CAT E Series Backhoe Intraduction

SERVXXX February 2006

GLOBAL SERVICE LEARNING TECHNICAL PRESENTATION

"E" SERIES BACKHOE LOADERS INTRODUCTION

PRELIMINARY Service Training Meeting Guide (STMG)

"E" SERIES BACKHOE LOADERS 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" "Fundamentals of Mobile Hydraulics Self Study Course" "Fundamentals of Power Train Self Study Course" "Fundamentals of Electrical Systems Self Study Course"

Estimated Time: 16 Hours Illustrations: XX Handouts: XX Form: SERVXXX Date: 02/06 © 2006 Caterpillar Inc.

TEMV3001 TEMV3002 TEMV3003 TEMV3004

SERVXXX 2/06

-3-

Text Reference

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

SERVXXX 2/06

-4-

NOTES

Text Reference

SERVXXX 2/06

-5-

Text Reference

"E" SERIES BACKHOE LOADERS INTRODUCTION

© 2006 Caterpillar Inc.

1

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.

SERVXXX 2/06

-6-

Text Reference

"E" SERIES BACKHOE LOADER MACHINE SYSTEMS MODEL 416E

420E

LOADER LINKAGE

BACKHOE LOADER BACKHOE POWER TRAIN STEERING LINKAGE HYDRAULICS HYDRAULICS

Single Tilt Center Pivot Single Tilt Parallel Lift

Center Pivot

Mechanical

Pilot

Mechanical Mechanical Pilot

2WD AWD

2WS

2WD AWD

2WS

ENGINE 3054C NA 3054C Turbo 3054C Turbo 3054C NA

BRAKES No Boost

Boosted

422E

Single Tilt

Side Shift

Mechanical

Mechanical

2WD or AWD

2WS

428E

Parallel Lift

Side Shift

Mechanical

Mechanical

AWD

2WS

3054C Turbo

No Boost

Center Pivot

Pilot

AWD

2WS

3054C Turbo

Boosted

2WS / AWS 3054C Turbo

Boosted

3054C Turbo

Boosted

2WS/AWS 3054C Turbo

Boosted

3054C Turbo

Boosted

430E

Single Tilt Parallel Lift

Mechanical Pilot

432E

Parallel Lift

Side Shift

Pilot

Pilot

AWD

434E

Parallel Lift

Side Shift

Pilot

Pilot

AWD

442E

Parallel Lift

Side Shift

Pilot

Pilot

AWD

444E

Parallel Lift

Side Shift

Pilot

Pilot

AWD

AWS

AWS

3054C Turbo

No Boost

2

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.

SERVXXX 2/06

-7-

Text Reference

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.

SERVXXX 2/06

-8-

Text Reference

SIMILARITIES WITH FORMER MACHINES -

Engine

-

Steering System

-

Ride Control

-

Maintenance

3

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.

SERVXXX 2/06

-9-

Text Reference

DIFFERENCES FROM FORMER MACHINES -

Operator’s Station

-

E-Stick

-

Electrical System

-

Transmission

-

Rear Axle

-

Joysticks

-

Pattern Switching Valve

-

Brake Master Cylinders

-

Steering and Implement Pump

-

PPPC Implement Hydraulic System

-

Powered Sideshift Option

4

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 2/06

- 10 -

Text Reference

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.

SERVXXX 2/06

- 11 -

Text Reference

5

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.

SERVXXX 2/06

- 12 -

Text Reference

1

6

2

3

7 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)

SERVXXX 2/06

- 13 -

Text Reference

8

1

9 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.

SERVXXX 2/06

- 14 -

Text Reference

1

10 2 5 3 4

6

7 8

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)

11

SERVXXX 2/06

- 15 -

Text Reference

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.

SERVXXX 2/06

- 16 -

Text Reference

1 3 4 4

2

1

5

4

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.

SERVXXX 2/06

- 17 -

Text Reference

2

1

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.

SERVXXX 2/06

- 18 -

Text Reference

1

3 2 3

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.

SERVXXX 2/06

- 19 -

Text Reference

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

SERVXXX 2/06

- 20 -

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

Text Reference

SERVXXX 2/06

- 21 -

Text Reference

6 1

2 3

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).

SERVXXX 2/06

- 22 -

Text Reference

6

1 2

3

4

5

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.

SERVXXX 2/06

- 23 -

1

Text Reference

3

2

7

4

5 6

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).

SERVXXX 2/06

- 24 -

2

Text Reference

3

1

4

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)

SERVXXX 2/06

- 25 -

Text Reference

4

2

6 5 1 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)

7

SERVXXX 2/06

- 26 -

4

3

20

Text Reference

6

2

5

1

9 8

7

12

13

10 11

14

15

16

17

18

19

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)

SERVXXX 2/06

- 27 -

1

4

Text Reference

2

3

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.

SERVXXX 2/06

- 28 -

Text Reference

1 3

2

24

25

4

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).

SERVXXX 2/06

- 29 -

Text Reference

7

3 4

1

2

5

6

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.

SERVXXX 2/06

- 30 -

1

Text Reference

1

6 27

5

3

2 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).

SERVXXX 2/06

- 31 -

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

Text Reference

SERVXXX 2/06

- 32 -

1

Text Reference

2

29

30

3

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.

SERVXXX 2/06

- 33 -

Text Reference

31 1 3

2 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).

SERVXXX 2/06

- 34 -

Text Reference

1

33

3 2

34 1

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.

SERVXXX 2/06

- 35 -

Text Reference

35

1 3 2

5

4

6 7 10

36 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)

SERVXXX 2/06

- 36 -

Text Reference

- 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.

SERVXXX 2/06

- 37 -

Text Reference

4 2

3

1

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.

SERVXXX 2/06

- 38 -

Text Reference

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)

SERVXXX 2/06

- 39 -

Text Reference

39

1 2

3

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.

SERVXXX 2/06

- 40 -

Text Reference

2

1

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.

SERVXXX 2/06

- 41 -

Text Reference

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).

SERVXXX 2/06

- 42 -

Text Reference

2

1

42

42A

3

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.

SERVXXX 2/06

- 43 -

Text Reference

FUEL INJECTION PUMP

3054C NATURALLY ASPIRATED ENGINE Flyweight

Control Lever

Governor Lever Full-load Adjusting Screw

Drive Shaft

Engine Shutoff Solenoid

Distributor Head Control Sleeve Feed Pump Plunger

Roller Holder Cam Plate

Timing Advance Mechanism

Plunger Return Spring

Delivery Valve

High Pressure Pump Chamber

43

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.

SERVXXX 2/06

- 44 -

Text Reference

FUEL INJECTION PUMP 3054C TURBOCHARGED ENGINE

Governor Spring

Low Idle Stop

High Idle Stop

Throttle Lever Metering Valve Fuel Shutoff Solenoid

Vent Orifice

Fuel Inlet

Fuel Return Check Valve

Transfer Pressure Regulator

Scroll Link Plate

Screen Transfer Pump

Drive Shaft Shifter and Sleeve

Plungers To Injector

Governor Flyweights

Shoes Scroll Plates

Rollers

Cam Ring

Automatic Advance Mechanism

Orifice Check Valve

44

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.

SERVXXX 2/06

- 45 -

Text Reference

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.

SERVXXX 2/06

- 46 -

Text Reference

"E" SERIES STARTING AND CHARGING SYSTEM EMISSIONS ENGINE / START

123-EF53 WH G

S

Mtr

309 GY To Lamp Group

Bat

Motor

101-EF9 RD 304 WH

Starter

Pos Neg

1 5 2 4 3

Pos Neg D+

450-YL

W

308 YL

B+

Power Module 1

CBL CC1 RD

Power Module 2

B+

Fuel Lift Pump Relay

B+ 123-EF18 WH

1 2 3 4 5 6 7 8 9 10 11 12

Alternator

TachR

Start Relay

Battery Ground Forward Sol Return Reverse Sol Return Forward Sol. Out Reverse Sol. Out Start Relay Out Key Start Sw. Start Not Used Not Used Not Used Not Used

Excitation Resistor

1 2

CBL LL1 RD

CBL AA1 RD

60 A

60 A

60 A

60 A

1 5 2 4 3

308 YL 202 BK

X977 YL 308 YL

1 2

1 2

306 GN

307 OR USB

SB

USB

1 2

1 2

Fuel Lift Pump

Fuel Lift Pump Arc Suppressor

SB

Motor

146-PA2 RD

Shuttle Control

146-PA6 RD

Cold Start Advance Solenoid

123-EF23 WH

103-PA20 RD 103-PA1 RD

Fuse Block Key Start Switch

123-EF28 WH Key Start

Off On St

C S B

1 2 3 4

308 YL

20 A

307 OR 105 RD

Machine ECM

Lift Pump

Cold Start Temp. Sw.

A B

101-EF11 RD 123-EF10 WH

Cold Start Advance Solenoid

1 5 2 4 3

146-PA2 RD 310 PU

15 A

334 BU °T

1 2

Fuel Shutoff Solenoid

10 A

R

123 WH

Start Aid Switch

384 BU

Start Aid Relay

1

Glow Plugs

46

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.

SERVXXX 2/06

- 47 -

Text Reference

3 1

2

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).

SERVXXX 2/06

- 48 -

Text Reference

"E" SERIES BHL MACHINE ECM INPUTS AND OUTPUTS Quick Coupler Relay

Transmission Output Speed Sensor Transmission Auto / Manual Switch

Transmission Forward Low Clutch Solenoid

Hydraulic Oil Temperature Sensor

Transmission Reverse Clutch Solenoid

Stabilizer Neutral Switch Loader Quick Coupler Pins Switch

Loader Auxiliary Valve Solenoid 1 Loader Auxiliary Valve Solenoid 2

Continuous Flow Switch

Backhoe Auxiliary Valve 1 Solenoid 1

Ride Control Switch

Backhoe Auxiliary Valve 1 Solenoid 2

Park Brake Switch

Backhoe Auxiliary Valve 2 Solenoid 1

Transmission Lock Switch

Backhoe Auxiliary Valve 2 Solenoid 2

Implement Lockout Switch

Transmission Forward High Clutch Solenoid

Alternator W Terminal

Feature Alarm

Key Start Switch (+BAT)

Transmission Speed Clutch Solenoid 1

Hydraulic Oil Filter Bypass Switch Loader Joystick Thumb Switch Machine Handle Attachment (8th Function) Switch Transmission Shift Lever

Transmission Speed Clutch Solenoid 2 Machine ECM

Transmission Speed Clutch Solenoid 3 Ride Control Relay Action Lamp Implement Enable Relay

Engine Oil Pressure Switch Engine Coolant Temperature Switch

Backup Alarm Relay

Brake Fluid Level Switch

Hydraulic Filter Bypass Indicator

Air Filter Switch

Torque Limiter Relay

Fuel Water Separator Switch

Hydraulic Temperature Indicator

Right Joystick (7th Function) Switch Right Joystick Neutralize Switch

CAT Data Link CAN Data Link

CAT ET Product Link (If Equipped)

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).

SERVXXX 2/06

- 49 -

Text Reference

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.

SERVXXX 2/06

- 50 -

Text Reference

50

This illustrations shows the Machine Status screen. Although the engine is not electronically controlled, the Machine ECM monitors several engine parameters.

SERVXXX 2/06

- 51 -

Torque Converter Housing

Text Reference

Forward Clutch

Idler Shaft Reverse Clutch

Pump

STANDARD BACKHOE LOADER TRANSMISSION TWO WHEEL DRIVE

Input Shaft

51

Countershaft Output Shaft

Forward Drive Gear

Speed Gear Synchronizer Assembly

Torque Converter Housing

Forward Clutch

Idler Shaft Reverse Clutch

Pump

STANDARD BACKHOE LOADER TRANSMISSION ALL WHEEL DRIVE

Input Shaft

52

Countershaft Output Shaft

Forward Drive Gear

Speed Gear Synchronizer Assembly

AWD Shaft

AWD Clutch

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.

SERVXXX 2/06

- 52 -

Text Reference

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.

SERVXXX 2/06

- 53 -

Text Reference

STANDARD POWER TRAIN HYDRAULIC SYSTEM

Load Piston Flow Control Orifice

FORWARD

R Modulating Relief Valves

Filter

F Relief Valve

Pump Supply Pump

Suction Screen

Directional Selector Solenoid Valve

Torque Converter Inlet

Torque Converter Inlet Relief Valve

Transmission Lube Lube

Oil Cooler

Load Piston

Torque Converter

Torque Converter Outlet

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.

SERVXXX 2/06

- 54 -

Text Reference

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.

SERVXXX 2/06

- 55 -

Text Reference

STANDARD POWER TRAIN HYDRAULIC SYSTEM

Load Piston Flow Control Orifice

ALL WHEEL DRIVE/FORWARD

R Modulating Relief Valves

Filter

F Relief Valve

Directional Selector Solenoid Valve

AWD Soleniod Valve

Pump Supply

AWD

Pump

Suction Screen

Torque Converter Inlet

Torque Converter Inlet Relief Valve

Transmission Lube Lube

Oil Cooler

Load Piston

Torque Converter

Torque Converter Outlet

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.

SERVXXX 2/06

- 56 -

Text Reference

AUTOSHIFT TRANSMISSION Solenoid Valves Pump Input Shaft

Counter Shaft

Output Shaft

AWD Shaft

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.

SERVXXX 2/06

- 57 -

Text Reference

AUTOSHIFT POWER TRAIN HYDRAULIC SYSTEM Data Link Service Port

FIRST GEAR FORWARD LOW

Shift Lever

Parking Brake Switch

Ride Control Switch

Downshift / Neutralizer Switch

Machine ECM

Auto / Manual Switch

Transmission Output Speed Sensor

Neutral Lock Switch

Ride Control Disable

Regulated Pressure Orifice Filter

5

6

3

Speed Clutch 3 Solenoid

Speed Clutch 2 Solenoid

Forward High 2 Clutch Solenoid

Reverse Clutch Solenoid

1

Forward Low Clutch Solenoid

1

3 Pump Supply

4

Load Piston

2 Modulating Relief Valve

Load Piston

Load Piston

Modulating Relief Valves

Relief Valve

LO R Pump Suction Screen

Speed Clutch 1 Solenoid

Torque Converter Inlet

HI

Transmission Lube

Oil Cooler

Lube

Torque Converter Torque Converter Outlet

Torque Converter Inlet Relief Valve

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.

SERVXXX 2/06

- 58 -

Text Reference

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.

SERVXXX 2/06

- 59 -

Text Reference

AUTOSHIFT POWER TRAIN HYDRAULIC SYSTEM ALL WHEEL DRIVE/FIRST SPEED FORWARD Data Link Service Port Shift Lever

Parking Brake Switch

Ride Control Switch

Downshift / Neutralizer Switch

Machine ECM

Auto / Manual Switch

Transmission Output Speed Sensor

Neutral Lock Switch

Ride Control Disable

Regulated Pressure Orifice Filter

5

6

3

Speed Clutch 3 Solenoid

Speed Clutch 2 Solenoid

Reverse Clutch Solenoid

Forward High 2 Clutch Solenoid

1

Forward Low Clutch Solenoid

4

1

3

Load Piston

2 AWD

Modulating Relief Valve

Load Piston

Load Piston

Modulating Relief Valves

Relief Valve

LO Pump Supply Pump Suction Screen

Speed Clutch 1 Solenoid

R

Torque Converter Inlet

HI

Transmission Lube

Oil Cooler

Lube

Torque Converter Torque Converter Outlet

Torque Converter Inlet Relief Valve

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.

SERVXXX 2/06

- 60 -

Text Reference

Reverse Clutch

AUTOSHIFT TRANSMISSION

Forward High Clutch

Forward Low Clutch

Input Shaft Clutch 1

CLUTCH ENGAGEMENT Gear

Forward Forward Low High Reverse

5F

X

4F

2

X

3F

X

2F 1F

1

3 X

2 AND 6

X

1 and 6

X

X X

Counter Shaft

Solenoid Clutch 3

Output Shaft

2 and 5

X

2 and 4

X

1 and 4

N

AWD Clutch

­­

1R

X

2R

X

3R

X

X

Clutch 2

3 and 4 X

AWD Shaft

3 and 5 X

3 and 6

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.

