Service manual Caterpillar 416F Backhoe Loader with C4.4, 3054C Engine | LWT00001-UP

416F, 420F and 430F Backhoe Loaders Hydraulic and Steering System
– Bank Valve (Backhoe) – Mechanically Operated
– Bank Valve (Backhoe) – Pilot Operated
– Bank Valve (Loader) – Pilot Operated
– Bank Valve (Loader) – Single Tilt – Direct Operating
– Control Valve (Auxiliary)
– Control Valve (Auxiliary) – Mechanically Operated
– Control Valve (Auxiliary)(Loader) – Mechanically Operated
– Control Valve (Auxiliary)(Loader) – Pilot Operated
– Control Valve (Boom) – Mechanically Operated
– Control Valve (Boom) – Mechanically Operated
– Control Valve (Boom) – Pilot Operated
– Control Valve (Bucket) – Mechanically Operated
– Control Valve (Bucket) – Pilot Operated
– Control Valve (Extendable Stick) – Mechanically Operated
– Control Valve (Extendable Stick) – Pilot Operated
– Control Valve (Lift) – Mechanically Operated
– Control Valve (Lift) – Pilot Operated
– Control Valve (Stabilizer) – Mechanically Operated
– Control Valve (Stabilizer) – Pilot Operated
– Control Valve (Stick) – Mechanically Operated
– Control Valve (Stick) – Pilot Operated
– Control Valve (Swing) – Mechanically Operated
– Control Valve (Swing) – Pilot Operated
– Control Valve (Tilt) – Mechanically Operated
– Control Valve (Tilt) – Pilot Operated
– Crossover Relief Valve (Swing Cushion) – If Equipped
– General Information (Hydraulic System)
– General Information (Steering)
– Hydraulic Oil Contamination – Test
– Hydraulic Pump – Test and Adjust
– Hydraulic Pump – Test and Adjust
– Hydraulic System Lockout
– Hydraulic Tank and Filter
– Metering Pump (Steering)
– Pilot Oil Accumulator – Test and Charge
– Pilot System Pressure – Test
– Piston Pump (Work Tool and Steering)
– Piston Pump (Work Tool and Steering)
– Priority Valve – Inlet Manifold of the Loader
– Pump Flow – Test
– Quick Coupler System – (Coupler with Pilot Operated Check
– Relief Valve (Line) – Test and Adjust
– Relief Valve (Loader) – Test and Adjust
– Relief Valve (Steering Priority) – Test and Adjust
– Relief Valve (Steering) – Test and Adjust
– Ride Control – Test
– Ride Control Accumulator – Test and Charge
– Ride Control System
– System Pressure – Release
– Worksheets – Troubleshoot
416F, 420F, 422F, 428F, 430F, 432F, 434F and 444F Backhoe Loaders Transmission (Autoshift)
– 28.pdf
– Flexible Coupling Drive
– General Information
– Governor Control
– Governor Control
– Machine Preparation for Troubleshooting
– Operational Checks
– Power Train Troubleshooting
– Pressure Taps
– Pump Drive
– Solenoid Valve (Autoshift)
– Solenoid Valve (Autoshift)
– Solenoid Valve (Autoshift)
– Solenoid Valve (Autoshift)
– Steering Lines
– Steering Lines
– Torque Converter
– Torque Converter
– Torque Converter
– Transmission
– Transmission (Autoshift) – All Wheel Drive
– Transmission (Autoshift) – All Wheel Drive
– Transmission (Autoshift) – Lockup Clutch
– Transmission (Autoshift) – Lockup Clutch
– Transmission and Torque Converter – Test
– Transmission and Torque Converter – Test
– Transmission Control
– Transmission Control
– Visual Inspection
416F, 420F, 422F, 428F, 430F, 432F, 434F and 444F Backhoe Loaders Transmission (Standard Shift)
– Flexible Coupling Drive
– General Information
– Governor Control
– Governor Control
– Machine Preparation for Troubleshooting
– Machine Preparation for Troubleshooting
– Operational Checks
– Power Train Troubleshooting
– Pressure Taps
– Pump Drive
– Solenoid Valve (Standard Shift)
– Solenoid Valve (Standard Shift)
– Steering Lines
– Steering Lines
– Torque Converter
– Torque Converter
– Torque Converter
– Transmission (All-Wheel Drive)
– Transmission (Standard Shift) – All Wheel Drive
– Transmission (Standard Shift) – All Wheel Drive
– Transmission (Standard Shift) – Two Wheel Drive
– Transmission (Standard Shift) – Two Wheel Drive
– Transmission (Two-Wheel Drive)
– Transmission and Torque Converter – Test
– Transmission Control
– Transmission Control
– Transmission Hydraulic System
