Series
Backhoe Loader. This presentation may also be used for self-paced and self-directed learning.
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 electrical system, power
train, implement and steering systems; and,
2. diagnose problems in the "E" Series Backhoe Loader electrical system, power train, and
implement and steering systems.
REFERENCES
STMG "Distributor-type Mechanical Fuel Pump - 3044C/3046

Tier II Engines" SERV1777
PREREQUISITES
"Fundamentals of Engines Self Study Course" TEMV3001

"Fundamentals of Mobile Hydraulics Self Study Course" TEMV3002
"Fundamentals of Power Train Self Study Course" TEMV3003
"Fundamentals of Electrical Systems Self Study Course" TEMV3004
Estimated Time: 16 Hours

Illustrations: XX
Handouts: XX
Form: SERVXXX
Date: 02/06
© 2006 Caterpillar Inc.

SERVXXX -3- Text Reference
2/06
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................ 5
OPERATOR'S STATION............................................................................................................ 19
ENGINE....................................................................................................................... ............... 38
ELECTRICAL SYSTEM ........................................................................................................... 45
POWER TRAIN ......................................................................................................................... 51

Standard Transmission .......................................................................................................... 51
Autoshift Transmission ......................................................................................................... 56
Axles and Brakes .................................................................................................................. 70
416E/422E/428E IMPLEMENT HYDRAULIC SYSTEM ....................................................... 77

Implement and Steering Pump.............................................................................................. 79
Mechanical Loader Valve Group .......................................................................................... 86
Ride Control System............................................................................................................. 95
Mechanical Backhoe Valve Group ....................................................................................... 99
420E/430E/432E/434E/442E/444E IMPLEMENT HYDRAULIC SYSTEM......................... 113

Implement and Steering Pump............................................................................................ 117
Mechanical Loader Valve Group ........................................................................................ 124
Ride Control System........................................................................................................... 133
Pilot Loader Valve Group ................................................................................................... 135
Pilot Backhoe Valve Group ................................................................................................ 142
STEERING SYSTEM ............................................................................................................. . 163

Two Wheel Steer System.................................................................................................... 163
All Wheel Steer (AWS) System ......................................................................................... 166
CONCLUSION......................................................................................................................... 170
HYDRAULIC SCHEMATIC COLOR CODE......................................................................... 171
HANDOUTS..................................................................................................................... ........ 173

2/06
NOTES
2/06

INTRODUCTION
© 2006 Caterpillar Inc.
INTRODUCTION
The "E" Series Backhoe Loader family is the latest generation of Caterpillar Backhoe Loaders
retaining many of the features proven on the "D" Series machines along with additional
performance and design improvements.
This presentation discusses the components and system operation of the "E" Series Backhoe
Loaders.
The hydraulic system has been changed from a Load Sensing/Pressure Compensated LS/PC
system to a Proportional Priority, Pressure Compensated PPPC system. Two types of PPPC
systems are used. The 416E/422E/428E machines with mechanically controlled implement
hydraulic valves use one type of PPPC system. The 420E/430E/432E/434E/442E/444E
machines use another type of PPPC system.
The "E" Series BHL product line is the first new complete redesign since the "C" Series, and
brings significant improvements in performance, operator comfort, controllability, versatility,
and styling.
2/06
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The "E" Series machines include models that are equipped with the center pivot backhoe and
the sideshift backhoe. The sideshift models 434E and 444E are equipped with Equal Size Tires
(ETS). The last digit ("4") in the model number designates the ETS option.
The 416E and 422E models are equipped with a single tilt loader and the 420E and 430E models
can be equipped with a single tilt or parallel lift loader. The 428E and the 432E through 444E
models come standard with the parallel lift loader.
The 416E, 422E, and 428E include mechanically controlled loader and backhoe implement
hydraulic valves. The 420E and 430E models can be equipped with mechanically controlled or
pilot controlled loader valves. The backhoe valves on the 420E and 430E are pilot controlled.
The loader and backhoe valves on the 432E-444E are pilot controlled hydraulic valves.
The "E" Series machines are equipped with either a two wheel drive or All Wheel Drive (AWD)
power train and a standard or autoshift transmission.
NOTE: The standard countershaft transmission is available in all "E" Series models.
The autoshift transmission is also available on the 420E/430E/432E/434E/442E/444E
models.
The standard and autoshift transmissions feature new control solenoids which provide improved
clutch pressure modulation for smoother clutch engagement and longer life.
2/06
An All Wheel Steer (AWS) system is available on the 432E and 442E models and standard on
the 434E and 444E models.
The "E" Series backhoe loaders are powered by direct injection, four cylinder Caterpillar
3054C diesel engines. Turbocharged engines are optional on the 416E and 422E models and
standard on all other models.
The 420E/430E/432E/434E/442E/444E machines are equipped with hydraulically assisted