SERVXXX 2/06

- 61 -

Text Reference

AUTOSHIFT ELECTRONIC TRANSMISSION CONTROL SYSTEM Key Start Switch

Forward Low No. 1 Solenoid

Transmission Shift Lever

Forward High No. 2 Solenoid Parking Brake Switch Neutral Lock Switch

Start Relay

Transmission Output Speed Sensor Autoshift Control Switch Transmission Neutralizer Switch

Reverse No. 3 Solenoid

Machine Electronic Control Module

Speed Clutch 1 No. 4 Solenoid Speed Clutch 2 No. 5 Solenoid Speed Clutch 3 No. 6 Solenoid Park Brake Alarm Relay

Cat Data Link

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.

SERVXXX 2/06

- 62 -

Text Reference

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.

SERVXXX 2/06

- 63 -

Text Reference

60

The Machine ECM status screens that are available to aid in autoshift transmission diagnosis are: - Transmission Basic - Transmission Neutralizer - Transmission Speed - Transmission Solenoids

SERVXXX 2/06

- 64 -

Text Reference

61

This transmission status screen shows the neutral status of the autoshift transmission.

SERVXXX 2/06

- 65 -

Text Reference

62

This transmission status screen shows the autoshift transmission gear status, engine speed, transmission output speed, and the ground speed/machine direction.

SERVXXX 2/06

- 66 -

Text Reference

63

This transmission status screen shows the status of the autoshift transmission solenoids in amps.

SERVXXX 2/06

- 67 -

Text Reference

64

This shift lever status screen shows the autoshift transmission gear lever status and load lever position.

SERVXXX 2/06

- 68 -

Text Reference

AUTOSHIFT TRANSMISSION 1ST GEAR ENABLED

Shift Lever Position 4F

Gears Available 1, 2, 3, 4, 5

3F

1, 2, 3

2F

1, 2

1F

1

N 1R

1

2R

1, 2

3R

1, 2, 3

65

With FIRST gear enabled, the following gears are available in the given conditions. Shift lever in FIRST: The transmission will be held in FIRST gear. Shift lever in SECOND: The transmission will automatically shift between FIRST and SECOND in response to machine speed. Shift lever in THIRD: The transmission will automatically shift between FIRST, SECOND and THIRD in response to machine speed. The downshift switch can be used to force the transmission into FIRST or SECOND gear. Shift lever in FOURTH: The transmission will automatically shift between FIRST through FIFTH in response to machine speed. THIRD gear may be skipped by the software. The downshift switch can be used to force the transmission into FIRST, SECOND, THIRD or FOURTH gear. Whenever a machine is downshifted into a lower gear, the machine maximum gear will be limited to the lower gear for five seconds, then return to normal Automatic Mode.

SERVXXX 2/06

- 69 -

Text Reference

AUTOSHIFT TRANSMISSION 1ST GEAR DISABLED

Shift Lever Position 4F

Gears Available 2, 3, 4, 5

3F

2, 3

2F

2

1F

1

N 1R

1

2R

2

3R

2, 3 66

With FIRST gear disabled, the following gears are available in the given conditions. Shift lever in FIRST: The transmission will be held in FIRST. Shift lever in SECOND: The transmission will be held in SECOND unless the operator forces the transmission into FIRST through the downshift switch. Shift lever in THIRD: The transmission will automatically shift between SECOND and THIRD in response to machine speed. The downshift switch can be used to force the transmission into FIRST or SECOND gear. Shift lever in FOURTH: The transmission will automatically shift between SECOND through FIFTH in response to machine speed. THIRD gear may be skipped by the software. The downshift switch can be used to force the transmission into FIRST, SECOND, THIRD or FOURTH gear. If the machine is downshifted into a lower gear, upshifts will be disabled for five seconds, then return to normal Automatic Mode.

SERVXXX 2/06

- 70 -

Text Reference

1 2

1

67

Axles and Brakes The rear final drive planetary gears (1) have been moved outboard of the differential (2). There are now separate reservoirs for final drive and differential gear oil. Brake inspection ports have been added to the axle. The inspection ports allow for brake wear measurements with the axle installed in the machine. The differential lock can now be engaged on the move in either first or second gear, which improves differential lock functionality. NOTE: The differential lock must not be engaged in third or fourth gear. On machines with the autoshift transmission, the Machine ECM may limit the differential lock function depending on the selected gear.

SERVXXX 2/06

- 71 -

Text Reference

1

1

2

3

68

The brake inspection ports (1) are accessible from the rear with the axle installed in the machine. The differential oil level/fill plug (2) and drain plug (3) are also located at the rear of the axle.

SERVXXX 2/06

- 72 -

Text Reference

BOOSTED BRAKES VALVE GROUP

RIGHT BRAKE ENGAGED / LEFT BRAKE RELEASED

To Left Wheel Brake Left Brake Pedal

Boost Brake Valve

Slave Cylinder

Master Cylinder Bridge Passage Master Cylinder

Slave Cylinder To Right Wheel Brake

Right Brake Pedal

Boost Brake Valve To Tank From Pilot Accumulator

69

The 420E/430E/432E/434E/442E and 444E machines are equipped with hydraulically assisted master cylinders, which decreases the amount of pedal effort when braking. This illustration shows the boosted brakes valve group, which 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. In this illustration, the right brake is engaged and the left brake is released. When the brake pedal is depressed, the brake linkage moves the brake boost valve to the right. Oil is directed from the pilot accumulator to the large chamber of the master cylinder. The distance that the brake pedal is depressed, determines the amount of oil flow to the master cylinder. The master cylinder piston moves to the right and forces the slave cylinder to the right (hydraulic assist). Oil in the master cylinder spring chamber flows to the tank. The slave cylinder directs oil to brake piston to engage the brakes and blocks the oil in the brake circuit from returning to tank.

SERVXXX 2/06

- 73 -

Text Reference

The oil in the brake circuit between the slave cylinder and wheel brake is a closed circuit. When the brakes are released, the slave cylinder moves to the left and oil from the brake piston returns to the slave cylinder. With the slave cylinder in the released position, the oil in the brake circuit (between the slave cylinder and wheel brake) can flow between the right and left brake circuits only (closed circuit). The bridge passage connects the slave cylinders together, which allows the pressures to equalize when both brake pedals are depressed at the same time. When the brakes are released, the master cylinder piston moves to the right and oil in the master cylinder chamber is drained to tank through the boost brake valve. NOTE: The master cylinders on the 416E/422E/428E machines are not hydraulically assisted.

SERVXXX 2/06

- 74 -

Text Reference

BOOSTED BRAKES GROUP To Wheel Brake

Slave Cylinder

To Tank

From Pilot Accumulator

Boost Brake Valve

Master Cylinder

70

This illustration shows a sectional view of the boosted brake valve group. When the brake pedal is depressed, the boost brake valve moves to the left and inlet oil from the pilot manifold is directed to the master cylinder.

SERVXXX 2/06

- 75 -

1

Text Reference

3 2

4

5

71

The brake boost valves are connected to the master cylinder (1) at each brake pedal (2). Oil enters the master cylinder through the supply hose (3) and exits the master cylinder through the return hose (4). The oil flows to the service brakes through the hoses (5) at the bottom of the master cylinder. The master cylinders can be removed from the machine from inside the operator's compartment.

SERVXXX 2/06

- 76 -

Text Reference

72

The 416E/422E machine brakes are not hydraulically assisted and are equipped with a brake reservoir. The brake reservoir (arrow) is located at the rear of the engine compartment.

SERVXXX 2/06

- 77 -

Text Reference

416E / 422E / 428E BACKHOE LOADER HYDRAULIC SYSTEM

Pump

Tank

E-stick Cooler

Stick Bucket

HMU

Swing

Back Pressure Check Valve

Boom Aux Inlet Manifold Right Stabilizer Left Stabilizer

I n l e t

Sideshift Lock Pistons (422E / 428E)

L i f t

T i l t

A u x

Parallel Lift (428E)

Single Tilt (416E / 422E)

Ride Control

73

416E/422E/428E IMPLEMENT HYDRAULIC SYSTEM This illustration shows a block diagram of the 416E/422E/428E machines which are equipped with mechanically controlled loader and backhoe valves. The 422E/428E sideshift machines include lock pistons to lock the backhoe on the slider. The 416E and 422E machines include a single tilt loader. The 428E is equipped with a parallel lift loader. The standard loader valve group contains two control valves. Three control valves are installed on the machine if equipped with the auxiliary function. The priority valve is also contained within the loader control valve. The standard backhoe valve group contains six control valves. Seven or eight control valves are installed in the backhoe valve group if the machine is equipped with an E-Stick and/or an auxiliary valve.

SERVXXX 2/06

- 78 -

Text Reference

"E" SERIES BACKHOE LOADER SIGNAL NETWORK 416E / 422E / 428E MECHANICALLY CONTROLLED VALVES

Right Stabilizer

Left Stabilizer

Aux

Boom

Swing

Bucket

Stick

E-Stick

Backhoe Section Loader Aux

Loader Tilt

Loader Lift

HMU

Loader Section

Pump Control Valve

74

This illustration shows the resolver signal network in the 416E/422E/428E machines. The resolver signal network is similar to late production "C" Series machines. A signal line from the backhoe section and a signal line from the loader section are connected to a tee which is equipped with a resolver. The highest resolved signal between the two valve sections flows to the pump.

SERVXXX 2/06

- 79 -

Text Reference

75

Implement and Steering Pump The implement and steering pump on the 416E/422E/428E machines is a similar design and operates the same as the pump on the "A" Series machines. The pump is located below the cab floor plate. The pump control valve is mounted on top of the pump and contains a flow compensator spool and pressure cutoff spool. The implement and steering pump supplies oil flow to the loader valve group, backhoe valve group, and steering system.

SERVXXX 2/06

- 80 -

Text Reference

416E / 422E / 428E IMPLEMENT / STEERING PUMP ENGINE OFF

Load Sensing Signal To Backhoe Valve Flow Compensator

Pressure Cutoff

Pump Group

76

This illustration shows the 416E/422E/428E pump hydraulic circuit with the engine OFF. When the pump is OFF, a spring holds the swashplate at maximum angle. The pump control valve contains two spools. The flow compensator (margin spool) regulates output flow in response to the load signal received through the signal network. The flow supplied by the pump will be the amount of flow required to keep supply pressure above the signal pressure. The difference between supply pressure and the signal pressure is called "margin pressure." The pressure cutoff spool limits maximum system pressure and serves as the relief valve for the system. Both spools have adjustment screws. Low pressure standby and margin pressure are controlled by the flow compensator. The flow compensator will simultaneously increase or decrease both pressures, but not necessarily by the same amount.

SERVXXX 2/06

- 81 -

Text Reference

416E / 422E / 428E IMPLEMENT/STEERING PUMP LOW PRESSURE STANDBY

Load Sensing Signal To Backhoe Valve Flow Compensator

Pressure Cutoff

Pump Group

77

As the pump produces oil flow, system pressure begins to build because oil flow is blocked at the implement control valves. This pressure is felt at the margin spool and the pressure cutoff spool. The margin spool moves right against the low spring force and permits system oil to flow to the actuator piston. As pressure in the actuator piston increases, the piston overcomes the bias spring force and moves the swashplate to a reduced angle. When no flow is demanded from the implements, no signal pressure is generated. At this minimum swashplate angle, the pump produces enough flow to compensate for system leakage at a pressure to provide instantaneous implement response when an implement is activated.

SERVXXX 2/06

- 82 -

Text Reference

416E /422E /428E IMPLEMENT /STEERING PUMP UPSTROKE Load Sensing Signal To Backhoe Valve Flow Compensator

Pressure Cutoff

Pump Group

78

When an implement is activated, a signal is sent to the pump control valve. This signal plus the margin spring force overcomes the supply pressure at the left end of the spool. The spool then moves to the right, blocks the oil flow to the actuator and opens a passage to drain. Pressure at the actuator piston is reduced or eliminated which allows the bias spring to move the swashplate to an increased angle. The pump upstrokes to produce more flow.

SERVXXX 2/06

- 83 -

Text Reference

416E / 422E / 428E HYDRAULIC SYSTEM CONSTANT FLOW

Load Sensing Signal To Backhoe Valve Flow Compensator

Pressure Cutoff

Pump Group

79

As pump flow increases, pump supply pressure also increases. When the pump supply pressure increases and equals the sum of the signal pressure plus the margin spring pressure, the margin spool moves to a metering position and the system becomes stabilized. The swashplate is held at a relatively constant angle to maintain the required flow. The difference between the signal pressure and the pump supply pressure is the value of the margin spring.

SERVXXX 2/06

- 84 -

Text Reference

416E / 422E / 428E IMPLEMENT / STEERING PUMP DESTROKE

Load Sensing Signal To Backhoe Valve Flow Compensator

Pressure Cutoff

Pump Group

80

When less oil flow is needed, the pump destrokes. When signal pressure decreases, oil pressure moves the margin spool to the right. The actuator piston then overcomes spring force and moves the swashplate to a reduced angle. The pump produces less flow. As pump flow decreases, pump supply pressure also decreases. When the pump supply pressure decreases and becomes the sum of load pressure plus margin pressure, the margin spool moves to a metering position and the system stabilizes.

SERVXXX 2/06

- 85 -

Text Reference

416E / 422E / 428E HYDRAULIC SYSTEM HIGH PRESSURE STALL Load Sensing Signal To Backhoe Valve Flow Compensat or

Pressure Cut off

Pump Group

81

The pressure compensator or cutoff spool is in parallel with the margin spool. The pressure compensator limits the maximum system pressure for any pump displacement. The pressure compensator spool is forced down during normal operation by the pressure cutoff spring. During a stall or when system pressure is maximum, signal pressure is equal to pump supply pressure. The combination of the signal pressure and the margin spring forces the margin spool to the left. This movement of the margin spool normally opens a passage in the pump control valve for the oil in the actuator piston to drain, causing the pump to upstroke. However, since the supply pressure is high enough, the pressure cutoff spool is now forced to the right against the spring. The movement of the pressure cutoff spool blocks the oil from the actuator piston from going to drain and allows supply oil to the actuator. Oil pressure at the actuator allows it to overcome spring force to destroke the pump. The pump is now at minimum flow and pump supply pressure is at maximum. This condition is maintained for a single implement in a stall condition.

SERVXXX 2/06

- 86 -

Text Reference

82

Mechanical Loader Valve Group The 416E/422E/428E machines are equipped with a mechanically controlled loader valve that is accessed from below the floor plate. This illustration shows the auxiliary control lever (1) and loader joystick (2) connected to the loader valve linkage (4). The loader control valve group contains an inlet manifold (5), lift control valve (6), tilt control valve (7), and auxiliary control valve (8, if equipped). The transmission neutralizer switch (3) is also located on the loader joystick.

SERVXXX 2/06

- 87 -

1

Text Reference

2

83

The loader joystick (1) controls the position of the lift and tilt valve spools in the loader control valve. The auxiliary control lever (2) controls the position of the auxiliary valve spool.

