"E" SERIES BACKHOE LOADERS

INTRODUCTION, OPERATOR’S STATION,

ENGINE, ELECTRICAL SYSTEM, AND
POWER TRAIN

© 2007 Caterpillar Inc.

 "E" SERIES BACKHOE LOADER MACHINE SYSTEMS

LOADER BACKHOE BACKHOE LOADER

MODEL TRANSMISSION POWER TRAIN STEERING ENGINE BRAKES
LINKAGE LINKAGE HYDRAULICS HYDRAULICS

2WD 3054C NA
416E Single Tilt Center Pivot Mechanical Mechanical Standard (O) AWD 2WS No Boost
3054C Turbo

420E Single Tilt Mechanical Standard 2WD

Center Pivot Pilot (O) AutoShift 2WS 3054C Turbo Boosted
(O) AWD
420E IT Parallel Lift Pilot

2WD 3054C NA
422E Single Tilt Side Shift Mechanical Mechanical Standard (O) AWD 2WS No Boost
3054C Turbo

428E Parallel Lift Side Shift Mechanical Mechanical Standard AWD 2WS 3054C Turbo No Boost

430E Single Tilt Mechanical Standard

Center Pivot Pilot (O) AutoShift AWD 2WS 3054C Turbo Boosted
430E IT Parallel Lift Pilot
Standard 2WS
432E Parallel Lift Side Shift Pilot Pilot (O) Autoshift AWD 3054C Turbo Boosted
(O) AWS

Standard
434E Parallel Lift Side Shift Pilot Pilot AWD AWS 3054C Turbo Boosted
(O) AutoShift

Standard 2WS
442E Parallel Lift Side Shift Pilot Pilot AWD 3054C Turbo Boosted
(O) AutoShift (O )AWS

Standard
444E Parallel Lift Side Shift Pilot Pilot AWD AWS 3054C Turbo Boosted
(O) AutoShift

(O) Optional
SIMILARITIES WITH FORMER MACHINES

- Engines
- Fuel Syst ems
- All Wheel Steering (AWS)
- Ride Control
- Transmissions
- St andard Brake Syst em ( 4 1 6 E/ 4 2 2 E/ 4 2 8 E)
- Maint enance
DIFFERENCES FROM FORMER MACHINES
- Machine Appearance and Operator s Station
- Electrical System
- Cat erpillar Immobilizer Syst em
- Transmission Cont rol Valves
- Rear Axle and Differential Lock
- Brake Mast er Cylinders
- PPPC Implement Hydraulic Syst ems:
- St eering and Implement Pump
- Main Cont rol Valve Groups and St eering Syst em
- Joysticks
- Pattern Change Valve
- Powered Sideshift Option
- E-St ick
- Test Procedures
 FUEL INJECTION PUMP
3054C NATURALLY ASPIRATED ENGINE
Control Flyweight
Lever
Governor Lever
Full-load Adjusting
Screw

Drive
Shaft Engine Shutoff Solenoid

Distributor Head
Control Sleeve
Feed Pump

Roller Holder Plunger

Cam Plate

Timing
Advance High Pressure
Mechanism Plunger Return Spring Delivery Valve Pump Chamber
 FUEL INJECTION PUMP
3054C TURBOCHARGED ENGINE
Low Idle High Idle Throttle Lever
Stop Stop
Governor Metering Valve
Spring
Fuel Shutoff
Solenoid
Vent Orifice
Fuel Inlet

Transfer
Fuel Return
Pressure
Check Valve
Regulator

Scroll Link Screen

Plate

Transfer
Drive
Pump
Shaft

Shifter and Plungers

Sleeve
To Injector
Governor
Flyweights Shoes
Scroll Plates

Rollers Cam Ring Automatic Advance Orifice

Mechanism Check Valve
 3054C TURBO TIER II FUEL HYDRAULIC SYSTEM
ENGINE RUNNING / COLD START ADVANCE POSITION

Boost Priming Pump/ Filter / Water Transfer

Separator Main
Pressure Pressure
Fuel Tank Filter
Regulator

Boost Feed
Controller Pump

Shutoff
Solenoid
Injector
Fuel Return
Torque
Check Valve Vent Orifice
Trimmer
Delivery
Valve