master cylinders to reduce the amount of pedal effort. An external brake boost valve uses oil
from the pilot accumulator to add boost to the master cylinder. The hydraulic force multiplies
the pedal effort so the operator can get more braking force with less effort.
2/06
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The "E" Series machines have many similarities to the machines they are replacing.
The basic engine and fuel system are the same as the updated "D" Series Tier II machines.
Glow plugs have replaced the thermal starting aid and a start aid relay has been added.
The two wheel steering system is the same except two crossover relief valves have been added.
The All Wheel Steer system is the same as the updated "D" Series machines.
The ride control system is similar except for a second solenoid that has been added, which
combines the check valve and shutoff valve.
Most of the daily service fill and check points are the same and can be accessed through the
hinged engine hood.
2/06
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The "E" Series machines feature several changes over the previous models to improve operator
comfort and machine performance.
The operator compartment features new console layouts. The heating, ventilation, and air
conditioning includes 15 louvers and air towers, which provide significant improvements to air
circulation.
The E-Stick uses an extendible slider with a new wear pad design.
The electrical system has changed significantly from the previous models. One fuse and relay
block replaces the two fuse and relay blocks on the previous machine. The Cat ET connector is
also located below the fuse panel and is now accessible without removing the fuse block access
panel. The Machine ECM replaces the Auxiliary ECM and Autoshift ECM.
Modulation valves have been added to the standard and autoshift transmissions to improve
clutch modulation, which results in smoother transmission shifting. A forward drive gear has
been added to the countershaft in the standard transmission. The forward drive gear increases
the machine top speed to 40 km/h (25 mph) the same as the autoshift transmission.
The rear final drive planetary gears have been moved outboard of the differential. Brake
inspection ports have been added to the axle.
The pilot loader joysticks and pilot backhoe joysticks have been redesigned.
SERVXXX - 10 - Text Reference
2/06
The pattern switching valve is controlled by a switch and two solenoids rather than
mechanically as on the "D" Series.
The 420E/430E/432E/434E/442E/444E machines are now equipped with hydraulically assisted

master cylinders, which decreases pedal effort when braking.
A torque selector solenoid has been added to the steering and implement pump on the
420E/430E/432E/434E/442E and 444E machines, which provides a higher pump setting.
The implement hydraulic system has changed from a LS/PC system to a PPPC system, which
provides better performance when using multiple functions.
The sideshift machines can be equipped with an optional powered sideshift, which allows the
backhoe to be hydraulically shifted across the slider.
2/06
The new "E" Series cab with curved glass and contoured fenders gives the machine a distinct
new look, improves serviceability, and provides superior visibility. The sleek hood is lowered
for visibility and tilts forward for easy access.
A new mainframe provides a longer wheelbase for improved balance and is designed to provide
durability for improved performance. The swing casting has an improved geometry for hose
routing clearance and increased durability. With replaceable bushings in the swing casting,
adjustable shim packs in the E-Stick and sideshift stabilizer legs, and a Diagonal Retention
System for bucket tooth tips, the "E" Series is easier to maintain.
2/06
2 3
8
4
7
6 5
Access to the top of the engine and several maintenance items is obtained by opening the
hood (1). Service points accessible when the hood is opened are:
- Hydraulic tank fill tube (2)
- Washer fill bottle (3)
- Transmission oil fill tube (4)
- Engine oil fill tube (5)
- Engine oil dipstick (6)
- Air filter housing (7)
- Air filter indicator (8)
2/06
8
1
2
3
The hydraulic oil sight gauge (1) is located on the left side of the machine in front of the cab.
The hydraulic oil filter (2) is located below the machine at the left frame rail. The hydraulic oil
filter bypass switch (3) is mounted to the oil filter base.
2/06
10
5
3
6 7
8 11
The left side of the engine (top illustration) and right side of the engine (bottom illustration)
are accessed by removing the side panels. The side panels are light weight non-metallic for
easy removal. The following components are visible with the side panels removed:
- Air conditioning compressor (1) - Hydraulic oil cooler (5)
- Cold start temperature switch (2) - Coolant temperature sender (6)
- Electrical fuel priming pump relay (3) - Coolant temperature switch (7)
- Oil pressure switch (4) - Transmission oil cooler (8)

2/06
12
The new extendible stick (E-Stick) uses an external slider with a new wear pad design, which
provides increased life and simplified serviceability. The E-Stick outer slider protects the inner
slider from damage and debris and includes serrated gripping edges for improved clamping
capabilities.
Provisions for mounting a hydraulically controlled thumb is standard equipment on some