SERVXXX 2/06

From Backhoe Valve

- 88 -

Text Reference

To From Backhoe Backhoe Valve Valve

To Backhoe Valve

From Backhoe Valve

Load Sensing Relief Valve

Ride Control Valve

Flow Compensator

Priority Valve

To HMU

Oil Filter

Oil Cooler Pressure Cutoff

Lift Cylinders Lift Valve

Pump Group

Pressure Compensator

Tilt Cylinders (Parallel Lift 428E)

Line Relief Valves

Tilt Cylinder (Single Tilt 416E / 422E)

MP Bucket Cylinders

Pressure Compensator

Tilt Valve

416E / 422E / 428E HYDRAULIC SYSTEM MECHANICALLY CONTROLLED LOADER VALVE HOLD

Line Relief Valve

Pressure Compensator

Auxiliary Valve

84

This illustration shows the mechanically controlled loader valve on the 416E/422E/428E machines. The loader valve is closed-center and pressure compensated. The loader valve includes the lift and tilt valves in the standard loader valve group. The tilt valve contains two line relief valves. The auxiliary valve (if equipped) contains one line relief valve. Oil flows from the pump through the backhoe valve and to the priority valve. Before the engine is started, the spring holds the priority spool to the left. The priority valve ensures the steering circuit receives oil flow first. If oil flow is not needed for steering and an implement valve in the loader section is activated, the priority valve will direct most of the supply oil to the loader implement circuits.

SERVXXX 2/06

- 89 -

416E / 422E / 428E MECHANICAL LOADER INLET MANIFOLD To HMU Load Sensing Relief Valve

Text Reference

From Loader Valves From HMU

From Pump

To Tank

To HMU

Orifice

Priority To Loader Valve Control Valves

85

This illustration shows the inlet manifold in the 416E/422E/428E mechanically controlled loader valve. When the engine is started, the flow from the pump is directed to the priority valve. With the spool to the left, the pump supply oil is directed to the HMU. As the HMU passage fills, oil also enters the axial-drilled hole in the priority spool and flows to the left end of the spool. As pressure builds on the left end, the spool starts to move to the right, against spring force. The spool begins to restrict the oil flow to the HMU supply passage as the spool continues to move to the right. Oil restricted by the priority spool from entering the HMU supply passage flows to the loader implement valves. The priority spool never completely blocks the flow of oil to the HMU supply passage. A small amount of oil is allowed to flow through the dynamic bleed orifice to the priority spool spring cavity where it becomes signal oil.

SERVXXX 2/06

- 90 -

Text Reference

Signal oil flows from the spring cavity through the HMU signal line to the HMU, where the oil flows to the tank. This action causes the priority spool to meter oil continuously to the HMU supply passage to maintain a predetermined pressure in the HMU supply passage. This predetermined pressure in the HMU supply passage provides instantaneous steering response when the steering is activated. The metering action also reduces spool travel when steering is required, which results in faster steering response. With all implements in HOLD in this closed-center system, this signal oil is sensed at the pump control valve resulting in an increase in the LOW PRESSURE STANDBY setting.

SERVXXX 2/06

- 91 -

Text Reference

416E / 422E / 428E MECHANICAL LOADER LIFT CONTROL VALVE HOLD

To Lift Cylinder Head End

To Lift Cylinder Rod End

Compensator Valve

Lift Spool To Tank

From Pump

86

This illustration shows the mechanically controlled lift valve in the 416E/422E/428E machines in the HOLD position. In the HOLD position, the spring keeps the lift spool in the center position and pump oil is blocked. The loader joystick has four positions: RAISE, HOLD, LOWER, and FLOAT.

SERVXXX 2/06

- 92 -

Text Reference

416E / 422E / 428E MECHANICAL LOADER LIFT CONTROL VALVE RAISE

To Lift Cylinder Head End

To Lift Cylinder Rod End

Compensator Valve

Lift Spool To Tank

From Pump

87

This illustration shows the mechanically controlled lift valve in the 416E/422E/428E machines in the RAISE position. When the loader joystick is moved to the RAISE position, the lift spool is moved to the right. Pump oil flows past the lift spool and acts on the pressure compensator valve. The compensator valve moves up and oil flows to the head end of the lift cylinder. The lift cylinder moves to the RAISE position. Return oil flows from the rod end of the cylinder around the lift spool back to the tank. The oil also flows around the compensator and enters the signal oil passage. The signal oil chamber pressure and the compensator spring force balances against the oil pressure in the pump supply passage. The oil in signal passage flows to the resolver. If the lift circuit is the only active circuit, or if the lift circuit has a work port pressure higher than the other circuits that are active, the oil pressure from the lift circuit acts on the pump actuator to control pump output.

SERVXXX 2/06

- 93 -

Text Reference

416E / 422E / 428E MECHANICAL LOADER TILT CONTROL VALVE HOLD

To Lift Cylinder Head End

To Lift Cylinder Rod End

Compensator Valve

Line Relief Valve

Detent Solenoid

Tilt Spool

Line Relief Valve

To Tank

From Pump

88

This illustration shows the mechanically controlled tilt valve in the 416E/422E/428E machines in the HOLD position. The tilt valve also includes head end and rod end line relief valves that limit the oil pressure in the TILT BACK and DUMP circuits. The tilt control spool also includes a magnetic detent (solenoid) that is part of the "return-todig" feature. The loader tilt control valve has three positions: RACK BACK, HOLD, and DUMP.

SERVXXX 2/06

- 94 -

Text Reference

416E / 422E / 428E MECHANICAL LOADER AUXILIARY CONTROL VALVE Compensator Valve

Port A

HOLD

Port B

Line Relief Valve

Lift Spool

To Tank

From Pump

89

This illustration shows the optional mechanically controlled auxiliary valve in the 416E/422E/428E machines in the HOLD position. The auxiliary valve controls the oil to the auxiliary circuit. The loader auxiliary valve is typically used for the Multi-Purpose (MP) Bucket. The auxiliary control valve has a line relief valve for the rod end work port. The auxiliary control lever has three positions: OPEN, HOLD, and CLOSE.

SERVXXX 2/06

- 95 -

Text Reference

1

3

3

4

2

5

90 Ride Control System Travel at high speeds over rough terrain causes bucket movement. The optional Ride Control System acts as a shock absorber by absorbing bucket forces, which stabilize the machine. The Ride Control System components include the ride control switch (1), ride control relay (2), ride control solenoids (3), ride control accumulator (4), and ride control pressure switch (5). Two solenoids are now used on the "E" Series machines Ride Control System. The ride control switch includes an ON and OFF position. When the ride control switch is in the OFF position, the ride control solenoids are not energized. To energize the ride control relay and solenoids, the pressure switch must be closed. The pressure switch senses the loader lift cylinder rod end pressure. When the rod end pressure is below the ride control actuation pressure, the switch closes. NOTE: The pressure switch prevents the Ride Control System from activating if the pressure in the rod end of the loader lift cylinder is too high. An example is when the loader arms are used to lift the front wheels off the ground. If the Ride Control System was engaged, the machine would fall to the ground.

SERVXXX 2/06

- 96 -

Text Reference

If the macine ground speed is less than approximately 9.5 kilometers per hour (6 mph), the ride control system will not engage. NOTE: On 420E/430E/432E/434E/442E and 444E machines equipped with an autoshift transmission, the Ride Control System is monitored by the Machine ECM and will be discussed later in the presentation.

SERVXXX 2/06

- 97 -

Text Reference

RIDE CONTROL SYSTEM

To Tank

ON

Ride Control Valve Pressure Switch

Solenoid

Solenoid

Lift Cylinders

To /From Lift Control Valve To /From Lift Control Valve

91

This illustration shows a hydraulic schematic of the Ride Control System. With the Ride Control System ON and the lift control valve in HOLD, oil is blocked at both the rod and head ends of the lift cylinders. When the ride control solenoids are energized, the head ends of the loader lift cylinders are connected to the ride control accumulator and the rod ends of the loader lift cylinders are open to the tank. When the machine is driven over rough terrain with the Ride Control System ON, the loader lift cylinders extend and retract. As the lift cylinders extend, oil displaced from the rod ends of the cylinders flows to the tank and oil which is stored in the accumulator flows into the head ends of the cylinders. As the lift cylinders retract, oil displaced from the head ends of the cylinders flows into the accumulator, and oil is drawn from the tank into the rod ends of the cylinders. The accumulator acts as a shock absorber when the cylinders retract, providing a smoother ride. When the Ride Control System is OFF, the ride control solenoids are not energized. The check valves seat and block the passage from the rod ends of the lift cylinders to the tank and the head ends of the cylinders to the accumulator.

SERVXXX 2/06

- 98 -

Text Reference

The orifice in the line between the accumulator and cylinder head ends prevents the rapid loss of the oil which is stored in the accumulator when the loader arms are lowered. The orifice also allows the accumulator to be charged, without adversely affecting machine performance when the loader arms are lifted.

SERVXXX 2/06

- 99 -

Text Reference

92

Mechanical Backhoe Valve Group The 416E/422E/428E machines are equipped with a mechanically controlled backhoe valve that is accessed from below the floor plate. The backhoe control valve group contains the following components: -Optional E-Stick control valve (1) -Stick control valve (2) -Bucket control valve (3) -Swing control valve (4) -Boom control valve (5) -Optional auxiliary valve (6) -Inlet manifold (7) -Left stabilizer valve control valve (8) -Right stabilizer control valve (9) -End cover (10) -Inlet ports (11) -Sideshift lock valve (12) (422E/428E machines) -Outlet ports (13)

SERVXXX 2/06

- 100 -

Text Reference

1 1

2

93

The backhoe joysticks (1) control the position of the boom, swing, bucket, and stick backhoe valve spools in the backhoe control valve group. The stabilizer control levers (not visible), located on the side console, control the position of the right and left stabilizer valve spools. The pedal (2) on the floor to the right of the joysticks controls the E-Stick (if equipped) or a hammer (if installed). The auxiliary functions are controlled by a pedal (not shown) on the floor to the left of the joysticks.

SERVXXX 2/06

Right Stabilizer Cylinder

- 101 -

Left Stabilizer Cylinder

Boom Cylinder

Side Shift Lock Pistons (422E / 428E)

Text Reference

Swing Cylinders

Bucket Cylinder

E-Stick Cylinder

Stick Cylinder

Lock Pistons ON / OFF Valve (422E/428E)

Load Sensing Relief Valve Pressure Reducing Valve

AUX

Right Stabilizer

Boom

Bucket

Swing

Left Stabilizer

E-Stick

Stick

From Loader Valve Inlet Manifold

To Loader Valve Inlet Manifold From Loader Valve Inlet Manifold

Oil Filter

Flow Compensator

416E / 422E / 428E HYDRAULIC SYSTEM MECHANICALLY CONTROLLED BACKHOE VALVE HOLD

Pressure Cutoff

Oil Cooler

Pump Group

94

This illustration shows the mechanically controlled backhoe valve on the 416E/422E/428E machines. The standard backhoe valve group contains six control valves. A valve group with seven or eight control valves is available if the machine is equipped with an E-Stick valve and/or auxiliary valve. All the valves are PPPC valves except the stabilizer valves. The 422E/428E machines are equipped with side shift lock pistons to lock the side shift mechanism in place. The side shift lock piston ON/OFF solenoid valve controls the oil flow to the side shift pistons.

SERVXXX 2/06

- 102 -

Text Reference

416E / 422E / 428E MECHANICAL BACKHOE AUXILIARY CONTROL VALVE HOLD

Compensator Valve

Port B

Port A

Line Relief Valve

Auxiliary Spool

Line Relief Valve

To Tank

From Pump

95

This illustration shows the optional mechanically controlled backhoe auxiliary valve in the 416E/422E/428E machines in the HOLD position. The auxiliary valve controls the oil to the auxiliary circuit attachments. The auxiliary control valve has a line relief valve for the rod end work port and the head end work port. The auxiliary control lever has three positions: OPEN, HOLD, and CLOSE.

SERVXXX 2/06

- 103 -

Text Reference

416E / 422E / 428E MECHANICAL BACKHOE BOOM CONTROL VALVE To Boom Cylinder Head end

HOLD

To Boom Cylinder Rod End

Compensator Valve Line Relief Valve

Line Relief Valve

Boom Spool To Tank

From Pump

96

This illustration shows the mechanically controlled boom valve in the 416E/422E/428E machines in the HOLD position. The boom valve controls the oil to the head end and rod end of the boom cylinder. The boom control valve has a line relief valve for the rod end and the head end of the boom cylinder. The boom control lever has three positions: RAISE, HOLD, and LOWER.

SERVXXX 2/06

- 104 -

Text Reference

416E / 422E / 428E MECHANICAL BACKHOE BOOM CONTROL VALVE To Boom Cylinder Head End

RAISE

To Boom Cylinder Rod End

Compensator Valve Line Relief Valve

Boom Spool

Line Relief Valve

To Tank

From Pump

97

This illustration shows the mechanically controlled boom valve in the 416E/422E/428E machines in the RAISE position. When the backhoe joystick is moved to the BOOM RAISE position, the boom spool is moved to the left. Pump oil flows past the boom spool and acts on the pressure compensator valve. The compensator valve moves up and oil flows to the rod end of the boom cylinder. The boom cylinder moves to the RAISE position. Return oil flows from the head end of the cylinder around the boom spool back to the tank. The oil also flows around the compensator and enters the signal oil passage. The signal oil chamber pressure and the compensator spring force balances against the oil pressure in the pump supply passage. The oil in signal passage flows to the resolver. If the boom circuit is the only active circuit, or if the lift circuit has a work port pressure higher than the other circuits that are active, the oil pressure from the boom circuit acts on the pump actuator to control pump output.

SERVXXX 2/06

- 105 -

Text Reference

416E / 422E / 428E MECHANICAL BACKHOE SWING CONTROL VALVE To Swing Cylinders

HOLD

To Swing Cylinders

Compensator Valve Line Relief Valve

Swing Spool

Line Relief Valve

To Tank

From Pump

98

This illustration shows the mechanically controlled swing valve in the 416E/422E/428E machines in the HOLD position. The swing control valve controls the oil to the head end and rod end of the swing cylinders. The swing control valve has a line relief valve for the rod end and the head end of the swing cylinders. The swing control lever has three positions: SWING RIGHT, HOLD, and SWING LEFT.

SERVXXX 2/06

- 106 -

Text Reference

416E / 422E / 428E MECHANICAL BACKHOE BUCKET CONTROL VALVE HOLD

To Bucket Cylinder Head End

To Bucket Cylinder Rod End

Compensator Valve Line Relief Valve

Bucket Spool

Line Relief Valve

To Tank

From Pump

99

This illustration shows the mechanically controlled bucket valve in the 416E/422E/428E machines in the HOLD position. The bucket control valve controls the oil to the head end and rod end of the bucket cylinder. The bucket control valve has a line relief valve for the rod end and the head end of the bucket cylinder. The bucket control lever has three positions: LOAD, HOLD, and DUMP.

SERVXXX 2/06

- 107 -

Text Reference

416E / 422E / 428E MECHANICAL BACKHOE STICK CONTROL VALVE To Stick Cylinder Head End

HOLD

To Stick Cylinder Rod End

Compensator Valve Line Relief Valve

Line Relief Valve

Stick Spool To Tank

From Pump

100

This illustration shows the mechanically controlled stick valve in the 416E/422E/428E machines in the HOLD position. The stick control valve controls the oil to the head end and rod end of the stick cylinder. The stick control valve has a line relief valve for the rod end and the head end of the stick cylinder. The stick control lever has three positions: STICK IN, HOLD, and STICK OUT.

SERVXXX 2/06

- 108 -

Text Reference

416E / 422E / 428E MECHANICAL BACKHOE E-STICK CONTROL VALVE To E-Stick Cylinder Head End

HOLD

To E-Stick Cylinder Rod End

Compensator Valve Line Relief Valve

E-Stick Spool

From Pump

101

This illustration shows the optional mechanically controlled E-Stick valve in the 416E/422E/428E machines in the HOLD position. The E-Stick control valve controls the oil to the head end and rod end of the stick cylinder. The E-Stick control valve has a line relief valve for the rod end of the E-Stick cylinder. The E-Stick control lever has three positions: STICK EXTEND, HOLD, and STICK RETRACT.