– Visual Inspection
416F, 420F, 422F, 428F, 430F, 432F, 434F, 444F and 450F Backhoe Loaders Monitoring System
– Connector Contact Description
– Data Link
– Diagnostic Operation
– Display Module
– Electrical Connector – Inspect
– General Information
– Input Components
– Menus
– Module – Configure
– Module – Flash Program
– Module – Replace
– Monitoring System
– Output Components
– Self Test
– System Schematic
– Warning Operation
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
Air Conditioning and Heating R134a for All Caterpillar Machines
– Refrigerant Compressor
– System Capacities for Refrigerant (Off-Highway Trucks)
– General Information
– Identifying the Refrigerant
– Identifying the Air Conditioning System
– Identifying the Heating System
– Refrigerant Expansion Valve System
– Refrigerant Orifice Tube System
– Refrigerant Compressor
– Refrigerant Condenser
– Refrigerant Receiver-Dryer
– Refrigerant Compressor
– Refrigerant Expansion Valve
– In-line Refrigerant Dryer
– Refrigerant Orifice Tube Assembly
– Evaporator Coil
– Refrigerant Accumulator
– Refrigerant Compressor Protection System
– Temperature Control
– Pressure Switch (Refrigerant)
– Cab Pressurization and Filtration System
– Condensate Drainage System
– Refrigerant Compressor
– Service Intervals
– Glossary of Terms
– Required Tools
– Machine Preparation for Troubleshooting
– General Troubleshooting Information
– General Troubleshooting Information
– Visual Inspection (Troubleshooting)
– Air Conditioning System Troubleshooting
– Heating System Troubleshooting
– Automatic Temperature Control System (ECM Controlled)
– Refrigerant Compressor
– Troubleshooting Heating and Air Conditioning Control System
– Troubleshooting Heating and Air Conditioning Control System
– Automatic Temperature Control Panel Troubleshooting – 584
– Troubleshooting Condensate Drainage System
– Machine Preparation for Testing and Adjusting
– Air Conditioning Performance – Test
– Refrigerant Leakage – Test
– Manifold Gauge Set (Refrigerant) – Install
– Refrigerant Recovery
– Refrigerant System – Flush
– Refrigerant Compressor
– Refrigerant Oil – Test
– Refrigerant Compressor – Test
– Refrigerant System – Evacuate
– Refrigerant System – Charge
– Manifold Gauge Set (Refrigerant) – Remove
– Compressor Protection System – Test
– Electronic Heat Control – Test
– Heater Performance – Test
– Heating and Air Conditioning Service Publications
– General Information
– Refrigerant Compressor
– Machine Preparation for Disassembly and Assembly
– Air Conditioner Lines – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Accumulator – Remove and Install
– Refrigerant Expansion Valve – Remove and Install
– Refrigerant Receiver-Dryer – Remove and Install
– In-Line Refrigerant Dryer – Remove and Install
– Refrigerant Orifice Tube Assembly – Remove and Install
– Refrigerant Compressor
– System Capacities for Refrigerant (Motor Graders)
– System Capacities for Refrigerant (Off-Highway Trucks) –
– Refrigerant Compressor
Disassembly and Assembly 3054C Engines for Caterpillar Built Machines
– Fuel Injection Lines – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet and Exhaust Valve Guides – Remove and Install
– Inlet and Exhaust Valve Seat Inserts – Remove and Install
– Engine Oil Filter Base – Remove and Install
– Engine Oil Cooler – Remove
– Engine Oil Cooler – Install
– Engine Oil Relief Valve – Remove and Install – Engine without
– Engine Oil Pump – Remove – Engines Without a Balancer
– Engine Oil Pump – Install – Engines Without a Balancer
– Water Pump – Remove and Install
– Fuel Injection Nozzles – Remove
– Water Temperature Regulator – Remove and Install
– Flywheel – Remove
– Flywheel – Install
– Crankshaft Rear Seal – Remove
– Crankshaft Rear Seal – Install
– Crankshaft Wear Sleeve (Rear) – Remove
– Crankshaft Wear Sleeve (Rear) – Install
– Flywheel Housing – Remove and Install
– Crankshaft Pulley – Remove and Install
– Crankshaft Front Seal – Remove
– Fuel Injection Nozzles – Install