machines.
2/06
4
4 2
1
13
The E-Stick is adjustable up and down by sliding the wedges (1) located at each end of the E-
Stick. The wedges can be moved by loosening the two bolts (2) on the E-Stick and adjusting the
set screw (3). Slide the wedges in to tighten and out to loosen the E-Stick.
The E-Stick is adjustable back and forth by changing the amount of shims (4) located in two
places along the side of the E-Stick. The shims can be accessed by removing four bolts and a
plate (5) on the E-Stick.
2/06
14
"E" Series sideshift machines have a new slide frame (top right illustration) with new externally
serviceable slide frame lock cylinders and reversible/replaceable wear plates (1). The lock
cylinders can be serviced in the field with standard tools.
The stabilizers (2) are now externally adjustable.
A powered sideshift (bottom right illustration) is available, which allows the operator to
hydraulically shift the backhoe across the slider.
The 434E and 444E sideshift models are equipped with equal size tires as shown in this
illustration, which provides lower ground pressure due to a larger tire footprint in contact with
the ground.
2/06
3
2
15
This illustration shows the optional powered sideshift (1) attachment. The powered sideshift
moves the backhoe across the slider using a hydraulic cylinder (2). Wear pads (3) on the slider
and powered sideshift assembly are serviceable.
2/06
16
OPERATOR'S STATION
The new "E" Series cab offers an improved operator environment, with increased visibility,
ergonomics, and comfort. The pod-mounted joystick controls on machines with a pilot
controlled backhoe valve offer increased comfort, control, and versatility.
The air conditioning system performance has improved with 15 louvers and air towers at the
rear. There is now a separate accumulator and dryer. The dryer requires replacement every
3000 hours or two years.
Other cab features include:
- Automotive style finish
- Curved glass maximizes space within the cab and provides 360° visibility
- Air Suspension seat
- Low effort machine controls
- Personal storage space

2/06
- Joystick pattern switch (pilot controlled machines)
- Continuous flow for auxiliary functions (optional)

2/06
6
1 2
5 4
17
The front of the cab includes the features described below.
The left turn and parking brake indicator (1) are located at the left side of the steering console.
To the right is the high beam and right turn indicators (2). Also located on the steering console
is the hazard switch (3).
On the right of the steering column is the turn signal/lights/wiper control lever (4). The
transmission control lever (5) is on the left of the steering column.
Also visible is the optional AWS position indicator gauge (6).

2/06
1
5
4
2 3
18
On the floor of the cab in front of the operator seat is the differential lock switch (1). Below
the steering column are the left brake pedal (2) right brake pedal (3), steering column tilt
lever (4), and the accelerator pedal (5). A large storage compartment (6) is located below the
front dash.
2/06
3
1 2 4
7
56
19
To the left of the steering column are the following components:
- Quick coupler switch (1) (if equipped)
- Continuous loader flow switch (2)
- 12 volt auxiliary circuit switch (3) (if equipped)
- Transmission neutral switch (4)
- Broom angle control switch (5) (if equipped)
The AWD switch (6, if equipped) is now a three-position switch. The three positions (from left
to right) are AWD, AWD BRAKING, and OFF.
On the left side of the console is the service hour meter (7).
2/06
2
1 3
5
6
20
To the right of the steering column are the following components:
- Autoshift switch (1) (if equipped)
- Ride control switch (2) (if equipped)
- Roading lights switch (3) (if equipped)
- Horn switch (4) (if equipped)
- All Wheel Steer control switch (5) (if equipped)
- All Wheel Steer indicators (6) (if equipped)

2/06
4
2
6
7
5
3
8
21
Located to the right of the operator seat are the following components:
- Loader joystick (1)
- Parking brake lever (2)
- Switch panel (3)
- Gauge cluster (4)
- Governor lever (5)
- Left stabilizer control lever (6)
- Right stabilizer control lever (7)
- Boom lock lever (8)