SERVXXX 2/06

- 109 -

Right St abilizer Cylinder

Left St abilizer Cylinder

Text Reference

416E / 422E / 428E HYDRAULIC SYSTEM STABILIZER CIRCUIT

Lock Check Valves

Left Stabilizer Load Sensing Signal To Tank Right Stabilizer

From Pressure Reducing Valve From Pump To Tank

102

This illustration shows the stabilizer circuit in the 416E/422E/428E machines with the right stabilizer in the STABILIZER DOWN position and the left stabilizer in the HOLD position. The stabilizer cylinders are controlled by closed-center valves equipped with lock check valves and pilot lock check valves. The check valves prevent cylinder drift in either direction. When the right stabilizer control lever is moved to the DOWN position pump, oil flows through the right lock check valve to the head end of the right stabilizer cylinder. Pilot oil is sent to the left lock check valve to unseat the check valve. Oil from the rod end of the cylinder flows through the left lock check valve and the stabilizer control valve to the tank.

SERVXXX 2/06

- 110 -

Text Reference

5 2 1

4

3

103

Sideshift machines feature a boom (1) that can be shifted to different positions along a frame (2). Lock pistons (4) are used to lock the boom to the frame rails. Lock piston solenoids, located on the backhoe valve outlet manifold, actuate the lock pistons. The sideshift switch (3) in the cab sends a signal to energize the lock piston solenoids. The stabilizers (5) are used to raise and lower the machine. Sideshift and center pivot machines use the same type of control valves to operate the stabilizers. NOTE: The switch for the powered sideshift attachment is shown in this illustration. The switch for the mechanical sideshift machines is in the same location.

SERVXXX 2/06

- 111 -

Text Reference

SIDESHIFT SLIDE LOCK SOLENOID VALVE RELEASED

ENGAGED

Solenoid

Pump Supply

Pump Supply Check Valve Slide Lock Piston

Slide Bar

Slide Rail

104

This schematic shows the sideshift slide lock solenoid and orifice check valve operation. In the ENGAGED position, the solenoid is not energized. The solenoid blocks the system oil flow. Pump oil flows past the check valve to the slide lock pistons. The pistons clamp the stabilizer frame slide rails against the bolts on the slide bars to prevent slide frame movement. The check valve will seat as shown to maintain pressure on the pistons when system pressure decreases. In the RELEASED position, the solenoid is energized. The solenoid allows system supply oil to go to the tank. The slide lock pistons are no longer pressurized. The slide bar can then move along the slide rail.

SERVXXX 2/06

- 112 -

Text Reference

POWERED SIDESHIFT CIRCUIT

Sideshift Outboard Cylinder Sideshift Inboard Cylinder

SHIFT LEFT

Sideshift Solenoid Valve Control Manifold Group

Relief Valve

Sideshift Lock Solenoid

To Load Signal

From Pump

105

This illustration shows the powered sideshift hydraulic circuit in the SHIFT LEFT position. When the powered sideshift is not activated, supply oil from the implement/steering pump is blocked by the sideshift lock solenoid. When the top of the powered sideshift switch on the right console is pressed, the sideshift lock solenoid is energized. The left end of the sideshift solenoid valve is also energized and oil is directed to the head end of the inboard cylinder and the rod end of the outboard cylinder. The cylinders will shift the slide and the backhoe frame to the left. Oil from the rod end of the inboard cylinder and head end of the outboard cylinder returns to the tank. Some oil will also flow through the load signal line and signal the pump to upstroke. The relief valve limits the load signal line pressure. When the bottom of the powered sideshift switch is pressed, the sideshift slide and frame is shifted to the right.

SERVXXX 2/06

- 113 -

Text Reference

2 1

2

106

This illustration shows the optional powered sideshift (1) attachment. The powered sideshift moves the backhoe across the slider using two hydraulic cylinders (2).

SERVXXX 2/06

- 114 -

Text Reference

420E / 430E BACKHOE LOADER HYDRAULIC SYSTEM SINGLE TILT

Tank Outlet Manifold Left Stabilizer

Pump

Lever

Cooler

Aux

Bucket

Joystick

E-stick

Swing

Boom Right Stabilizer

Joystick

Stick

Lever

Inlet Manifold Pilot Manifold

Diff Pressure Switch

HMU

Back Pressure Check Valve

I n l e t

L i f t

Temperature Switch

T i l t

A u x

Brake Boost Ride Control

107

420E/430E/432E/434E/442E/444E IMPLEMENT HYDRAULIC SYSTEM The 420E/430E machines can be equipped with a mechanically controlled or a pilot controlled loader valve. The 420E/430E backhoe valve is pilot controlled. The 432E/434E/442E/444E machines are equipped with a pilot controlled loader valve and backhoe valve. This illustration shows a block diagram of the 420E/430E machines with a mechanically controlled loader valve and a pilot controlled backhoe valve. The 420E/430E machines with a mechanically controlled loader valve are a single tilt arrangement. The 420E/430E mechanically controlled loader valve is similar to the 416E/422E/428E loader valve but includes a different compensator valve and no resolver network. The standard loader control valve group contains two control valves. Three control valves are installed on the machine if equipped with the auxiliary function. The priority valve is also contained within the loader valve.

SERVXXX 2/06

- 115 -

Text Reference

The standard pilot controlled backhoe valve group contains six control valves. Seven or eight valves are installed in the backhoe valve group if the machine is equipped with an E-Stick and/or an auxiliary valve. The auxiliary valve and E-Stick valve are controlled by the Machine ECM via solenoid valves. The solenoid valves direct pilot oil to each end of the auxiliary valve and E-Stick directional spools. The pilot accumulator allows the backhoe implements to be lowered if the engine will not run. The accumulator also provides oil to the brake boost valve.

SERVXXX 2/06

- 116 -

Text Reference

420E / 430E BACKHOE LOADER HYDRAULIC SYSTEM PARALLEL LIFT

Tank Outlet Manifold Left Stabilizer

Pump

Lever

Cooler

Aux Joystick

E-stick Bucket Swing

Joystick

Stick Boom

HMU

Back Pressure Check Valve

Temperature Switch

Lever

Joystick

Right Stabilizer

Diff Pressure Switch

Inlet Manifold I n l e t

Pilot Manifold Brake Boost

L i f t

T i l t

A u x

Ride Control

108

This illustration shows a block diagram of the 420E/430E machines with a pilot controlled loader valve and a pilot controlled backhoe valve. The 420E/430E machines with a pilot controlled loader valve are a parallel lift arrangement. The standard pilot controlled loader valve group contains six control valves. Three control valves are installed on the machine if equipped with the auxiliary function. The auxiliary valve is controlled by the Machine ECM via two solenoid valves. The solenoid valves direct pilot oil to each end of the auxiliary valve directional spool. The priority valve is also contained within the loader control valve group. The pilot controlled backhoe valve and pilot accumulator, as previously described, is the same on all 420E/430E machines. The pilot accumulator allows the loader and backhoe implements to be lowered if the engine will not run.

SERVXXX 2/06

- 117 -

Text Reference

432E / 434E / 442E / 444E BACKHOE LOADER HYDRAULIC SYSTEM Sideshift Lock Pistons Pump Tank Outlet Manifold

Joystick

E-stick Bucket

Diff Pressure Switch

Swing Left Stabilizer Right Stabilizer

Front Steering Cylinder

Back Pressure Check Valve

Lever Lever

Temperature Switch

Joystick

Boom

HMU

Joystick

Stick

AWS Valve

Cooler

Aux

Rear Steering Cylinder

Inlet Manifold I n l e t

Pilot Manifold Brake Boost

L i f t

T i l t

A u x

Ride Control

109

This illustration shows a block diagram of the 432E/434E/442E/444E machines with a pilot controlled loader valve and a pilot controlled backhoe valve. The 432E/434E/442E/444E machines are all equipped with a parallel lift arrangement. The pilot controlled loader valve, as previously described, is the same as the 420E/430E machines. The pilot controlled backhoe valve, as previously described, is similar to the 420E/430E machines, but the stabilizer valves are in different locations within the control valve group. The 420E/430E stabilizer valves are located on the outboard ends of the backhoe valve group. The 432E/434E/442E/444E stabilizer valves are located near the center of the backhoe valve group. The pilot accumulator allows the loader and backhoe implements to be lowered if the engine will not run. The accumulator also provides oil to the brake boost valve. The 432E/434E/442E/444E sideshift machines include lock pistons to lock the backhoe on the slider.

SERVXXX 2/06

- 118 -

Text Reference

109A

The hydraulic configurations screen shows the configuration status of the loader and backhoe auxiliary valves, the ride control system and activation speed, and the hydraulic oil temperature sensor installation.

SERVXXX 2/06

- 119 -

Text Reference

1

4 3

2 5

110

Implement and Steering Pump The implement and steering pump on the 420E/430E/432E/434E/442E and 444E machines is similar to the "D" Series machines, but now includes a torque control solenoid (not visible). The torque control solenoid provides an additional pump setting. The implement and steering pump (1) is located below the floor plate in the cab. The pump control valve (2) contains a torque control spool adjustment screw (3) and a flow compensator adjustment screw (4). The adjustment screws and the load sensing pressure tap (5) are accessible from the cab. In the "D" Series machines, the pressure cutoff spool in the pump served as the relief valve for the hydraulic system. In the "E" Series machines, the signal relief valve, located in the backhoe valve outlet manifold, serves as the hydraulic system relief valve since the system is PPPC. The margin spool or flow compensator is located in the pump control in the same location as the former pressure cutoff valve was located. The torque control spool is located in the pump control in the same location as the margin spool or flow compensator valve was located. The new system also features a margin relief valve, located in the backhoe outlet manifold, which increases pump flow in a standby condition to improve response. The margin relief valve provides the system with similar operating characteristics as an open center system. NOTE: DO NOT adjust the torque control spool. If adjustment is required, please contact DSN-CPI to get the latest recommendations. The torque control spring is set lower than the flow compensator.

SERVXXX 2/06

- 120 -

Text Reference

3 1 2

5

6 7

4

8 9

111

These illustrations show the implement and steering pump out of the machine. The following components are visible: - Torque control adjustment (1) - Flow compensator adjustment (2) - Load sensing pressure tap (3) - Inlet port (4) - Case drain port (5) - Torque control solenoid (6) - Discharge pressure tap (7) - Torque limiter (8) - Outlet port (9)

SERVXXX 2/06

- 121 -

Small Orifice

Text Reference

STEERING AND IMPLEMENT PUMP

Torque Control Solenoid

LOW PRESSURE STANDBY

Torque Limiter

Large Orifice

Torque Control

Flow Compensator Pressure Differential Relief Valve

Signal Relief Valve

Backhoe Inlet Manifold

Signal Drain Valve LS Signal

Pump Output

112

Steering and Implement Pump Operation With all the implements in HOLD, the steering priority valve bleeds some supply oil through a dynamic bleed orifice back to the tank through the HMU. This oil flow creates a load sensing signal, which is sensed at the pump flow compensator. The LOW PRESSURE STANDBY reading will be higher than margin pressure on "E" Series machines due to an internal minimum angle stop. This minimum angle stop is not adjustable, which prevents the swashplate from moving to a true minimum angle position. As shown in the illustration above, the swashplate is at the prescribed minimum angle, applying the maximum setting on the spring in the torque limiter. The spring setting of the torque limiter changes with the swashplate angle. As the swashplate angle is increased, the spring setting is reduced.

SERVXXX 2/06

- 122 -

Small Orifice

Text Reference

STEERING AND IMPLEMENT PUMP

Torque Control Solenoid

CONSTANT FLOW

Torque Limiter

Large Orifice

Torque Control

Flow Compensator Pressure Differential Relief Valve

Signal Relief Valve

Backhoe Inlet Manifold

Signal Drain Valve LS Signal

Pump Output

113

The pump will UPSTROKE or DESTROKE to match changes in flow requirements. Pump supply oil flows to the flow compensator and acts on the compensator spool lands. Supply oil also flows into a cross-drilled passage and an axial drilled passage in the flow compensator spool. The pump supply pressure moves the flow compensator up, which opens a small passage between the spool lands and the body of the pump control valve. The flow compensator spool meters reduced pump supply oil to the large actuator piston in the pump case moving the swashplate to an angle that satisfies system needs. When pump flow matches system needs, the pump supply pressure equals the sum of the system load pressure plus the flow compensator spring pressure. The flow compensator is in a metering position and the system is stabilized. CONSTANT FLOW is maintained until there is a change in system flow requirements.

SERVXXX 2/06

- 123 -

Text Reference

PUMP TORQUE MODES High Torque Mode

Low Torque Mode Flow (Q)

Pressure (P) Torque Limiter Control Flow Compensator Control

114

This illustration shows a Pressure/Flow (P-Q) Curve Chart for the steering and implement pump. The purpose of this chart is to show how the torque limiter affects the maximum flow rate for the loader and backhoe sections when the torque limiter opens. Initial pump flow on the chart is low which reflects STANDBY pressure from the pump. When flow is required, the chart illustrates an increase in pump flow that slowly decreases as pressure in the system increases. The flow compensator spool regulates pump flow when system pressure and flow requirements are below the curves. This is the area shown in pink. The first sweeping curved line (Low Torque Mode) shows where the torque limiter has control over the pump flow. The torque limiter destrokes the pump as the system pressure increases. The rate of destroke closely follows the torque curve of the engine. The second sweeping curved line (High Torque Mode) shows where the torque control solenoid changes the operating characteristics of the torque limiter providing an additional (higher) pump setting. This area is shown in red.

SERVXXX 2/06

- 124 -

Text Reference

PUMP SOLENOID TORQUE PARAMETERS DIRECTIONAL MODE ENABLED (FORWARD - OR - REVERSE) SOLENOID ENERGIZED

SOLENOID DE-ENERGIZED

High Torque

Low Torque

420E

1600 rpm

1300 rpm

430E

1600 rpm

1200 rpm

432E

1600 rpm

1300 rpm

434E

1600 rpm

1300 rpm

442E

1600 rpm

1200 rpm

444E

1600 rpm

1200 rpm

114A

This chart shows the operational parameters of the new torque control solenoid. When the solenoid is energized, the pump is in the high torque mode, and when the solenoid is deenergized, the pump is in the low torque mode. When the machine is in a directional mode, FORWARD and/or REVERSE, and the implements are operating, the pump solenoid is not energized until a certain engine rpm is obtained. By keeping the pump solenoid de-energized at a lower engine rpm, all of the available engine horsepower is utilized by the power train for optimum efficiency. As the power train and hydraulic system consume engine horsepower, the engine rpm decreases and the torque control solenoid is de-energized. The hydraulic torque on the pump is decreased and the engine rpm increases to regain the needed horsepower for full utilization of the power train. There is a slight delay when the torque control solenoid is energized or de-energized based upon engine rpm. This delay also occurs when the directional mode is changed (forward to reverse) and assists in stabilizing the engine and the hydraulic system.

SERVXXX 2/06

- 125 -

Text Reference

PUMP SOLENOID TORQUE PARAMETERS DIRECTIONAL MODE ENABLED (NEUTRAL) SOLENOID ENERGIZED

SOLENOID DE-ENERGIZED

High Torque

Low Torque

420E

1200 rpm

1100 rpm

430E

1200 rpm

1100 rpm

432E

1200 rpm

1100 rpm

434E

1200 rpm

1100 rpm

442E

1200 rpm

1100 rpm

444E

1200 rpm

1100 rpm

114B

This chart shows the operational parameters of the torque control solenoid when the machine is in a non-directional mode (NEUTRAL), or operating the backhoe loader hydraulics. When the solenoid is energized, the pump is in the high torque mode, and when the solenoid is de-energized, the pump is in the low torque mode. When the machine is in the non-directional mode (NEUTRAL) or backhoe loader mode, the pump solenoid is not energized until a certain engine rpm is obtained. When in NEUTRAL or backhoe loader mode, the pump torques control solenoid is energized at a lower engine rpm so that all of the available engine horsepower is available for utilization by the hydraulic system for optimum efficiency. As the hydraulic system consumes engine horsepower, the engine rpm will decrease, and at a certain rpm the torque control solenoid is de-energized. The pump hydraulic torque is decreased and the engine increases to to regain the needed horsepower for full utilization of the hydraulic system. There is a slight delay when the torque control solenoid is energized and/or de-energized based upon the selection of the engine rpm when in the NEUTRAL mode, also known as the backhoe loader mode. This delay assists in stabilizing the engine and the hydraulic system.