Rotor
Cam
Ring
Rollers Transfer
Pump
Metering
Valve
Plungers
Cold Start
Advance
Solenoid
Shoes
Flat
Scroll Plates Automatic Hydraulic
Advance Head
Mechanism

Orifice
Check Valve
Light Load
Latch
Advance Valve
Valve
 "E" SERIES STARTING AND CHARGING SYSTEM
TURBO ENGINE / START

123-EF53 WH 1 Excitation
2 Resistor
G S CBL LL1 RD
CBL AA1 RD
309 GY To Lamp Group
Mtr Bat

Pos Neg Pos Neg

Motor
101-EF9 RD 1 D+
5
2 450-YL W
304 WH 4 308 YL B+
Starter Alternator
3
TachR
CBL CC1 RD
Start
Power Module 1 Power Module 2
Relay

B+ B+ Fuel Lift
123-EF18 WH 1 Pump
5 Relay
60 A 60 A
2
4
60 A 60 A 3
Battery 1 308 YL
Ground 2 202 BK X977 YL 1 Motor
Forward Sol Return 3 2
Reverse Sol Return 4 308 YL 1 1
Forward Sol. Out 5 2 2
Reverse Sol. Out 6 1
Start Relay Out 7 306 GN 307 OR 2 Fuel Lift
Key Start Sw. Start 8 Pump
Not Used 9 Fuel Lift Pump
Not Used 10 USB SB USB SB Arc Suppressor
Not Used 11
Not Used 12
146-PA2 GY
Shuttle Control
146-PA6 GY Cold Start
103-PA20 RD 123-EF23 WH 334 BU Advance
103-PA1 RD T Solenoid
Cold Start
Fuse Block Temp. Sw.

Key Start
Fuel Shutoff
Switch 123-EF28 WH 1 327 PK A
2 B Solenoid
Key Start Turbo
R 10 A

1 308 YL 20 A
Off C
2
On S Machine ECM 101-EF11 RD
3 307 OR 1
St B
4 105 RD 123-EF10 WH 5
112-PA7 PU 2 Start Aid
4 Relay
3
Lift Pump
384 BU 1
15 A 310 PU

123 WH Start Glow

Aid Switch Plugs
 "E" SERIES STARTING AND CHARGING SYSTEM
TURBO ENGINE / RUN

123-EF53 WH 1 Excitation
2 Resistor
G S CBL LL1 RD
CBL AA1 RD
309 GY To Lamp Group
Mtr Bat

Pos Neg Pos Neg

Motor
101-EF9 RD 1 D+
5
2 450-YL W
304 WH 4 308 YL B+
Starter Alternator
3
TachR
CBL CC1 RD
Start
Power Module 1 Power Module 2
Relay

B+ B+ Fuel Lift
123-EF18 WH 1 Pump
5 Relay
60 A 60 A
2
4
60 A 60 A 3
Battery 1 308 YL
Ground 2 202 BK X977 YL 1 Motor
Forward Sol Return 3 2
Reverse Sol Return 4 308 YL 1 1
Forward Sol. Out 5 2 2
Reverse Sol. Out 6 1
Start Relay Out 7 306 GN 307 OR 2 Fuel Lift
Key Start Sw. Start 8 Pump
Not Used 9 Fuel Lift Pump
Not Used 10 USB SB USB SB Arc Suppressor
Not Used 11
Not Used 12
146-PA2 GY
Shuttle Control
146-PA6 GY Cold Start
103-PA20 RD 123-EF23 WH 334 BU Advance
103-PA1 RD °T Solenoid
Cold Start
Fuse Block Temp. Sw.