2/06
3 4
20 2 6 5
1
9 10
7 8 11
18 19
12 13 14 15 16 17
22
The right console contains the key start switch (1) located to the left of the gauge cluster. The
gauge cluster includes the engine coolant temperature gauge (2), torque converter outlet
temperature gauge (3), fuel level gauge (4), and tachometer gauge (5). The indicator panel (6)
is in the center of the gauge cluster. Below the gauge cluster are the following switches:
- Starting aid (7)
- Rotating beacon (8)
- Rear fog light (9) (if equipped)
- Spare (10)
- Rear wiper and washer (11)
- Implement lockout (12)
- Heater A/C (13)
- Front flood lights (14)
- Temperature control knob (15)
- Rear flood lights (16)
- Fan speed (17)
- Sideshift control switch for powered sideshift machines (18) (if equipped)
NOTE: The mechanical sideshift control switch is not shown in this illustration.
- Continuous backhoe flow switch (19) (if equipped)
- Machine security system indicator (20) (if equipped)
2/06
1 2 3
4
5 6
23
The indicator panel located in the center of the right console dash includes the following
indicators:
The action light (1) illuminates when a malfunction occurs in a machine system.
The engine oil pressure alert indicator (2) will light and an audible alarm will sound when the
engine oil pressure is low.
The brake oil level alert indicator (3) will light and an audible alarm will sound when the brake
reservoir oil is low.
The air filter alert indicator (4) will light when the air filter becomes clogged.
The charging system alert indicator (5) comes on if there is a malfunction in the electrical
system.
The fuel system water separator alert indicator (6) indicates a plugged fuel/water separator.
2/06
2
24
25
These illustrations show the loader joystick (1) with a pilot controlled loader valve. The pilot
controlled loader valve joystick includes a thumbwheel switch (2) that controls the auxiliary
functions and two buttons (3) that control the AWS maneuvering. Also located on the front of
the joystick is the transmission neutralizer and downshift switch (4).
2/06
7
3
2
4 1 5
26
This illustration shows the loader joystick (1) with a mechanically controlled loader valve.
With a mechanically controlled loader control valve an auxiliary control lever (2) is located
between the joystick and parking brake lever (3). Also located on the front of the joystick is
the transmission neutralizer switch (4). The neutralizer switch disengages the transmission.
The parking brake release lever (5) is located at the front of the parking brake lever.
Also visible in this illustration is the transmission shift lever (6) for machines equipped with the
standard transmission. A transmission neutralizer switch (7) is also located on the front of the
transmission shift lever.
2/06
1
1
6
27
5
2
3
4
1 1
28
These illustrations show the backhoe joysticks (1) with a pilot controlled backhoe valve. The
left pilot joystick is equipped with a thumbswitch (2) to control the auxiliary functions (if
equipped) and a horn switch (3). The right joystick is equipped with a thumbswitch (4) to
control the E-Stick (if equipped) or a hammer (if installed).
The boom lock lever (5) locks the boom in place for machine travel. The pilot control pod
lever (6) allows adjustment of the pilot lever pods.
The joystick default pattern is the excavator pattern. An alternate backhoe pattern can be
selected using the joystick pattern switch (not visible) located to the right of the operator's seat
(when facing toward rear).
2/06
The joystick excavator pattern is:
Left joystick: Right joystick:
- Forward: Stick out - Forward: Boom lower

- Rear: Stick in - Rear: Boom raise
- Right: Swing right - Right: Bucket dump
- Left: Swing left - Left: Bucket close
The joystick backhoe pattern is:
Left joystick: Right joystick:
- Forward: Boom lower - Forward: Stick in

- Rear: Boom raise - Rear: Stick out
- Right: Swing right - Right: Bucket dump
- Left: Swing left - Left: Bucket close
2/06
2
1
29
30
These illustrations show the backhoe controls with a mechanically controlled backhoe valve.
The standard control pattern for the "E" Series is the same as on all previous backhoe models.
The left joystick (1) is used to control the boom and swing functions. The right joystick (2) is
used to control the bucket and stick functions.
The pedal (3) on the floor to the right of the joysticks controls the E-Stick (if equipped) or a
hammer (if installed).
NOTE: The auxiliary functions (if installed) are controlled by a pedal (not shown) on
the floor to the left of the joystick.
2/06
31
1
32
The joystick pattern switch (1) is located to the right of the operator's seat (when facing toward
the rear) on machines with a pilot controlled backhoe. The joystick pattern switch controls two
solenoids that allow the backhoe controls to change from an excavator to a backhoe control
pattern. Press the top of the switch to select the excavator pattern. Press the bottom of the
switch to select the backhoe pattern.
A decal (2) illustrates the joystick pattern options. The top half of the decal shows the
excavator pattern and the bottom half of the decal shows the backhoe pattern.
Also located next to the joystick pattern switch is a storage compartment (3).
2/06
33
34
Located inside the door on each side of the machine are 12 volt power ports (1).
NOTE: The 12 volt power port on the left side of the machine is not available on the
416E/422E/428E machines.
Also located inside the right door is the Cat ET connector (2) and the fuse panel (3). The fuse
panel cover has been removed in the top illustration.
2/06
35
1
5 4
6
7
36
10
8
11
9
12
This illustration shows the fuse panel (1) with the cover (2) removed. The fuse panel includes
a decal (3) that lists the machine fuses and relays.
The machine relays are:
- K1 Backup alarm (4)

- K2 Horn (5)
- K3 Position lamp (6)
- K4 Differential lock (7)
- K5 Not used (8)
2/06
- K6 Not used (9)

- K7 Ride control (10)
- K8 AWD brake (11)
- K9 Implement enable (12)
NOTE: There are six fuses (not visible) for the three power relay modules. The fuses
are located next to the fuse panel. Part of the console must be removed to access the
power relay modules and fuses.
2/06
37
The cab air filter (1) is located behind a panel (2) on the right side of the operator's station.
The cab air filter is accessed by opening a panel (3) on the right fender.
A clean air intake (4) is also located on the right side of the cab.
2/06
38
ENGINE
The "E" Series Backhoe Loader machines are equipped with a 3054C engine. The 3054C
engine meets EPA Tier II emissions requirements, the same as the "D" Series update machines.
The standard engine for the 416E and 422E is the 3054C DINA (Direct Injection Naturally
Aspirated) engine which maintains the same horsepower as the previous machines at 55
kW (74hp).
The optional engine for the 416E and 422E is the 3054C DIT (Direct Injection Turbocharged)
engine. The horsepower has been increased from 60 kW (80 hp) in the "D" Series models to 66
kW (89 hp) in the "E" Series models.
The 420E/428E/430E/432E/434E/442E and 444E machines are all equipped with the 3054C
turbocharged engine. Horsepower ratings are:
- 420E/428E/432E/434E with standard transmission: 66 kW (89 hp)
- 428E/430E/442E/444E with standard transmission: 72 kW (97 hp)
- 420E/430E/432E/434E/442E/444E with autoshift transmission: 72 kW (97 hp)