SERVXXX 2/06

- 126 -

Small Orifice

Text Reference

STEERING AND IMPLEMENT PUMP

Torque Control Solenoid

TORQUE LIMITER OPEN

Torque Limiter

Large Orifice

Torque Control

Flow Compensator Pressure Differential Relief Valve

Signal Relief Valve

Backhoe Inlet Manifold

Signal Drain Valve LS Signal

Pump Output

115

The torque limiter monitors the pump swashplate angle and the pump discharge pressure. The torque limiter pressure setting varies with the swashplate angle: the greater the swashplate angle, the lower the pressure setting on the torque limiter spring due to the mechanical linkage between the swashplate and the torque limiter. As the swashplate angle decreases, the mechanical linkage increases the force on the torque limiter springs, therefore, increasing the pressure setting of the torque limiter. When a higher flow rate from the pump is required, the flow compensator receives a signal from the control valve to move the pump to maximum displacement. With the increased pressure in the passage between the torque control spool and the torque limiter, the torque limiter opens and allows oil to drain to the tank. As the oil drains to tank at the torque limiter, a pressure reduction occurs at the top of the torque control spool, which allows oil to start flowing through the axial drilled passage in the torque control spool. Due to the reduced pressure at the top of the torque control spool and increased pump discharge pressure at the bottom of the torque control spool, the torque control spool shifts up. When the torque control spool shifts up, oil is metered across the flow compensator spool to the large actuator piston which moves the swashplate toward minimum angle.

SERVXXX 2/06

- 127 -

Small Orifice

Text Reference

STEERING AND IMPLEMENT PUMP

Torque Control Solenoid

TORQUE CONTROL SOLENOID ON

Torque Limiter

Large Orifice

Torque Control

Flow Compensator Pressure Differential Relief Valve

Signal Relief Valve

Backhoe Inlet Manifold

Signal Drain Valve LS Signal

Pump Output

116

When the appropriate engine speed for a loading or backhoe operation is obtained, the torque control solenoid is ENERGIZED. With the torque control solenoid energized, the variable displacement pump flow increases. Pump discharge oil flows through the solenoid and a large and small orifice. The combined discharged pump flow increases the pressure on the top of the torque control spool. This increased pressure at the top of the torque control spool keeps the torque control spool seated. At the same time a higher work port pressure occurs which generates a higher signal pressure to keep the flow compensator in the down position. The combination of the two spools assists in keeping the swashplate in a partially upstroked position to meet the higher operating flow requirements and system pressure. Due to the mechanical linkage working between the swashplate of the pump and the torque limiter, the torque limiter spring force increases. With the increased spring force the pump will destroke at a higher pressure. In summary, full pump supply pressure is always available, however, flow is regulated to maintain maximum input torque from the engine.

SERVXXX 2/06

- 128 -

Text Reference

Due to the torque control solenoid, the torque limiter has two different torque curves: one for the low torque mode, and one for the high torque mode. When the hydraulic demand falls below the conditions stated above, the torque limiter closes. The flow compensator now has control over the pump swashplate angle to regulate pump flow and meet the required system pressure and flow demands.

SERVXXX 2/06

- 129 -

5

4

Text Reference

3

2

1

117

Mechanical Loader Valve Group The 420E/430E machines can be equipped with a mechanically controlled loader valve (1) or a pilot controlled loader valve (not shown). The loader valve is accessed from below the floor plate. The loader control valve group contains an inlet manifold (2), lift control valve (3), tilt control valve (4), and auxiliary control valve (5, if equipped). NOTE: 420E/430E machines with a mechanically controlled loader valve or a pilot controlled loader valve use the same inlet manifold.

SERVXXX 2/06

- 130 -

1

Text Reference

2

118

The loader joystick (1) controls the position of the lift and tilt valve spools in the loader control valve. The auxiliary control lever (2) controls the position of the auxiliary valve spool.

SERVXXX 2/06

- 131 -

Text Reference

Orifice ( inside Torque Cont rol Spool)

To Backhoe Valve

To Backhoe Valve

Load Sensing Relief Valve

Ride Cont rol Valve Priorit y Valve

From Backhoe Valve

Torque Cont rol Flow Compensat or

To HMU

Torque Cont rol Solenoid Oil Filt er

Lift Valve Oil Cooler

Torque Limit er Valve

Lift Cylinders

From Backhoe Valve

Pressure Compensat or

Pump Group

Tilt Valve

Tilt Cylinder Pressure Compensat or

420E / 430E HYDRAULIC SYSTEM

Auxiliary Valve

MP Bucket Cylinders

Line Relief Valve

MECHANICALLY CONTROLLED LOADER VALVE HOLD

Pressure Compensat or

119

This illustration shows the mechanically controlled loader valve on the 420E/430E machines. The loader valve is closed-center. The loader valve includes the lift and tilt valves in the standard loader valve group. The tilt valve contains two line relief valves. The auxiliary valve (if equipped) contains one line relief valve. The loader valves in the 420E/430E are a PPPC type, but there are no resolvers in the signal network. The pressure compensator creates the load signal pressure by diverting part of the supply oil going to the cylinder into the signal line. The highest load signal is sensed at all compensator valves and at the pump control valve. The pressure compensator valve maintains a controlled pressure differential across the spool to control flow to the circuit. If more than one circuit is used at a time, the circuit with the highest workport pressure is used to regulate the flow through each control valve. The "E" Series Backhoe Loader hydraulic system is similar to the PPPC hydraulic system used on other Caterpillar products. The system shown incorporates the flow control, signal duplication, and resolver into one component called a pressure compensator valve.

SERVXXX 2/06

- 132 -

Text Reference

The pressure compensator valve acts as a resolver to compare the different circuit workport pressures and to send a signal pressure equal to the highest circuit pressure back to the pump. The priority valve in the 420E/430E loader valve is a three-section valve that operates similarly to the two-section priority valve in the 416E/422E/428E loader valve previously described.

SERVXXX 2/06

- 133 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E LOADER INLET MANIFOLD Load Sensing Signal

To HMU

From Pump To Loader Valve

120

This illustration shows the loader inlet manifold in the 420E/430E/432E/434E/442E and 444E machines. NOTE: The 420E/430E machines with a mechanically controlled loader valve and the 420E/430E/432E/434E/442E and 444E machines with a pilot controlled loader valve use the same inlet manifold. Oil flows from the pump to the priority valve. Before the engine is started, the spring holds the priority spool to the left. When the engine is started, oil flow from the pump is directed to the priority valve. With the spool to the right, the pump supply oil is directed to the HMU. As the HMU passage fills, oil also enters the axial-drilled hole in the priority spool and flows to the right end of the spool. As pressure builds on the right end, the spool starts to move to the left, against spring force. Oil continues to flow to the HMU and restricted oil flows to the loader valves. As the priority valve spool continues to move to the left, oil is restricted by the priority spool from entering the HMU supply passage and all oil flows to the loader implement valves. When the priority spool is moved completely to the left, oil flow to the HMU supply passage is blocked.

SERVXXX 2/06

- 134 -

Text Reference

420E / 430E MECHANICAL LOADER LIFT CONTROL VALVE To Lift Cylinder Rod End

HOLD

To Lift Cylinder Head End

Signal Passage from Priority Valve

Signal Passage

Compensator Valve

Lift Spool

From To Tank Pump

121

This illustration shows the mechanically controlled lift valve in the 420E/430E machines in the HOLD position. In the HOLD position, the spring keeps the lift spool in the center position and pump oil is blocked. The loader joystick has four positions: RAISE, HOLD, LOWER, and FLOAT. Signal pressure from the priority valve in the inlet manifold is directed to the top of the compensator spools in the loader control valve group. A signal passage allows signal oil to flow to the top of the adjoining compensator spools and to the load sensing relief valve in the inlet manifold.

SERVXXX 2/06

- 135 -

Text Reference

420E / 430E MECHANICAL LOADER LIFT CONTROL VALVE LOWER

To Lift Cylinder Rod End

To Lift Cylinder Head End

Signal Passage from Priority Valve

Signal Passage

Compensator Valve

Lift Spool

To Tank

From P

122

This illustration shows the mechanically controlled lift valve in the 420E/430E machines in the LOWER position. When the loader joystick is moved to the LOWER position, the lift spool is moved to the right. Pump oil flows past the lift spool and acts on the pressure compensator valve. The compensator valve moves up and oil flows to the rod end of the lift cylinder. The lift cylinder moves to the LOWER position. Return oil flows from the head end of the cylinder around the lift spool back to the tank. The oil also flows around the compensator and enters the signal oil passage. The signal oil chamber pressure and the compensator spring force balances against the oil pressure in the pump supply passage. The oil in signal passage flows to the compensator valve in each loader control valve. If the lift circuit is the only active circuit, or if the lift circuit has a work port pressure higher than the other circuits that are active, the oil pressure from the lift circuit acts on the pump actuator to control pump output.

SERVXXX 2/06

- 136 -

To Tilt Cylinder Rod End

To Tilt Cylinder Head End

Compensator Valve

Text Reference

420E / 430E MECHANICAL LOADER TILT CONTROL VALVE HOLD

Signal Passage Line Relief Valve

Line Relief Valve

Tilt Spool

Detent Solenoid From Pump

To Tank

123

This illustration shows the mechanically controlled tilt valve in the 420E/430E machines in the HOLD position. The tilt valve also includes head end and rod end line relief valves that limit the oil pressure in the TILT BACK and DUMP circuits. The tilt control spool also includes a magnetic detent (solenoid) that is part of the "return-todig" feature. The loader tilt control valve has three positions: RACK BACK, HOLD, and DUMP.

SERVXXX 2/06

- 137 -

Text Reference

420E / 430E MECHANICAL LOADER AUXILIARY CONTROL VALVE To Auxiliary Cylinder Rod End

HOLD

To Auxiliary Cylinder Head End

Compensator Valve

Signal Passage Line Relief Valve

Auxiliary Spool To Tank

From Pump

124

This illustration shows the optional mechanically controlled auxiliary valve in the 420E/430E machines in the HOLD position. The auxiliary valve controls the oil to the auxiliary circuit. The loader auxiliary valve is typically used for the Multi-Purpose (MP) Bucket. The auxiliary control valve has a line relief valve for the rod end work port. The auxiliary control lever has three positions: OPEN, HOLD, and CLOSE.

SERVXXX 2/06

- 138 -

Text Reference

2

1

4

3

5

125

Ride Control System The Ride Control System, on machines with the optional autoshift transmission, is controlled by the Machine ECM (1). The Machine ECM monitors the position of the ride control switch (2) and determines when to operate the ride control system. On machines with the autoshift transmission, the ride control switch is a three position switch; OFF, ON, and AUTO. When the ride control switch is in the ON position, power is transferred to the ride control relay (3). Power available at the ride control switch illuminates the indicators in the switch and the ride control indicator on the instrument panel. The Machine ECM will energize the ride control solenoids (4) via the ride control relay if the pressure switch (5) is closed. When the ride control switch is in the AUTO position, the Machine ECM uses input from the pressure switch and the transmission speed sensor to determine when to operate the ride control system.

SERVXXX

- 139 -

NPI

If the speed sensor input indicates ground speed is less than approximately 9.5 kilometers per hour (6 mph), the Machine ECM will not engage the ride control system. If the input indicates that the ground speed is greater than approximately 9.5 kilometers per hour (6 mph), the Machine ECM directs an output signal to close the ride control relay. When the relay closes the solenoid is energized. NOTE: Hydraulic system operation of the Ride Control System on machines with the autoshift transmission is the same as that on machines with the standard transmission, as previously described. Refer to visual No. 91.

SERVXXX 2/06

- 140 -

Text Reference

125A

The ride control status screen displays the ride control switch and the ride control relay. This screen also shows the ride control activation speed and the machine ground speed.

SERVXXX 2/06

- 141 -

Text Reference

126

Pilot Loader Valve Group The 420E/430E machines can be equipped with a mechanically controlled loader valve as previously discussed, or a pilot controlled loader valve as shown in this illustration. The 432E/434E/442E and 444E machines are all equipped with the pilot controlled loader valve. The loader valve is accessed from below the floor plate. The loader control valve group contains an outlet manifold (1), auxiliary control valve (2, if equipped), tilt control valve (3), lift control valve (4), inlet manifold (5), and load sensing relief valve (6). NOTE: 420E/430E machines with a mechanically controlled loader valve or a pilot controlled loader valve use the same inlet manifold as previously discussed.

SERVXXX 2/06

- 142 -

1

Text Reference

3

2

127

The loader joystick (1) controls the position of the lift and tilt valve spools in the loader control valve. The thumbswitch (2) controls the position of the auxiliary valve spool. The AWS buttons (3) that control the All Wheel Steering are also located on the loader joystick. AWS will be discussed later in the presentation.

SERVXXX 2/06

- 143 -

Text Reference

127A

The hydraulic joysticks status screen displays status of the joystick thumbswitches for the loader and the backhoe.

SERVXXX 2/06

- 144 -

Text Reference

127B

The joysticks thumbswitches can be calibrated. This Cat ET screen displays the status of the joysticks thumbswitches calibration.

SERVXXX 2/06

- 145 -

To Backhoe Valve

Text Reference

From Backhoe Orifice Valve ( inside Torque Cont rol Spool)

To Backhoe Valve Load Sensing Relief Valve (420E / 430E / 432E / 442E)

Ride Cont rol Valve

Torque Cont rol Flow Compensat or

Priorit y Valve

Torque Select or Solenoid

To HMU Lift Valve

Lift Cylinders

To / From Loader Joystick

Oil Filt er Torque Limit er Valve

Manual Lower Valve

Tilt Valve

From Backhoe Valve

Oil Cooler Pump Group

To / From Loader Joystick

Tilt Cylinders

Auxiliary Valve

420E / 430E / 432E / 434E / 442E / 444E HYDRAULIC SYSTEM

Line Relief Valve

MP Bucket Cylinders

PILOT CONTROLLED LOADER VALVE HOLD

Coupler Cylinder To Pilot Manifold

From Pilot Manifold

128

The 420E/430E/432E/434E/442E and 444E pilot controlled loader valve illustration is shown above. The internal components of the pilot controlled loader valve are basically the same as the 420E/430E mechanically controlled loader valve except that the movement of the valve spools is controlled by pilot oil.

SERVXXX 2/06

- 146 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E PILOT LOADER LIFT CONTROL VALVE To Lift Cylinder Rod End

HOLD To Lift Cylinder Head End

Signal Passage from Priority Valve

Signal Passage

Compensator Valve

Lift Spool

Manual Lower Valve

To Tank

From Pump

129

This illustration shows the pilot controlled lift valve in the 420E/430E/432E/434E/442E/444E machines in the HOLD position. In the HOLD position, the spring keeps the lift spool in the center position and pump oil is blocked. Pilot oil shifts the lift spool, which directs pump oil to the lift cylinders. The loader joystick has four positions: RAISE, HOLD, LOWER, and FLOAT. The pilot controlled loader valve also contains a manual lower valve to lower the lift arms if the engine won't start or the implement pump fails.