Key Start
Fuel Shutoff
Switch 123-EF28 WH 1 327 PK A
2 B Solenoid
Key Start Turbo
R 10 A

1 308 YL 20 A
Off C
2
On S Machine ECM 101-EF11 RD
3 307 OR 1
St B
4 105 RD 123-EF10 WH 5
112-PA7 PU 2 Start Aid
4 Relay
3
Lift Pump
384 BU 1
15 A 310 PU

123 WH Start Glow

Aid Switch Plugs
 "E" SERIES STARTING AND CHARGING SYSTEM
NATURALLY ASPIRATED ENGINE / RUN

123-EF53 WH 1 Excitation
2 Resistor
G S CBL LL1 RD
CBL AA1 RD
309 GY To Lamp Group
Mtr Bat

Pos Neg Pos Neg

Motor
101-EF9 RD 1 D+
5
2 450-YL W
304 WH 4 308 YL B+
Starter Alternator
3
TachR
CBL CC1 RD
Start
Power Module 1 Power Module 2
Relay

B+ B+ Fuel Lift
123-EF18 WH 1 Pump
5 Relay
60 A 60 A
2
4
60 A 60 A 3
Battery 1 308 YL
Ground 2 202 BK X977 YL 1 Motor
Forward Sol Return 3 2
Reverse Sol Return 4 308 YL 1 1
Forward Sol. Out 5 2 2
Reverse Sol. Out 6 1
Start Relay Out 7 306 GN 307 OR 2 Fuel Lift
Key Start Sw. Start 8 Pump
Not Used 9 Fuel Lift Pump
Not Used 10 USB SB USB SB Arc Suppressor
Not Used 11
Not Used 12
146-PA2 GY
Shuttle Control
146-PA6 GY Cold Start
103-PA20 RD 123-EF23 WH 334 BU Advance
103-PA1 RD T Solenoid
Cold Start
Fuse Block Temp. Sw.

Key Start Fuel Shutoff

Switch 123-EF28 WH 1 A Solenoid
2 B NA
Key Start
R 10 A

1 308 YL 20 A
Off C
2
On S Machine ECM 101-EF11 RD
3 307 OR 1
St B
4 105 RD 123-EF10 WH 5
112-PA7 PU 2 Start Aid
4 Relay
3
Load Check
384 BU 1
10A 310 PU

123 WH Start Glow

Aid Switch Plugs
 "E" SERIES BHL MACHINE ECM INPUTS AND OUTPUTS
DIRECT DRIVE TRANSMISSION
Transmission Output Speed Sensor Quick Coupler Relay
Hydraulic Oil Temperature Sensor Transmission Forward Solenoid
Stabilizer Neutral Switch Transmission Reverse Solenoid
Loader Quick Coupler Pins Switch
Loader Auxiliary Valve Solenoid 1
Continuous Flow Switch
Loader Auxiliary Valve Solenoid 2
Ride Control Switch
Backhoe Auxiliary Valve 1 Solenoid 1
Park Brake Switch
Transmission Lock Switch Backhoe Auxiliary Valve 1 Solenoid 2

Implement Lockout Switch Backhoe Auxiliary Valve 2 Solenoid 1

Alternator R Terminal Backhoe Auxiliary Valve 2 Solenoid 2

Key Start Switch (+BAT) Feature Alarm

Hydraulic Oil Filter Bypass Switch Ride Control Relay

Action Lamp
Loader Joystick Thumb Switch
Implement Enable Relay
Machine Handle Attachment (8th Function) Switch
Machine Backup Alarm Relay
Transmission Shift Lever
ECM Hydraulic Filter Bypass Indicator
Engine Oil Pressure Switch
Torque Limiter Relay
Engine Coolant Temperature Switch
Hydraulic Temperature Indicator
Brake Fluid Level Switch
Air Filter Switch CAT ET
CAT Data Link
Fuel Water Separator Switch Product Link
Right Joystick (7th Function) Switch CAN Data Link (If Equipped)

Right Joystick Neutralize Switch

 "E" SERIES BHL MACHINE ECM INPUTS AND OUTPUTS
AUTOSHIFT TRANSMISSION
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 Auxiliary Valve Solenoid 1
Loader Quick Coupler Pins Switch 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
Implement Lockout Switch Backhoe Auxiliary Valve 2 Solenoid 2