2/06
39
40
2
The air filter (1) is similar to the air filter used on the updated "D" Series Backhoe Loaders, but
the air intake (2) is from the top of the air filter on the "E" Series machines. Air is vented from
the fan to the air filter through an opening (3) in the hood. The air filter incorporates both the
precleaner and air cleaner functions.
2/06
40A
The fuel tank (1) is located on the left side of the machine. The fuel level sender (2) is located
on the top of the fuel tank.
2/06
3
1
2
4
41
The "E" Series Backhoe Loaders use different fuel pumps depending on whether the engine is
naturally aspirated or turbocharged. Both fuel pumps have been used on other Caterpillar
products. These fuel pumps are not serviceable except by the manufacturer's certified service
centers.
Machines equipped with a naturally aspirated 3054C DINA engine (not shown) will have a
distributor-type mechanical fuel pump. These fuel pumps use a cam plate, rollers, and springs
to move the distributor plunger in and out of the fuel pump housing. This motion creates
pressurized fuel which is distributed to the injectors.
Machines equipped with a turbocharged 3054C DIT engine will have a distributor-type,
plunger-type mechanical fuel pump (1). These fuel pumps contain plungers, a cam ring, and
shoes in the rotor assembly. As the rotor turns, the cam ring forces the shoes and plungers in to
increase the fuel pressure. The pressurized fuel is then directed to the injectors.
If a new pump is installed on the engine, a locking bolt (2) and a two position spacer in the
pump flange below the timing mark on the pump engine flange must be loosened after installing
the pump on the engine. In the locked position, the bolt prevents the pump drive shaft from
turning. Move the spacer to provide additional clearance between the bolt head and the pump
flange to unlock the pump drive shaft. If this procedure is not performed, the fuel pump will be
damaged if an attempt is made to start the engine. If the screw is removed before being installed
on the engine, the fuel pump will no longer be timed and will require retiming at the
manufacturer's service center.
Both fuel pumps are also equipped with an engine shutdown solenoid (3) and automatic
advance mechanism (4).
2/06
2 1
42
42A
An electric fuel primer (1) is used on all "E" Series Backhoe Loaders. This primer pump
replaces the manually controlled lift pump used on previous backhoe engines.
The fuel primer and filter is located inside the left front frame rail next to the engine oil
filter (2).
The fuel filter water separator drain plug (3) is visible from below the engine.
2/06
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This cutaway illustration shows the distributor-type injection pump used on the naturally
aspirated 3054C which is standard on the 416E/422E models. The distributor pump has only
one high pressure pump chamber and one plunger regardless of the number of cylinders in the
engine. The fuel is delivered through a groove in the plunger to the outlet ports as determined
by the number of cylinders in the engine.
The injection pump consists of the following subassemblies:
Feed pump: Consists of a vane-type pump that pulls fuel from the tank and supplies fuel to
the high pressure pump chamber. The feed pump is driven by the pump drive shaft.
High pressure pump with distributor: Delivers fuel under high pressure through a plunger to
the delivery valves. The plunger moves axially due to the rotation of the cam plate. The plunger
is also driven by the pump drive shaft.
Mechanical governor: Controls engine speed through various load ranges. The flyweights
control the governor lever position.
Timing advance mechanism: Adjusts the start of fuel delivery as a function of pump speed
and load.
Engine shutoff solenoid: When de-energized, blocks fuel to the plunger fill port to stop the
engine.
NOTE: Refer to "Distributor-type Mechanical Fuel Pump-3044C/3046 Tier II Engines"