SERVXXX 2/06

- 147 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E PILOT LOADER LIFT CONTROL VALVE To Lift Cylinder Rod End

RAISE

To Lift Cylinder Head End

Signal Passage from Priority Valve

Signal Passage

Compensator Valve

Lift Spool

Manual Lower Valve

To Tank

From Pump

130

This illustration shows the pilot controlled lift valve in the RAISE position. When the loader joystick is moved to the RAISE position, the lift pilot control valve directs oil to the right end of the lift spool. The lift spool is moved to the left by the pilot oil pressure. Pump oil flows past the lift spool and acts on the pressure compensator valve. The compensator valve moves up and oil flows to the head end of the lift cylinder. The lift cylinder moves to the RAISE position. Return oil flows from the head end of the cylinder around the lift spool back to the tank. The oil also flows around the compensator and enters the signal oil passage. The signal oil chamber pressure and the compensator spring force balances against the oil pressure in the pump supply passage. The oil in signal passage flows to the compensator valve in each loader control valve. If the lift circuit is the only active circuit, or if the lift circuit has a work port pressure higher than the other circuits that are active, the oil pressure from the lift circuit acts on the pump actuator to control pump output.

SERVXXX 2/06

- 148 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E PILOT LOADER TILT CONTROL VALVE To Tilt Cylinder Rod End

HOLD

To Tilt Cylinder Head End

Compensator Valve

Signal Passage

Line Relief Valve

Line Relief Valve

Tilt Spool

From To Tank Pump

131

This illustration shows the pilot controlled tilt valve in the 420E/430E/432E/434E/442E/444E machines in the HOLD position. The tilt valve also includes head end and rod end line relief valves that limit the oil pressure in the TILT BACK and DUMP circuits. Pilot oil shifts the tilt spool, which directs pump oil to the tilt cylinders. The tilt control spool also includes a magnetic detent (solenoid) that is part of the "return-todig" feature. The loader tilt control valve has three positions: RACK BACK, HOLD, and DUMP.

SERVXXX 2/06

- 149 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E PILOT LOADER AUXILIARY CONTROL VALVE HOLD To Auxiliary Circuit

To Auxiliary Circuit

Compensator Valve

Signal Passage

Line Relief Valve

Solenoid Valve

Solenoid Valve Auxiliary Spool

To Tank

From Pump

132

This illustration shows the optional pilot controlled auxiliary valve in the 420E/430E/432E/434E/442E/444E machines in the HOLD position. The auxiliary valve controls the oil to the auxiliary circuit. The auxiliary valve is controlled by two solenoid valves upon command of the Machine ECM. The thumbswitch on the loader joystick sends a signal to the Machine ECM to request an auxiliary function. The Machine ECM sends a corresponding signal to the solenoid valves, which direct oil to activate the work tool. The loader auxiliary valve is typically used for the Multi-Purpose (MP) Bucket. The auxiliary control valve has a line relief valve for the head end work port. The auxiliary control lever has three positions: OPEN, HOLD, and CLOSE.

SERVXXX 2/06

- 150 -

132A

This Cat ET screen shows the status of the loader auxiliary hydraulics functions.

Text Reference

SERVXXX 2/06

- 151 -

1

3

2

9

4

5

10

Text Reference

6

7

11

8

12

13 14

133

Pilot Backhoe Valve Group The 420E/430E/432E/434E/442E and 444E machines are equipped with a pilot controlled backhoe valve that is visible with the floor plate at the rear of the cab removed. This illustration shows a backhoe valve in a 420E Backhoe Loader. The components in the backhoe valve are: - Right stabilizer control valve (1) - Boom control valve (2) - Stick control valve (3) - Swing control valve (4) - Bucket control valve (5) - E-Stick control valve (6) - Auxiliary control valve (7) - Left stabilizer control valve (8) - Pilot shutoff valve (9) - Pattern switching valve (10) - Flushing/margin relief valve (11) - Signal drain valve (12)

SERVXXX 2/06

- 152 -

Text Reference

The pilot manifold (13) can also be accessed with the floor plate removed. The pilot pressure tap (14) is located on the pilot manifold. The pilot manifold routes pilot oil to and from the loader and backhoe pilot control valves.

SERVXXX 2/06

- 153 -

15

8

7

6

5

14

Text Reference

4

3

13

2 1

9 10

11

12

134

This illustration shows a sideshift machine pilot controlled backhoe valve with seven control valves. The auxiliary control valve is not installed in this control valve group. The components in the control valve group are: - Inlet manifold (1) - Boom control valve (2) - Pattern switching valve (3) - Stick control valve (4) - Right stabilizer control valve (5) - Left stabilizer control valve (6) - Swing control valve (7) - Bucket control valve (8) - E-Stick control valve (9) - Outlet manifold (10) - Sideshift lock solenoid (11) - Pilot pressure reducing valve (12) - Pilot ON/OFF valve (13) - Load sensing relief valve (14) - Signal drain valve (15)

SERVXXX 2/06

- 154 -

Text Reference

3

4 1

1

2

2 5

135

The backhoe joysticks (1) control the position of the boom, swing, bucket, and stick backhoe valve spools in the backhoe control valve. The stabilizer control levers (2) control the position of the right and left stabilizer valve spools. The thumbswitch (3) on the left joystick controls the auxiliary functions (if equipped). The thumbswitch on the right joystick (4) controls the E-Stick (if quipped) or a hammer (if installed). The joystick pattern switch (5) controls the pattern switching valve solenoids located on the backhoe valve group. The pattern switching valve allows the backhoe to change from an excavator to a backhoe control pattern.

SERVXXX 2/06

- 155 -

Text Reference

135A

The hydraulic joysticks status screen displays status of the joystick thumbswitches for the loader and the backhoe as previously shown.

SERVXXX 2/06

- 156 -

Text Reference

135B

The stabilizer lever position status and stabilizer alarm status is shown in this illustration.

SERVXXX 2/06

- 157 -

Text Reference

135C

This Cat ET screen displays the status of the joysticks thumbswitches calibration as previously shown.

SERVXXX 2/06

- 158 -

Text Reference

Swing Cylinders

Right Stabilizer Cylinder

Boom Cylinder

Bucket Cylinder

Stick Cylinder

E-Stick Cylinder

Left Stabilizer Cylinder

Swing Cushion Valves

From Loader Valve

Signal Relief Valve

To Pilot Manifold Accumulator

Signal Drain Valve

To Brake Booster

Pressure Differential Relief Valve

Pilot Pressure Reducing Valve Right Stabilizer

To/From Right Stabilizer Joystick

Boom

Swing

Stick

E-Stick

AUX

Left Stabilizer

To / From Left Stabilizer Joystick

Pattern Switching Valve

From Right Joystick

Bucket

To /From Left Joystick

From From Left Right Joystick Joystick

From Left Joystick

To / From Right Joystick

From Loader Valve Inlet Manifold From Ride Control Valve Orifice (Inside Torque Control Spool) Torque Control Flow Compensator Torque Selector Solenoid

To Loader Valve Inlet Manifold

Oil Filter

420E / 430E HYDRAULIC SYSTEM PILOT CONTROLLED BACKHOE VALVE HOLD

Oil Cooler

Torque Limiter Valve

Pump Group

136

This illustration shows the pilot controlled backhoe valve on the 420E/430E machines. The standard backhoe valve group contains six control valves. A valve group with seven or eight control valves is available if the machine is equipped with an E-Stick valve and/or auxiliary valve. All the valves are pressure compensated including the stabilizer valves. The backhoe valves in the 420E/430E are also a PPPC type similar to the pilot controlled loader valves. The pressure compensator creates the load signal pressure by diverting part of the supply oil going to the cylinder into the signal line. The highest load signal is sensed at all compensator valves in the backhoe group and at the pump control valve. There is a check valve in the signal network that prevents the loader compensators from sensing the signal. Oil from the pump flows into the backhoe valve then to the individual valve spools and the pilot pressure reducing valve. The pilot pressure reducing valve reduces the pump oil pressure to pilot pressure. Pilot oil pressure is available to the pilot manifold, pilot accumulator and to the E-Stick and auxiliary solenoid valves. The pilot accumulator supplies oil to the brake boost valve.

SERVXXX 2/06

- 159 -

Text Reference

The pilot controlled backhoe valve is also equipped with a pattern switching valve. The pattern switching valve allows the backhoe controls to be changed from an excavator to a backhoe control pattern. The outlet manifold contains the load sensing relief valve, the flushing/margin relief valve, and the signal drain valve. The signal relief valve limits the maximum signal pressure for the backhoe valve. On the 434E/444E machines, the signal relief valve limits the maximum signal pressure for the backhoe valve and the loader valve. The signal drain valve provides a means for the signal oil to flow to the tank when all circuits are returned to HOLD. The pressure differential relief valve directs some of the pump oil flow to the tank in the standby condition because the pump produces more output flow than is required for leakage makeup. The pressure differential relief valve directs some of the pump oil flow to the tank in three distinct circumstances. 1. In standby condition with all control valves in NEUTRAL (pressure differential relief valve functions as a flushing valve). 2. When a cylinder is suddenly bottomed or stalled. 3. When the control valve is rapidly returned to NEUTRAL. NOTE: The stabilizer, boom, and stick valves each include two anti-drift valves, which stop implement drift.

SERVXXX 2/06

- 160 -

Text Reference

Swing Cylinders

Boom Cylinder

Stick Cylinder

Right Stabilizer Cylinder

Bucket Cylinder

Left Stabilizer Cylinder

E-Stick Cylinder

Side Shift Lock Pistons (442E / 444E)

Swing Cushion Valves

From Loader Valve

Signal Relief Valve

To Pilot Manifold

Accumulator

Signal Drain Valve

To Brake Booster (434E / 444E)

Pressure Differential Relief Valve

Pilot Pressure Reducing Valve Boom

Stick

Right Stabilizer

Left Stabilizer

Swing

Bucket

E-Stick

AUX

Side Shift Lock Pistons ON/OFF Valve (442E/444E)

To /From Right Joystick To All Wheel Steer (432E / 434E / 444E)

Pattern Switching Valve

To/From Right Stabilizer Joystick

From From Right Left Joystick Joystick

From Right Joystick

To / From Left Stabilizer Joystick

To /From Left Joystick

From Left Joystick

From Loader Valve Inlet Manifold From Ride Control Valve Orifice ( Inside Torque Control Spool) Torque Control Flow Compensator Torque Selector Solenoid

To Loader Valve Inlet Manifold

Oil Filter Oil Cooler

432E / 434E / 442E / 444E HYDRAULIC SYSTEM PILOT CONTROLLED BACKHOE VALVE HOLD

Pump Group

137

This illustration shows the pilot controlled backhoe valve on the 432E/434E/442E/444E machines. This valve is similar to the pilot controlled backhoe valve on the 420E/430E, but the stabilizer valves are in different locations within the valve group. The 420E/430E stabilizer valves are located on the outboard ends of the backhoe valve group. The 432E/434E/442E/444E stabilizer valves are located near the center of the backhoe valve group. The 432E/434E/442E/444E machines are equipped with side shift lock pistons to lock the side shift mechanism in place. The side shift lock piston ON/OFF solenoid valve controls the oil flow to the side shift pistons.

SERVXXX 2/06

- 161 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E PILOT BACKHOE INLET MANIFOLD HOLD

Pilot ON / OFF Solenoid Valve

Pilot Pressure Reducing Valve

To Pilot Valves

To Pilot Accumulator

From Pump

138

This illustration shows the backhoe inlet manifold in the 420E/430E/432E/434E/442E and 444E machines. The inlet manifold contains the pilot pressure reducing valve and the pilot ON/OFF solenoid valve. The pilot pressure reducing valve reduces the implement and steering pump oil pressure to pilot pressure to be used for moving the control valve spools. The pilot ON/OFF solenoid controls the oil flow to the pilot system. The pilot ON/OFF solenoid is controlled by the implement lockout switch in the cab.

SERVXXX 2/06

- 162 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E PILOT BACKHOE STABILIZER CONTROL VALVE HOLD To Stabilizer Cylinder Rod End

To Stabilizer Cylinder Head End

Compensator Valve

Signal Passage

Line Relief Valve

Actuator Pin

Actuator Pin

Stabilizer Spool

To Tank

From Pump

139

This illustration shows the pilot controlled stabilizer valve in the 420E/430E/432E/434E/442E and 444E machines in the HOLD position. In the HOLD position, the spring keeps the stabilizer spool in the center position and pump oil is blocked. Pilot oil shifts the stabilizer spool, which directs pump oil to the stabilizer cylinders. The stabilizer control valve has a line relief valve for the rod end work port. The pilot controlled stabilizer joystick has three positions: UP, HOLD, and DOWN. The stabilizer valve also contains a check valve in the rod and head end ports that prevents the stabilizers from drifting. When the stabilizer is activated, the stabilizer spool moves one of the actuator pins up, which allows the return oil to flow to the tank.

SERVXXX 2/06

- 163 -

Text Reference

420E / 430E PILOT BACKHOE BOOM CONTROL VALVE HOLD

To Boom Cylinder Rod End

To Boom Cylinder Head End

Compensator Valve Line Relief Valve

Signal Passage

Line Relief Valve

Actuator Pin

Boom Spool

To Tank

From Pump

140

This illustration shows the pilot controlled boom valve in the 420E/430E machines in the HOLD position. In the HOLD position, the spring keeps the boom spool in the center position and pump oil is blocked. Pilot oil shifts the boom spool, which directs pump oil to the boom cylinder. The pilot controlled boom joystick has three positions: RAISE, HOLD, and LOWER. The boom valve also includes head end and rod end line relief valves that limit the oil pressure in the RAISE and LOWER circuits. The boom valve also contains a check valve in the rod end port that prevents the boom from drifting down. When the boom is lowered, the boom spool moves the actuator pin up, which allows the return oil to flow to the tank.

SERVXXX 2/06

- 164 -

Text Reference

420E / 430E PILOT BACKHOE STICK CONTROL VALVE To Lift Cylinder Rod End

HOLD

To Lift Cylinder Head End

Compensator Valve Line Relief Valve

Signal Passage

Line Relief Valve

Actuator Pin

Lift Spool

To Tank

From Pump

141

This illustration shows the pilot controlled stick valve in the 420E/430E/432E/434E/442E and 444E machines in the HOLD position. In the HOLD position, the spring keeps the stick spool in the center position and pump oil is blocked. Pilot oil shifts the stick spool, which directs pump oil to the stick cylinder. The pilot controlled stick joystick has three positions: STICK IN, HOLD, and STICK OUT. The stick valve also includes head end and rod end line relief valves that limit the oil pressure in the STICK IN and STICK OUT circuits. The stick valve also contains a check valve in the rod end port that prevents the stick from drifting out. When the stick is activated, the stick spool moves the actuator pin up, which allows the return oil to flow to the tank.

SERVXXX 2/06

- 165 -

Text Reference

420E / 430E / 432E / 434 / 442E / 444E PILOT BACKHOE SWING CONTROL VALVE To Swing Cylinder

HOLD

To Swing Cylinder

Signal Passage from Priority Valve Compensator Valve

Signal Passage

Line Relief Valve

Line Relief Valve

Swing Spool

To Tank

From Pump

142

This illustration shows the pilot controlled swing valve in the 420E/430E/432E/434E/442E and 444E machines in the HOLD position. In the HOLD position, the spring keeps the swing spool in the center position and pump oil is blocked. Pilot oil shifts the swing spool, which directs pump oil to the swing cylinders. The pilot controlled swing joystick has three positions: SWING LEFT, HOLD, and SWING RIGHT. The swing valve also includes head end and rod end line relief valves that limit the oil pressure in the SWING LEFT and SWING RIGHT circuits. Signal pressure from the priority valve in the loader inlet manifold is directed to the top of the compensator spools in the backhoe control valve group. A signal passage allows signal oil to flow to the top of the adjoining compensator spools in the backhoe control valve group.

SERVXXX 2/06

- 166 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E HYDRAULIC SYSTEM Swing Cylinders

SWING CUSHION VALVE

Swing Cushion Valve

Swing Cushion Valve To / From Swing Control Valve 143

When oil is directed from the swing control valve, the boom swings to the right. When the swing control valve is moved from the SWING RIGHT position to the NEUTRAL position, oil is blocked. The continued motion of the boom and stick causes pressure to increase, causing the boom to swing to the left. As pressure continues to increase the boom swings back to the right. The boom continues to move to the right until the pressure stabilizes. The swing cushion valves relieve the oil pressure by directing the oil from the rod end of the left cylinder and head end of the right cylinder to the rod end of the right cylinder and the head end of the left cylinder. The swing cushion valves will operate identically when the boom swings in either direction.