Alternator R Terminal Transmission Forward High Clutch Solenoid

Key Start Switch (+BAT) Feature Alarm

Hydraulic Oil Filter Bypass Switch Transmission Speed Clutch Solenoid 1

Loader Joystick Thumb Switch Transmission Speed Clutch Solenoid 2

Machine Transmission Speed Clutch Solenoid 3
Machine Handle Attachment (8th Function) Switch
ECM
Ride Control Relay
Transmission Shift Lever
Action Lamp
Engine Oil Pressure Switch
Implement Enable Relay
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
CAT ET
Right Joystick Neutralize Switch CAT Data Link
Product Link
CAN Data Link (If Equipped)
 Machine Immobilizer MACHINE IMMOBILIZER SYSTEM
Valve Assembly
Gnd 1 202-BK-18
Rtn Immobilizer Ind 2 A250-BK-18
Pwr 12v 3 105-RD-18 From Battery
Key Sw Pwr 4 308-YL-18 From Key Start Switch
Start Rly Pos 5 A346-BU-18
Start Rly Neg 6
Sig Immobilizer 7 G848-GN-18
Sig Immobilizer Ind 8 F846-PU-18

Crank Interrupt Relay

Diode Assembly 218-BK-18 1 30
86 +
1 A347-GN-18 A347-GN-18 5
2 333-GN-18 202-BK-18 2
3 225-BK-18 265-BK-18 4 85 -
200-BK-18 87
4 3 87A

Touchkey Reader
F846-PU-18 A Sig Immobilizer Ind
A250-BK-18 B Rtn Immobilizer Ind
G848-GN-18 C Sig Immobilizer
Solid State Relay
Battery 1 308-YL-18 From Key Start
Gnd 2 202-BK-18 Switch
Input Sig 3 A346-BU-18
Output Sig 4 333-GN-18 To Fuel Shutoff Solenoid
 "E" SERIES BACKHOE LOADER
STANDARD TRANSMISSION

TWO WHEEL DRIVE AWD WHEEL DRIVE

Torque Forward Idler Forward Idler

Converter Clutch Shaft Clutch Shaft
Housing
Reverse Reverse
Clutch Clutch
Pump Pump

Input Input
Shaft Shaft

Countershaft

Forward Drive Output Output

Gear Shaft Shaft

Speed Gear Speed Gear

Synchronizer AWD
Assembly Shaft

AWD
Clutch
 STANDARD POWER TRAIN Load
Piston
HYDRAULIC SYSTEM Flow
Control
FORWARD Orifice

Regulated
Pressure
R

Modulating
Relief
Filter Valves

F
Relief
Valve Directional
Selector
Solenoid Valve
Load
Piston
Pump
Supply
Torque
Torque Torque
Converter
Converter Converter
Inlet
Inlet Relief
Pump Valve
Transmission Torque
Lube Converter
Temperature
Oil Cooler Sensor
Lube (Outlet)
Suction Screen
 STANDARD POWER TRAIN Load
Piston
HYDRAULIC SYSTEM Flow
Control
ALL WHEEL DRIVE/FORWARD Orifice

Regulated
Pressure R

Modulating
Relief
Filter Valves

F
Relief
Valve Directional
Selector
AWD Soleniod Solenoid Valve
Load
Valve
Piston
AWD
Pump Torque
Supply Torque Torque
Converter
Converter Converter
Inlet
Inlet Relief
Pump Valve
Transmission Torque
Lube Converter
Temperature
Oil Cooler Sensor
Lube (Outlet)
Suction Screen
 AUTOSHIFT TRANSMISSION

Solenoid
Valves

Pump

Input
Shaft
Counter
Shaft

Output
Shaft

AWD
Shaft
 AUTOSHIFT POWER TRAIN HYDRAULIC SYSTEM
2WD / FIRST SPEED FORWARD
Data Link
Service Port

Shift Lever Parking Brake Switch

Ride Control Switch Machine Downshift / Neutralizer Switch
Auto / Manual Switch ECM Transmission Output Speed Sensor
Neutral Lock Switch Ride Control Disable

Regulated
Pressure

Orifice
Forward Forward
Filter 5 6 3 Reverse High 1 Low 4
2
Clutch Clutch Clutch
Solenoid Solenoid Solenoid
Speed Speed Speed
Clutch 2 Clutch 3 Clutch 1
Solenoid Solenoid Solenoid
1
3
Pump Load
Supply 2 Piston

Modulating Modulating
Relief Valve Relief Valves
Relief
LO Valve
Torque
R HI Converter Inlet