(SERV1777) for more information on the distributor-type mechanical fuel pump.
2/06
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This illustration shows the distributor-type fuel injection pump used on the turbocharged 3054C
engines.
Fuel is drawn by the transfer pump through the pressure regulator and sent to the metering
valve when the solenoid is energized. The fuel also flows through an annular groove around
the rotor to the orifice check valve and the automatic advance mechanism.
The metering valve controls the amount of fuel sent to the pumping elements inside the rotor
(plungers, cam ring, and shoes). As the rotor turns, the cam ring forces the shoes and plungers
in to increase the fuel pressure. The pressurized fuel is then directed to the injectors.
2/06
2
1
45
ELECTRICAL SYSTEM
The "E" Series backhoe loaders are equipped with conventional 12 volt electrical systems with
negative ground and either a 100 amp alternator or a 120 amp alternator. The 100 amp
alternator is installed on the 416E/422E machines. The 420E/428E/430E/432E/434E/442E and
444E machines are equipped with a 120 amp alternator. The batteries (1) are located below the
cab on the right side of the machine. The batteries are accessed by opening a panel (2) below
the step to the cab.
The standard machines are equipped with a 12 volt maintenance free battery to supply power to
the system. The machines can be equipped with two batteries along with a heavy duty alternator
for cold weather climates or for use with additional operating lights (attachments).
The system does not have a disconnect switch. To disable the electrical system, remove the
battery ground cable from the main frame. The starting system is a key start and stop system.
2/06
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The starting and charging system on the "E" Series machines is similar to the "D" Series
machines.
When the key is in the START-RUN position and the transmission shift control lever is in
NEUTRAL, the start relay is energized through the transmission shift lever. With the start relay
closed, power from the battery energizes the starter solenoid and motor. The starter then engages
the flywheel ring gear and starts the engine. If the transmission shift lever is not in NEUTRAL,
no power is directed to the start relay, so the engine will not crank.
For cold starts, the start aid switch can be used to energize the glow plugs. The glow plugs
replaced the thermal starting aid coil. A start aid relay has also been added to the start aid
circuit.
2/06
47
The Machine ECM (1) now controls most of the machine functions and replaces the Auxiliary
Control ECM and the Autoshift ECM on machines equipped with a pilot controlled backhoe
valve. The Machine ECM is mounted to the bottom of the cab floor plate (2). The Machine
ECM includes two 70 pin connectors (3).
NOTE: The Machine ECM is not installed on machines equipped with a mechanical
backhoe valve (416E/422E/428E).
2/06
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48
This illustration shows the Machine ECM input and output components on machines equipped
with a pilot controlled backhoe valve.
The Machine ECM receives signals from the machine input components and sends
corresponding signals to the machine output components to control several of the hydraulic
functions and the autoshift transmission.
NOTE: The Autoshift ECM has been eliminated. The power train is now controlled by
the Machine ECM.
The Machine ECM communicates on the Cat Data Link with Cat ET and on the J1939 CAN
Data Bus with Product Link (if equipped).
2/06
49
The Configuration screen in Cat ET shows the types of configurations that can be changed on
the "E" Series Backhoes. The left side of the screen also shows the available ECMs: Machine
Control, Product Link, and Shift Lever.
The configurations will be discussed later in the presentation.

2/06
50
This illustrations shows the Machine Status screen. Although the engine is not electronically
controlled, the Machine ECM monitors several engine parameters.
2/06
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POWER TRAIN
Standard Transmission
The standard countershaft transmission is similar to the "D" Series transmission. A forward
drive gear has been added to the countershaft, which increases the machine top speed to
40 km/h (25 mph) the same as the Autoshift transmission. The new gear is labeled in red for
both the two wheel drive transmission (top illustration) and All Wheel Drive (AWD)
transmission (bottom illustration).
The four-speed, direct drive, helical gear, constant mesh, synchronized standard transmission is
coupled with hydraulically engaged FORWARD and REVERSE clutches. Each multiple disc
clutch pack is controlled by a solenoid valve.
2/06
A manually actuated lever and shifter fork arrangement shifts the transmission through the four
fully synchronized speed ranges.
Power is transmitted from the torque converter to the input shaft. If FORWARD is selected, the
FORWARD clutch is engaged and power flows from the input shaft to the countershaft. The
countershaft causes all four speed gears to rotate. A synchronizer will engage one of the speed
gears with the output shaft. Power is then directed to the rear axle.
If the machine is equipped with All Wheel Drive (AWD), a separate shaft and clutch are
needed. An additional gear on the output shaft will transmit power to the AWD shaft.
A multiple disc clutch is part of the AWD shaft group. The clutch is hydraulically engaged and
spring released. A solenoid controlled valve (not shown) directs oil to pressurize or drain the
clutch. The solenoid is energized by the AWD switch on the left front console in the cab. The
front wheel drive axle can be engaged while the vehicle is moving by activating the AWD
switch.
2/06
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53
This illustration shows the power train hydraulic schematic for the standard transmission
equipped with two wheel drive.
Oil from the sump is drawn through a suction screen by a crescent-type gear pump located on
the transmission input shaft. From the pump, the oil is sent through a spin-on filter to the
transmission directional selector solenoid valve.
In NEUTRAL, the oil flow is blocked by the directional selector solenoid valve. Therefore, the
oil opens the relief valve and flows to the torque converter. A bypass orifice in the relief valve is
located between the supply circuit and torque converter circuit to make sure that oil is always
available to the torque converter when the machine is running.
The torque converter inlet relief valve protects the automotive-type torque converter from high
pressure (during cold start-up). Oil from the torque converter goes to the oil cooler, which is
located in front of the radiator.
From the cooler, the oil is used for lubrication. A passage directs lube oil to the input shaft of the
transmission. Oil from the shaft cools and lubricates the clutch assembly and input shaft bearings.
The output shaft, countershaft and reverse idler shaft are splash lubricated. The oil then returns to
the sump.
2/06
NOTE: The lines and fittings from the torque converter and the oil cooler are sized to
provide sufficient restriction to the oil in the torque converter. A torque converter outlet
relief valve is not required.
Modulating valves have been added to the directional selector solenoid valve. The modulating
valves improve clutch modulation, which results in smoother transmission shifting. The
modulating valves consists of a modulating relief valve, orifice, and load piston.
In this illustration with the directional selector spool shifted to the FORWARD position, oil
flows through an orifice and to the forward clutch. Oil also flows to one end of the modulating
relief valve and through an orifice to the other end of the modulating relief valve and to the load
piston.
As the oil flows into the clutch, pressure increases and the clutch begins to engage. Oil
pressure forces the modulating relief valve against spring force, which allows some oil to flow
through the relief valve to the tank.
Oil flows at a constant rate through the orifice to the load piston. The load piston moves at a
constant speed against spring force. The time it takes for the load piston to move down and
contact the stop is the hold time of the modulation valve.
The clutch fill time must be less than the hold time. When the load piston contacts the stop, the
large spring is compressed. When the load piston is completely down, the pressure increases to
system pressure. The relief valve limits the maximum clutch pressure.
2/06
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54
This illustration shows the power train hydraulic schematic for the standard transmission
equipped with All Wheel Drive (AWD).
The power train hydraulic system for AWD machines is the same as the two wheel drive
machines except for an external supply line which directs supply oil to the AWD solenoid
valve. When the solenoid is energized, oil engages the AWD clutch.
This schematic shows that the directional selector solenoid valve has been energized. Supply
oil flows through the valve to engage the FORWARD clutch.
2/06
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55
Autoshift Transmission
A torque converter (not shown) provides a fluid connection between the engine and the
transmission.
The five-speed forward, three-speed reverse autoshift transmission is a constant-mesh,