SERVXXX 2/06

- 167 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E PILOT BACKHOE BUCKET CONTROL VALVE To Lift Cylinder Rod End

HOLD

To Lift Cylinder Head End

Compensator Valve

Signal Passage Line Relief Valve

Line Relief Valve

Lift Spool

To Tank

From Pump

144

This illustration shows the pilot controlled bucket valve in the 420E/430E/432E/434E/442E and 444E machines in the HOLD position. In the HOLD position, the spring keeps the bucket spool in the center position and pump oil is blocked. Pilot oil shifts the bucket spool, which directs pump oil to the bucket cylinder. The pilot controlled bucket joystick has three positions: LOAD, HOLD, and DUMP. The bucket valve also includes head end and rod end line relief valves that limit the oil pressure in the LOAD and DUMP circuits.

SERVXXX 2/06

- 168 -

Text Reference

420E / 430E PILOT BACKHOE E-STICK CONTROL VALVE HOLD To E-Stick Cylinder Rod End

Line Relief Valve

To E-Stick Cylinder Head End

Compensator Valve

Signal Passage

Actuator Pin

Solenoids

E-Stick Spool

To Tank

From Pump

145

This illustration shows the pilot controlled E-Stick valve in the 420E/430E/432E/434E/442E and 444E machines in the HOLD position. In the HOLD position, the spring keeps the E-Stick spool in the center position and pump oil is blocked. The E-Stick valve is controlled by two solenoid valves upon command of the Machine ECM. The thumbswitch on the right backhoe joystick sends a signal to the Machine ECM to activate the E-Stick. The Machine ECM sends a corresponding signal to the solenoid valves, which direct oil to move the E-Stick cylinder. The E-Stick thumbswitch has three positions: STICK EXTEND, HOLD, and STICK RETRACT. The E-Stick valve also includes a rod end line relief valve that limits the oil pressure in the E-Stick rod end circuit. The E-Stick valve also contains a check valve in the rod end port that prevents the E-Stick from drifting out. When the E-Stick is activated, the boom spool moves the actuator pin up, which allows the return oil to flow to the tank.

SERVXXX 2/06

- 169 -

Text Reference

420E / 430E / 432E / 434E / 442E / 444E PILOT BACKHOE AUXILIARY CONTROL VALVE HOLD

To Auxiliary Circuit

To Auxiliary Circuit

Compensator Valve

Signal Passage

Line Relief Valve Solenoid

Solenoid

Line Relief Valve

Auxiliary Spool

To Tank

From Pump

146

This illustration shows the pilot controlled auxiliary valve in the 420E/430E/432E/434E/442E and 444E machines in the HOLD position. In the HOLD position, the spring keeps the auxiliary spool in the center position and pump oil is blocked. The auxiliary valve is controlled by two solenoid valves upon command of the Machine ECM. The thumbswitch on the left backhoe joystick sends a signal to the Machine ECM to activate the auxiliary function. The Machine ECM sends a corresponding signal to the solenoid valves, which direct oil to activate the work tool. The auxiliary thumbswitch has three positions: OPEN, HOLD, and CLOSE. The auxiliary valve also includes head end and rod end line relief valves that limit the oil pressure in the OPEN and CLOSE circuits.

SERVXXX 2/06

- 170 -

Text Reference

146A

This Cat ET screen shows the status of the backhoe auxiliary hydraulics functions.

SERVXXX 2/06

- 171 -

Text Reference

420E / 430E PILOT BACKHOE OUTLET MANIFOLD HOLD

Signal Relief Valve

Signal Drain Valve Pressure Differential Relief Valve

147

This illustration shows the outlet manifold in the 420E/430E machines. The outlet manifold contains the load sensing relief valve, the signal drain valve, and the margin relief valve. The load sensing relief valve limits the maximum load sensing pressure for the backhoe valve. The signal drain valve provides a path for the signal oil to flow to the tank when all circuits are returned to HOLD. The flushing/margin relief valve directs some of the pump oil flow to the tank in the standby condition because the pump produces more output flow than is required for leakage makeup. The flushing/margin relief valve directs some of the pump oil flow to the tank in three distinct circumstances. 1. In standby condition with all control valves in NEUTRAL. 2. When a cylinder is suddenly bottomed or stalled. 3. When the control valve is rapidly returned to NEUTRAL.

SERVXXX 2/06

- 172 -

Text Reference

432E / 434E / 442E / 444E PILOT BACKHOE OUTLET MANIFOLD HOLD

Signal Relief Valve

Signal Drain Valve Pressure Differential Relief Valve

Sideshift Lock Piston ON/OFF Valve

148

This illustration shows the outlet manifold in the 432E/434E/442E/444E machines. The outlet manifold contains the load sensing relief valve, the signal drain valve, and the margin relief valve the same as the outlet manifold in the 420E/430E machines previously discussed. On the 434E/444E machines, the load sensing relief valve limits the maximum load sensing pressure for the backhoe valve and the loader valve. The outlet manifold in the 432E/434E/442E/444E machines also contains the sideshift lock solenoid used to lock the boom to the frame rails.

SERVXXX 2/06

- 173 -

Text Reference

432E / 434E / 442E / 444E PILOT BACKHOE BOOM VALVE To Boom Cylinder Rod End

HOLD

To Boom Cylinder Head End

Compensator Valve

Signal Passage

Line Relief Valve

Line Relief Valve

Boom Spool

To Tank

From Pump

149

This illustration shows the pilot controlled boom valve in the 432E/434E/442E/444E machines in the HOLD position. The boom valve in the 432E/434E/442E/444E machines operates the same as the boom valve in the 420E/430E machines (previously described), but does not include a check valve in the rod and head end ports to prevent the boom from drifting.

SERVXXX 2/06

- 174 -

Text Reference

432E / 434E / 442E / 444E PILOT BACKHOE STICK CONTROL VALVE To Stick Cylinder Rod End

HOLD

To Stick Cylinder Head End

Compensator Valve

Signal Passage

Line Relief Valve

Line Relief Valve

Stick Spool

To Tank

From Pump

150

This illustration shows the pilot controlled stick valve in the 432E/434E/442E/444E machines in the HOLD position. The stick valve in the 432E/434E/442E/444E machines operates the same as the stick valve in the 420E/430E machines (previously described), but does not include a check valve in the rod and head end ports to prevent the stick from drifting.

SERVXXX 2/06

- 175 -

Text Reference

432E / 434E / 442E / 444E PILOT BACKHOE E-STICK CONTROL VALVE HOLD

To E-Stick Cylinder Rod End

To E-Stick Cylinder Head End

Compensator Valve

Signal Passage

Line Relief Valve Solenoid

Solenoid

E-Stick Spool

To Tank

From Pump

151

This illustration shows the pilot controlled E-Stick valve in the 432E/434E/442E/444E machines in the HOLD position. The E-Stick valve in the 432E/434E/442E/444E machines operates the same as the E-Stick valve in the 420E/430E machines (previously described), but does not include a check valve in the rod end port to prevent the E-Stick from drifting.

SERVXXX 2/06

- 176 -

Text Reference

TWO WHEEL STEERING SYSTEM From Backhoe Valve

416E / 422E / 428E BACKHOE LOADERS HOLD From Backhoe

To Backhoe Valve

From Backhoe Valve

Valve

Load Sensing Relief Valve

Flow Compensat or Oil Cooler

Oil Filt er

Priorit y Valve Pressure Cut off

From Loader Valve LS Relief Valve

HMU

Crossover Relief Valves

To Loader Valve

Pump Group From Loader Valve

Front St eering Cylinder

152

STEERING SYSTEM Two Wheel Steering This illustrations shows the steering system on the 416E/422E/428E machines. The steering system features a dynamic signal the same as the "D" Series machines. With the dynamic signal and the steering in HOLD, the steering priority spool sends oil through the HMU signal line and HMU back to the tank. When the steering wheel is turned, this dynamic signal oil shifts the priority spool to direct pump supply oil to the HMU, resulting in faster steering response than systems without a dynamic signal. The "E" Series HMU also includes two crossover relief and makeup valves, and a load sensing relief valve. The crossover relief and makeup valves provide steering capability when the engine is not running by allowing oil to recirculate between the HMU and the steering cylinder when the steering wheel is turned. The load sensing relief valve limits the maximum load sensing signal for the loader valve group.

SERVXXX 2/06

- 177 -

Text Reference

TWO WHEEL STEERING SYSTEM

420E / 430E / 432E / 434E / 442E / 444E BACKHOE LOADERS HOLD From Backhoe Valve To Backhoe Valve

To From Backhoe Ride Cont rol Valve Valve

Priorit y Valve From Loader Valve

To Loader Valve

From Backhoe Valve

Torque Cont rol Load Sensing Relief Valve

From Loader Valve

Flow Compensat or Torque Cont rol Solenoid Oil Filt er Oil Cooler

Torque Limit er Valve

Pump Group LS Relief Valve

HMU Crossover Relief Valves

From Pilot Manifold

Front St eering Cylinder

153

This illustrations shows the steering system on the 420E/430E/432E/434E/442E and 444E machines. The HMU is the same as the 416E/422E/428E machines, but the 420E/430E/432E/434E/442E and 444E machines are equipped with a different pump and priority valve as previously described.

SERVXXX 2/06

- 178 -

Text Reference

TWO WHEEL STEERING SYSTEM

420E / 430E / 432E / 434E / 442E / 444E BACKHOE LOADERS

From Backhoe Valve

From Backhoe Valve

TURN

To Backhoe Valve

To Backhoe Valve

Priorit y Valve From Loader Valve

To Loader Valve

From Ride Cont rol Valve

Load Sensing Relief Valve

Torque Cont rol Flow Compensat or Torque Cont rol Solenoid Oil Filt er

From Loader Valve Torque Limit er Valve

Oil Cooler

Pump Group

LS Relief Valve

HMU

From Pilot Manifold

Crossover Relief Valves

Front St eering Cylinder

154

This illustration shows the steering system during a turn. Signal oil is sent from the steering priority valve past the check valve to the HMU where the oil combines with the cylinder oil. The pressure in the HMU signal line is limited to the steering cylinder port pressure. The signal oil also enters the signal network and flows to the pump control valve. The pump then increases flow to meet the steering system flow requirements. Oil from the pump flows past the steering priority valve to the HMU and to the double rod steering cylinder. When the machine makes a turn, the HMU directs oil to the left side of the cylinder piston and opens the right side to the tank. A turn in the other direction operates inversely. The check valve in the pump supply line between the HMU and the loader valve inlet manifold prevents steering "kickback" due to an external force. The makeup valve provides steering capability when the engine is not running by allowing oil to recirculate between the HMU and the steering cylinder when the steering wheel is turned.

SERVXXX 2/06

- 179 -

Text Reference

ALL WHEEL STEER SYSTEM HOLD

Rear Axle

From Backhoe Valve

From Ride Cont rol Valve

Torque Control IRM Left Solenoid

Circle St eer Pilot Valve

Flow Compensat or

IRM From Right Solenoid Backhoe Valve

Circle St eer Valve

From Backhoe Valve

To Priorit y Valve

Torque Control Solenoid Oil Filt er

All Wheel St eer Valve Oil Cooler

To Backhoe Valve LS Port

Front Axle Crossover Relief Valves

Pump Group

HMU

From Pilot Manifold To Priorit y Valve

LS Relief Valve

From Priorit y Valve

155

All Wheel Steer The AWS system is the same as the updated "D" Series machines. The AWS system is available on the 432E and 442E models and standard on the 434E and 444E models. The line relief valves protect the rear steering cylinder and lines from external shocks and heat build up. The line reliefs will also open during the Circle Steer Mode if the rear steering cylinder reaches the end of its stroke prior to the front steering cylinder. The pilot valve is energized to direct oil to the pilot operated check valves to unseat them when CIRCLE STEER is selected. The circle steer valve allows TWO WHEEL STEERING when the valve is de-energized by allowing oil to pass between the two steering lines for the front axle. When CIRCLE STEER is selected, the circle steer valve is energized to block the flow between the two steering lines.

SERVXXX 2/06

- 180 -

Text Reference

The four upper pilot operated check valves are controlled by the circle steer pilot valve. When the pilot valve is energized, supply oil unseats the four pilot operated check valves. This action connects the front steering cylinder lines with the rear steering cylinder lines. The two lower pilot operated check valves are unseated by supply oil to the rear steering cylinder whenever one of the Independent Rear Maneuvering (IRM) solenoids are energized. The orifice check valves in the lines to the rear axle prevent cylinder voiding.

SERVXXX 2/06

- 181 -

Text Reference

6

1

2 4 3 5

156 These illustrations show the AWS components located in the cab and on the rear axle. The AWS mode select switch (1) allows the operator to choose between the three steering modes: TWO WHEEL STEER, CIRCLE STEER, and IRM STEERING. The AWS indicator lamp (2) illuminates when CIRCLE STEER or IRM STEERING is selected. The buttons (3) on the right loader joystick control the rear steering cylinder (4) in the IRM STEERING mode. The AWS position gauge (5) displays the position of the rear axle relative to the centerline of the machine. The rear steering position sensor (6) senses the position of the rear steering cylinder and sends a variable signal to the AWS position gauge.

SERVXXX 2/06

- 182 -

Text Reference

157

5 1

4

1 3

2

These illustrations show the location and components of the AWS control valve group. The following components are visible in the bottom illustration: - Pilot operated check valves (1) - Line relief valve (2) - Left IRM solenoid valve (3) - Right IRM solenoid valve (4) - Circle steer solenoid valve (5)

158

SERVXXX 2/06

- 183 -

Text Reference

159

CONCLUSION This presentation has provided service information on the "E" Series Backhoe Loaders. This presentation supports the service manual. When used in conjunction with the service manual, the information in this package should permit the technician to do a thorough job of analyzing a problem in these systems. For service repairs, adjustments, and maintenance, always refer to the Owner and Operator Manual, Service Manuals, and other related service publications.

SERVXXX 2/06

- 184 -

Text Reference

HYDRAULIC SCHEMATIC COLOR CODE Black - Mechanical connection. Seal

Red - High pressure oil

Dark Gray - Cutaway section

Red/White Stripes - 1st pressure reduction

Light Gray - Surface color

Red Crosshatch - 2nd reduction in pressure

White - Atmosphere or Air (No pressure)

Pink - 3rd reduction in pressure

Purple - Pneumatic pressure

Red/Pink Stripes - Secondary source oil pressure

Yellow - Moving or activated components

Orange - Pilot, charge, or Torque Converter oil

Cat Yellow - (R estricted usage) Identification of components within a moving group

Orange / White Stripes Reduced pilot, charge, or TC oil pressure

Brown - Lubricating oil

Orange Crosshatch - 2nd reduction in pilot, charge, or TC oil pressure.

Green - Tank, sump, or return oil

Blue - Trapped oil

Green / White Stripes Scavenge Oil or Hydraulic Void

HYDRAULIC SCHEMATIC COLOR CODE This illustration identifies the meanings of the colors used in the hydraulic schematics and cross-sectional views shown throughout this presentation.

Red Crosshatch - 2nd reduction in pressure Pink - 3rd reduction in pressure Red/Pink Stripes - Secondary source oil pressure Orange - Pilot, charge, or Torque Converter oil Orange / White Stripes Reduced pilot, charge, or TC oil pressure

Light Gray - Surface color

White - Atmosphere or Air (No pressure)

Purple - Pneumatic pressure

Yellow - Moving or activated components

Cat Yellow - (R estricted usage) Identification of components within a moving group

Blue - Trapped oil

- 185 -

Green / White Stripes Scavenge Oil or Hydraulic Void

Green - Tank, sump, or return oil

Orange Crosshatch - 2nd reduction in pilot, charge, or TC oil pressure.