Pump Torque
Transmission
Lube Converter Torque
Suction Oil Cooler Converter
Screen Torque Inlet
Converter Relief Valve
Lube Temperature
Sensor
(Outlet)
 AUTOSHIFT POWER TRAIN HYDRAULIC SYSTEM
ALL WHEEL DRIVE / SECOND SPEED FORWARD

Data Link
Service Port

Shift Lever Parking Brake Switch

Ride Control Switch Machine Downshift / Neutralizer Switch
Auto / Manual Switch ECM Transmission Output Speed Sensor
Neutral Lock Switch Ride Control Disable

Regulated
Pressure

Orifice
Forward Forward
Filter 5 6 3 Reverse High 1 Low 4
2
Clutch Clutch Clutch
Solenoid Solenoid Solenoid
Speed Speed Speed
Clutch 2 Clutch 3 Clutch 1
Solenoid Solenoid Solenoid
1
3
Load
2 Piston

Modulating Modulating
AWD Relief Valve Relief Valves
Relief
LO Valve
Torque
Pump
Supply R HI Converter Inlet

Pump Torque
Transmission
Lube Converter Torque
Suction Oil Cooler Converter
Screen Torque Inlet
Converter Relief Valve
Lube Temperature
Sensor
(Outlet)
 Reverse Clutch

AUTOSHIFT TRANSMISSION
Forward High Forward Low
Clutch Clutch

Input
Shaft

CLUTCH ENGAGEMENT Clutch 1

Forward Forward Counter

Gear Low High Reverse 1 2 3 Solenoid Shaft
5F X X 2 AND 6
Clutch 3
4F X X 1 and 6

3F X X 2 and 5 Output
Shaft
2F X X 2 and 4
AWD
1F X X 1 and 4
Clutch
N
Clutch 2
1R X X 3 and 4 AWD
Shaft
2R X X 3 and 5

3R X X 3 and 6
 AUTOSHIFT ELECTRONIC TRANSMISSION CONTROL SYSTEM

Forward Low
Key Start No. 1 Solenoid
Switch
Transmission
Forward High
No. 2 Solenoid
Shift
Parking Brake
Switch Reverse
Lever No. 3 Solenoid
Neutral Lock
Switch
Machine
Speed Clutch 1
No. 4 Solenoid
Transmission Output
Electronic
Speed Sensor Speed Clutch 2
Start Control No. 5 Solenoid
Relay
Autoshift Control
Switch Module Speed Clutch 3
No. 6 Solenoid
Transmission
Neutralizer Switch Park Brake
Alarm Relay

Cat Data Link

AUTOSHIFT TRANSMISSION
1ST GEAR ENABLED

Shift Lever Gears

Position Available
4F 1, 2, 3, 4, 5
3F 1, 2, 3
2F 1, 2
1F 1
N
1R 1
2R 1, 2
3R 1, 2, 3
AUTOSHIFT TRANSMISSION
1ST GEAR DISABLED
Shift Lever Gears
Position Available
4F 2, 3, 4, 5
3F 2, 3
2F 2
1F 1
N
1R 1
2R 2
3R 2, 3
 BRAKE MASTER CYLINDERS
Left Brake Right Brake From
Engaged Released Reservoir

To Brake To Brake
Piston Piston
Supply Port

Valve Stem

Plunger
Compensation Plunger
Valve

Bridge Pipe
Push Rod
 BOOSTED BRAKE GROUP
Both Released
RELEASED From Pilot
Secondary
Reservoir Piston To Brake
Pilot Circuit Spring Chamber Actuator
Supply
Port
Plunger

One Engaged

Primary
Piston Drain Compensation
Large
Port Passage Port
Spring Chamber

ENGAGED From Pilot Reservoir To Brake

Circuit Actuator

Compensation
Check Valve

Both Engaged

Primary
Piston Check Secondary
Feedback
Valve Piston
Spring Chamber
 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 Pink - 3rd reduction in pressure

Air (No 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) Orange / White Stripes -

Identification of components Reduced pilot, charge, or TC oil pressure
within a moving group
Orange Crosshatch - 2nd reduction in
Brown - Lubricating oil pilot, charge, or TC oil pressure.

Green - Tank, sump, or return oil Blue - Trapped oil

Green / White Stripes -

Scavenge Oil or Hydraulic Void