countershaft design. The transmission transfers power to the drive axles. The Machine ECM
electronically controls the transmission by selectively energizing speed and directional
solenoids. The transmission is equipped with three speed and three directional solenoids. One
speed solenoid and one directional solenoid must be simultaneously energized for a
transmission gear to be engaged.
Transmissions with the optional AWD system (shown in this illustration) are equipped with an
AWD solenoid and an additional output shaft.
NOTE: The reverse shaft and clutch are not shown in this sectional view. It is shown
later in this presentation.
2/06
1
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56
This illustration shows the power train hydraulic schematic for the autoshift transmission
equipped with two wheel drive.
Modulation valves have also been added to the forward low, forward high, and reverse clutch
solenoids. The modulation valves operate the same as previously described in the standard
transmission.
The Autoshift ECM has been eliminated. The autoshift transmission is now controlled by the
Machine ECM.
The Machine ECM contains the software to control transmission shifting. The software
compares the input information to the information stored in the Machine ECM to determine the
appropriate gear for the machine.
The Machine ECM then sends an output signal to energize solenoids for the appropriate clutch.
Through Cat ET, FIRST gear can be ENABLED or DISABLED.
2/06
FIRST gear is a relatively low (slow) gear ratio, and using it may not be necessary for normal
loader work or for roading. If using AUTOSHIFT for either loading or roading, disabling
FIRST gear eliminates an extra gear shift. In extreme hard digging conditions, the neutralizer
button can be used to downshift to FIRST, and then AUTOSHIFT will upshift the transmission
as the machine speed increases.
In summary, disabling FIRST makes the machine more responsive, smoother, and efficient
(more productive). Use FIRST gear only when required.
2/06
1
; +1 1
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*$!! ' &!$"!$ ! !% ;# &!
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57
This illustration shows the power train hydraulic schematic for the autoshift transmission
equipped with All Wheel Drive (AWD).
The power train hydraulic system for AWD machines is the same as the two wheel drive
machines except for the AWD solenoid and clutch. When the AWD solenoid is energized, oil
engages the AWD clutch.
This schematic shows the No. 1 and No. 4 solenoids energized to engage the forward low
directional clutch and the No. 1 speed clutch to obtain FIRST SPEED FORWARD. The relief
valve limits the maximum clutch pressure.
2/06
!&!$/! -"*)
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58
The five-speed forward, three-speed reverse transmission is equipped with six clutch packs.
The autoshift transmission uses six solenoids to control the engagement of the clutch packs.
Two clutch packs must be simultaneously engaged for the transmission to drive the machine.
The above chart shows the energized solenoids and the engaged clutch packs for each gear.
The solenoids are controlled by the Machine ECM.
In NEUTRAL, none of the solenoids are energized.
The chart can be used to identify which solenoids are energized to engage the speed and
direction clutches to obtain the desired speed range.
NOTE: The Machine ECM does not provide shift protection on the "E" Series. Shift
protection prevents the operator from changing directions at high speeds.
2/06
1'$:#$( ':
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: "*)
$# /4 // '
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59
This illustration shows the inputs and outputs used by the Machine ECM to control the
autoshift transmission.
The autoshift transmission has two modes of operation: Automatic and Manual. The modes
are selected using the autoshift control switch on the right side of the front dash.
In the Automatic Mode, the operator controls the highest desired gear and the transmission
control automatically selects the proper gear based on machine ground speed. The transmission
determines the ground speed through the transmission speed sensors and energized speed clutch.
In the Manual Mode, the transmission operates very similar to the standard power shift
transmission.
When the key start switch is ON, the transmission shift lever control provides an input signal to
the Machine ECM. The Machine ECM uses the shift lever control input to determine the gear
range selected on the transmission shift lever and the position of the key start switch. If the shift
lever control is not in NEUTRAL during starting, the Machine ECM will prevent the machine
from starting.
2/06
The parking brake switch provides an input signal to the Machine ECM. The Machine
ECM prevents the transmission from shifting if the parking brake is engaged and also
energizes the parking brake relay to sound the alarm.
The transmission neutral lock switch also provides an input signal to the Machine
ECM. If the transmission neutral lock switch is moved to the LOCK position, the
Machine ECM shifts the transmission into NEUTRAL and prevents the transmission
from shifting, regardless of the position of the shift lever control. The Machine ECM
will not shift the transmission until after the shift lever control is moved into the
NEUTRAL position and the transmission neutral lock switch is moved to the
UNLOCK position.
When the transmission neutralizer switch is activated by the operator, the