Red/White Stripes - 1st pressure reduction

Dark Gray - Cutaway section

Brown - Lubricating oil

Red - High pressure oil

Black - Mechanical connection. Seal

HYDRAULIC SCHEMATIC COLOR CODE

SERVXXX 2/06 Text Reference

STMG XXX 2/06

- 186 -

"E" Series Machine Walk-around Checklist Directions: Use this sheet when performing the machine orientation lab exercise. Place a check in the blank if the fluid level is acceptable. Model Engine oil level Transmission oil level Hydraulic system oil level Brake system oil level Cooling system fluid level Fuel level Place a check in the blank if acceptable or after task was performed. Drain water separator Check seat belt Check air filter indicator Check cab air filter Place a check in the blank if the indicator, switch or control is working correctly. Key start switch Turn signal Tachometer Engine coolant gauge Power train/converter oil temperature gauge Fuel level gauge Parking brake light Turn signal Horn Front work lights Rear work lights Windshield wipers Heating and air conditioner controls Service hour meter Backup alarm High beam indicator

Handout No. 1

STMG XXX 2/06

- 187 -

Handout No. 2

"E" Series Machine Walk-around Checklist - continued Place a check in the blank after locating and reading the following warnings labels on the machine. Model Do not operate No ether in air inlet Quick coupler pins Loader arm brace ROPS Use of jumper cables

High pressure accumulator Crush hazard No exit Pressurized system High cylinder pressure Seat belt

Place a check in the blank after locating each of the following controls. Front governor pedal Steering wheel Directional shifter Speed selector or shifter Transmission neutral lock switch Transmission neutralizer switches (both) All wheel drive (AWD) switch (if equipped) Transmission Auto/Manual switch (autoshift only) Differential lock pedal (if equipped) Brake pedals Parking brake lever and release Loader lift and tilt controls Loader auxiliary lever (mechanical controls) Continuous flow switch Rear governor lever Stabilizer controls Boom lock lever Boom lever Swing lever Stick lever Bucket lever E-stick/attachment control Pattern changer switch (if equipped) Implement lockout switch (if equipped)

STMG XXX 2/06

- 188 -

Handout No. 3

"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. Model 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 Turbocharger (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 Plug for checking engine boost

STMG XXX 2/06

- 189 -

Handout No. 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 Location

Part No.

Schematic Location Parts Manual Description

Schematic Description Starter motor Alternator Battery Key start fuse Engine oil pressure switch 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 relay (if equipped) Hydraulic filter bypass switch Cat ET Connector Machine ECM

STMG XXX 2/06

- 190 -

Handout No. 5

Standard Power Train Component Checklist Directions: Use this sheet to take notes during the slide 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 Transmission hydraulic system relief valve Torque converter inlet relief valve Transmission control valve AWD solenoid valve (if equipped) 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

7

6

5

B

1 A

C 7 AWD

D

4

2

E

J K

F

I

G

G

3

H

H

6

F

R

5

- 191 -

4

3

2

1

Identify Test Ports

K

J

I

H

G

F

E

D

C

B

A

Identify Components

Directions: Fill in the blanks next to the numbers and letters with the correct term.

Standard Power Train with AWD Component Checklist

STMG XXX 2/06 Handout No. 6

STMG XXX 2/06

- 192 -

Handout No. 7

Backhoe Loader Transmission Test Sheet Machine Model _____________________________ Name/Code ________________________________ Mach. S/N _________________________________ Trans. S/N _________________________________ Engine S/N _________________________________ S.M.U. _____________________________________

Oil Level Oil Type Oil Leaks Air/H2O in Oil

Dealer ________________________________________ Customer _______________________________________ Job ____________________________________________ Application _____________________________________ Date ___________________________________________ Serviceman _____________________________________

VISUAL CHECKS _______ Suction Screen _______ Oil Filter _______ Abrasives in Oil _______ Debris in Pan

_______ _______ _______ _______

PRESSURE TESTS PARKING BRAKE - ON PRESSURES PRESSURE TEST

SHIFT LEVER

LOW IDLE SPEC

ACTUAL

HIGH IDLE SPEC

Pump Supply

N

Forward Clutch

F

XXXX

Reverse Clutch

R

XXXX

Lube

N

XXXX

T.C. Inlet

N

XXXX

T.C. Outlet (T.C. Stall)

4th/FWD

XXXX

AWD Clutch Pressure

N

PRESSURE TEST

SHIFT LEVER

T.C. Outlet (T.C. Stall)

4th / FWD

T.C. Outlet (T.C. Stall)

4th / REV

ACTUAL

XXXX

XXXX XXXX

ENGINE SPEED SPEC

ACTUAL

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.

STMG XXX 2/06

- 193 -

Handout No. 8

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. Model Solenoid No. 1 - FORWARD LOW Solenoid No. 2 - FORWARD HIGH Solenoid No. 3 - REVERSE Solenoid No. 4 - speed clutch No. 1 Solenoid No. 5 - speed clutch No. 2 Solenoid No. 6 - speed clutch No. 3 All wheel drive solenoid (if available) Torque converter inlet relief valve Transmission speed sensor Input shaft Output shaft Machine ECM

Test Locations: Pump supply pressure FORWARD HIGH clutch pressure FORWARD LOW clutch 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)

H

G

F

E

D

C

B

A

Identify Components:

Directions: Fill in the blanks next to the letters with the correct term.

Autoshift Power Train Components

Shift Lever

Suction Screen

Pump

A

Auto/Manual Switch Neutral Lock Switch

Ride Control Switch

2

B

6

3

Orifice

Transmission Lube

E

R

3

Machine ECM

Data Link Service Port

C D

Oil Cooler

D

F

HI

2

Torque Converter

E

LO

Ride Control Disable

1

G

Transmission Output Speed Sensor

Downshift/Neutralizer Switch

Parking Brake Switch

D

1

H

4

STMG XXX 2/06 - 194 Handout No. 9

STMG XXX 2/06

- 195 -

Handout No. 10

Autoshift Transmission System Pressure Tests Machine Model ________________________ Name/Code ____________________________ Machine S/N __________________________ Transmission S/N ______________________ Engine S/N ____________________________ S.M.H. ________________________________

Dealer ____________________________ Customer__________________________ Job ______________________________ Application ________________________ Date______________________________ Technician ________________________

ENGINE SPEED PRESSURE TEST

LOW IDLE

HIGH IDLE

SPEC

ACTUAL

SPEC

ACTUAL

XXX

XXX

XXX

XXX

Pump Pressure Lube Pressure All Wheel Drive Pressure Torque Converter Inlet (Optional) FORWARD HIGH Torque Converter Outlet (Not Applicable) REVERSE FORWARD LOW Speed Clutch 1 Speed Clutch 2 Speed Clutch 3

Comments:

STMG XXX 2/06

- 196 -

Handout No. 11

Autoshift Transmission System Pressure Tests (continued)

ENGINE SPEED LOW IDLE

PRESSURE TEST SPEC Pressure difference between Pump and FORWARD LOW Pressure difference between Pump and FORWARD HIGH Pressure difference between Pump and REVERSE Pressure difference between Pump and Clutch 1 Pressure difference between Pump and Clutch 2 Pressure difference between Pump and Clutch 3 Pressure difference between Pump and All Wheel Drive Clutch

Comments:

ACTUAL

HIGH IDLE SPEC

ACTUAL

STMG XXX 2/06

- 197 -

Handout No. 12

"E" Series 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. Model Hydraulic tank Hydraulic oil filter Pump Pump control valve Torque limiter (if equipped) Torque control solenoid (if equipped) Loader valve group Backhoe valve group Implement controls Pump supply pressure test port Signal pressure test port Hand metering unit (HMU) Pilot accumulator (if equipped) Ride control accumulator (if equipped) Machine ECM (if equipped) Swing cushion valve (if equipped)

Directions: Fill in the blanks with the correct component name.

416E/422E/428E Hydraulic System Component Checklist

Tank

STMG XXX 2/06 - 198 Handout No. 13

Pump

SHOULD THE PISTONS BE GRAY???

Directions: Fill in the blanks with the correct component name.

420E/430E (Parallel Lift) Hydraulic System Component Checklist

Tank

STMG XXX 2/06 - 199 Handout No. 14

GRAY PISTON????

Directions: Fill in the blanks with the correct component name.

432E/434E/442E/444E Hydraulic System Component Checklist

Tank

STMG XXX 2/06 - 200 Handout No. 15

STMG XXX 2/06

- 201 -

Handout No. 16

"E" Series Hydraulic Pump Components Checklist 420E/430E/432E/434E/442E/444E Machines Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes during the slide presentation.

Small Orifice

A B

Large Orifice

C

D

L E K Signal Relief Valve

G F

J

H I

LS Signal

Backhoe Inlet Manifold Pump Output

A

G

B

H

C

I

D

J

E

K

F

L

STMG XXX 2/06

- 202 -

Handout No. 17

BACKHOE LOADER HYDRAULIC TESTS PRESSURE TEST

SPEC

ACTUAL

ADJUSTED

Low Pressure Standby

RUN ALL TESTS AT MAXIMUM RPM

Margin Pressure Maximum System Pressure

MACHINE AT NORMAL OPERATING TEMPERATURES

Pilot Pressure Steering Circuit Pressure Swing Circuit Pressure

CYCLE TIMES

TEST L O A D E R

1ST Bucket Dump Tilt Back Regenerative Dump (for parallel lift)

Float Raise Bucket Dump Bucket Load (Curl) Stick In Stick Out Swing

(Stop to Stop)

Swing

(Stop to Snubber)

B A C K H O E

E-Stick Extend E-Stick Retract Left Stabilizer Up Left Stabilizer Down Right Stabilizer Up Right Stabilizer Down Boom Lower Boom Pause Boom Raise (to snubber)

Boom Raise (to stop)

Auxiliary 1 Auxiliary 2

2ND

3RD

4TH

AVG.

SPEC

STMG XXX 2/06

- 203 -

Handout No. 18

416E/422E/428E Loader Lift Control Valve Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes during the slide presentation.

E

F A

B

A B C D E F

C

D

STMG XXX 2/06

- 204 -

Handout No. 19

420E/430E/432E/434E/442E/444E Loader Lift Control Valve Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes during the slide presentation.

B

A

C

D

H

E G A B C D E F G H

F

STMG XXX 2/06

- 205 -

Handout No. 20

416E/422E/428E Backhoe Boom Control Valve Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes during the slide presentation.

B

A I H

C

D G A B C D E F G H I

F

E

STMG XXX 2/06

- 206 -

Handout No. 21

420E/430E/432E/434E/442E/444E Backhoe Swing Control Valve Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes during the slide presentation.

B

A

C

I H

D

G A B C D E F G H I

F

E

K

J

I

H

G

F

E

D

C

B

A

K

From Backhoe Valve

G

A B

H

F

E

To From Backhoe Backhoe Valve Valve

To HMU

Pump Group

D

C

Oil Cooler

Oil Filter

From Backhoe Valve

- 207 -

I

J

To Backhoe Valve

Directions: Fill in the blanks next to the letters with the correct term.

416E/422E/428E Loader Valve Group

STMG XXX 2/06 Handout No. 22

J

I

H

G

F

E

D

C

B

A

From Loader Valve Inlet Manifold

A B

To Loader Valve Inlet Manifold

C

Directions: Fill in the blanks next to the letters with the correct term.

416E/422E/428E Backhoe Valve Group

D

E

F

G

Pump Group

H

Oil Cooler

From Loader Valve Inlet Manifold

I

Oil Filter

J

STMG XXX 2/06 - 208 Handout No. 23

M

L

K

J

I

H

G

F

E

D

C

B

A

M

L

To Pilot Manifold

F

Tilt Valve

J

K

To Backhoe Valve

G

H

I

A

D

To / From Loader Joystick

To / From Loader Joystick

To HMU

E

C

B

Pump Group

Oil Cooler

From Backhoe Orifice Valve (inside Torque Control Spool)

Oil Filter

From Backhoe Valve

- 209 -

From Pilot Manifold

To Backhoe Valve

Directions: Fill in the blanks next to the letters with the correct term.

420E/430E/432E/434E/442E/444E Loader Valve Group

STMG XXX 2/06 Handout No. 24

O

To Loader Valve Inlet Manifold

B

To Brake Booster

A

To Pilot Manifold

From Loader Valve

C

From Right Joystick

O

D

From From Left Right Joystick Joystick

E

From Left Joystick

F

To /From Left Joystick

N

G

To / From Right Joystick

J

Pump Group

Oil Cooler

To / From Left Stabilizer Joystick

I

From Loader Valve Inlet Manifold From Ride Control Valve

H

Oil Filter

M

L

K

- 210 -

N

M

L

K

J

I

H

G

F

E

D

C

B

A

Directions: Fill in the blanks next to the letters with the correct term.

420E/430E Backhoe Valve Group

STMG XXX 2/06 Handout No. 25

P

O

To Loader Valve Inlet Manifold

B

To Brake Booster

A

To Pilot Manifold

From Loader Valve

P

C

From From Right Left Joystick Joystick

D

From Right Joystick

To/From Right Stabilizer Joystick From Left Joystick

E F

To / From Left Stabilizer Joystick

G

H

I

To / From Left Joyst ick

Pump Group

From Loader Valve Inlet Manifold From Ride Cont rol Valve

To / From Right Joyst ick To All Wheel Steer (432E / 434E / 444E)

O

Oil Cooler

J

Oil Filt er

N

M

L

K

- 211 -

N

M

L

K

J

I

H

G

F

E

D

C

B

A

Directions: Fill in the blanks next to the letters with the correct term.

432E/434E/442E/444E Backhoe Valve Group

STMG XXX 2/06 Handout No. 26

J

I

H

G

F

E

D

C

B

A

I

All Wheel St eer Valve

H G

To Backhoe Valve LS Port

B C

From Ride Cont rol Valve

F

E

D

From Pilot Manifold

From Backhoe Valve

To Priorit y Valve

Pump Group

Oil Cooler

From Backhoe Valve

From Backhoe Valve

Oil Filt er

- 212 -

From Priorit y Valve

To Priorit y Valve

J

K

A

Directions: Fill in the blanks next to the letters with the correct term.

Two Wheel Steering

STMG XXX 2/06 Handout No. 27

K

J

I

H

G

F

E

D

C

B

A

I

All Wheel St eer Valve

H G

To Backhoe Valve LS Port

B C

From Ride Cont rol Valve

F

E

D

From Pilot Manifold

From Backhoe Valve

To Priorit y Valve

Pump Group

Oil Cooler

From Backhoe Valve

From Backhoe Valve

Oil Filt er

- 213 -

From Priorit y Valve

To Priorit y Valve

J

K

A

Directions: Fill in the blanks next to the letters with the correct term.

All Wheel Steering

STMG XXX 2/06 Handout No. 28

STMG XXX 2/06

- 214 -

Handout No. 29

PUMP SOLENOID TORQUE PARAMETERS DIRECTIONAL MODE ENABLED (FORWARD - OR - REVERSE)

SOLENOID ENERGIZED

SOLENOID DE-ENERGIZED

High Torque

Low Torque

420E

1600 rpm

1300 rpm

430E

1600 rpm

1200 rpm

432E

1600 rpm

1300 rpm

434E

1600 rpm

1300 rpm

442E

1600 rpm

1200 rpm

444E

1600 rpm

1200 rpm

DIRECTIONAL MODE DISABLED (NEUTRAL)

SOLENOID ENERGIZED

SOLENOID DE-ENERGIZED

High Torque

Low Torque

420E

1200 rpm

1100 rpm

430E

1200 rpm

1100 rpm

432E

1200 rpm

1100 rpm

434E

1200 rpm

1100 rpm

434E

1200 rpm

1100 rpm

444E

1200 rpm

1100 rpm