transmission will momentarily neutralize by de-energizing the direction clutch. Only
the directional clutch is de-energized. This will improve shift speed when the button
is released and the machine is placed back into gear. In the Manual Mode, the
Downshift/Neutralizer Switch will not permit the transmission to be downshifted.
The transmission speed sensor provides output speed information to the Machine
ECM. In the Automatic Mode, the operator controls the highest desired gear and the
transmission control automatically selects the proper gear based on machine ground
speed. The Machine ECM determines the ground speed through the transmission
speed sensors and energized speed clutch.
The Machine ECM uses the input signals described above to control transmission
shifting through the transmission solenoid valves.

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February 2006

GLOBAL SERVICE LEARNING

"E" SERIES BACKHOE LOADERS

STMG "Distributor-type Mechanical Fuel Pump - 3044C/3046

"Fundamentals of Engines Self Study Course" TEMV3001

Estimated Time: 16 Hours

© 2006 Caterpillar Inc.

ELECTRICAL SYSTEM ........................................................................................................... 45

POWER TRAIN ......................................................................................................................... 51

416E/422E/428E IMPLEMENT HYDRAULIC SYSTEM ....................................................... 77

420E/430E/432E/434E/442E/444E IMPLEMENT HYDRAULIC SYSTEM......................... 113

STEERING SYSTEM ............................................................................................................. . 163

HYDRAULIC SCHEMATIC COLOR CODE......................................................................... 171

HANDOUTS..................................................................................................................... ........ 173

"E" SERIES BACKHOE LOADERS

© 2006 Caterpillar Inc.

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The 420E/430E/432E/434E/442E/444E machines are equipped with hydraulically assisted

2 5!$#"'$6/ "#" '

The 420E/430E/432E/434E/442E/444E machines are now equipped with hydraulically assisted

- Air conditioning compressor (1) - Hydraulic oil cooler (5)

- Cold start temperature switch (2) - Coolant temperature sender (6)

- Oil pressure switch (4) - Transmission oil cooler (8)

Provisions for mounting a hydraulically controlled thumb is standard equipment on some

The stabilizers (2) are now externally adjustable.

Other cab features include:

- Automotive style finish

- Air Suspension seat

- Low effort machine controls

- Personal storage space

- Joystick pattern switch (pilot controlled machines)

- Continuous flow for auxiliary functions (optional)

The front of the cab includes the features described below.

Also visible is the optional AWS position indicator gauge (6).

To the left of the steering column are the following components:

- Quick coupler switch (1) (if equipped)

- Continuous loader flow switch (2)

- 12 volt auxiliary circuit switch (3) (if equipped)

- Transmission neutral switch (4)

- Broom angle control switch (5) (if equipped)

To the right of the steering column are the following components:

- Autoshift switch (1) (if equipped)

- Ride control switch (2) (if equipped)

- Roading lights switch (3) (if equipped)

- Horn switch (4) (if equipped)

- All Wheel Steer control switch (5) (if equipped)

- All Wheel Steer indicators (6) (if equipped)

- Loader joystick (1)

- Parking brake lever (2)

- Switch panel (3)

- Gauge cluster (4)

- Governor lever (5)

- Left stabilizer control lever (6)

- Right stabilizer control lever (7)

- Boom lock lever (8)

The joystick excavator pattern is:

Left joystick: Right joystick:

- Forward: Stick out - Forward: Boom lower

The joystick backhoe pattern is:

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