– Crankshaft Front Seal – Install
– Front Cover – Remove and Install
– Idler Gear – Remove and Install – Delphi DP210 Fuel Injection
– Housing (Front) – Remove
– Housing (Front) – Install
– Accessory Drive – Remove and Install
– Crankcase Breather – Remove and Install
– Valve Mechanism Cover – Remove and Install
– Rocker Shaft and Pushrod – Remove
– Rocker Shaft – Disassemble
– Fuel Injection Pump – Remove – Delphi DP210
– Rocker Shaft – Assemble
– Rocker Shaft and Pushrod – Install
– Cylinder Head – Remove
– Cylinder Head – Install
– Lifter Group – Remove and Install
– Camshaft – Remove and Install
– Camshaft Bearings – Remove and Install
– Engine Oil Pan – Remove and Install
– Piston Cooling Jets – Remove and Install
– Pistons and Connecting Rods – Remove
– Fuel Injection Pump – Install – Delphi DP210
– Pistons and Connecting Rods – Disassemble
– Pistons and Connecting Rods – Assemble
– Pistons and Connecting Rods – Install
– Connecting Rod Bearings – Remove
– Connecting Rod Bearings – Install
– Crankshaft Main Bearings – Remove
– Crankshaft Main Bearings – Install
– Crankshaft – Remove
– Crankshaft – Install
– Crankshaft Gear – Remove and Install
– Turbocharger – Remove
– Bearing Clearance – Check
– Coolant Temperature Sensor – Remove and Install
– Engine Oil Pressure Sensor – Remove and Install
– Glow Plugs – Remove and Install
– V-Belts – Remove and Install
– Fan – Remove and Install
– Fan Drive – Remove and Install
– Alternator – Remove
– Alternator – Install
– Electric Starting Motor – Remove and Install
– Turbocharger – Install
– Exhaust Manifold – Remove and Install
– Inlet and Exhaust Valve Springs – Remove and Install
– Fuel Priming Pump and Fuel Filter Base – Remove and Install
Disassembly and Assembly 416F, 420F, 422F, 428F, 430F, 432F, 434F and 444F Backhoe Loaders Engine Supplement
– Air Cleaner – Remove and Install
– Alternator – Remove and Install
– Alternator – Remove and Install
– Battery – Remove and Install
– Diesel Particulate Filter – Remove and Install
– Electric Starting Motor – Remove and Install
– Electric Starting Motor – Remove and Install – 434F and 444F
– Engine – Install
– Engine – Install
– Engine – Remove
– Engine – Remove
– Fan – Remove and Install
– Fan Drive – Remove and Install
– Fuel Filter and Water Separator – Remove and Install
– Fuel Priming Pump and Primary Filter (Water Separator) –
– Hood – Remove and Install
– Hydraulic and Transmission Oil Cooler – Remove and Install
– Muffler – Remove and Install
– Radiator – Remove and Install
– Radiator, Fuel Cooler, After Cooler, and Hydraulic and XMSN
– Refrigerant Compressor – Remove and Install
– Refrigerant Condenser – Remove and Install
– Side Panel – Remove and Install
– System Pressure – Release
– Turbocharger – Remove and Install
– Turbocharger – Remove and Install
– Water Pump – Remove and Install
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly C4.4 (Mech) Engines for Caterpillar Built Machines
– Fuel Injection Lines – Remove and Install
– Turbocharger – Install
– Exhaust Manifold – Remove and Install
– Exhaust Manifold – Remove and Install – Type 2 Exhaust
– Exhaust Elbow – Remove and Install
– Inlet and Exhaust Valve Springs – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet and Exhaust Valve Guides – Remove and Install
– Engine Oil Filter Base – Remove and Install
– Engine Oil Cooler – Remove
– Engine Oil Cooler – Install
– Fuel Injector Cover – Remove and Install
– Engine Oil Relief Valve – Remove and Install – Engines with a
– Engine Oil Relief Valve – Remove and Install – Engines Without
– Engine Oil Pump – Remove and Install – Engines Without a
– Water Pump – Remove
– Water Pump – Install
– Water Temperature Regulator – Remove and Install
– Flywheel – Remove
– Flywheel – Install
– Crankshaft Rear Seal – Remove
– Crankshaft Rear Seal – Install
– Fuel Injection Pump – Remove
– Flywheel Housing – Remove and Install
– Crankshaft Pulley – Remove and Install – Engines Without an
– Crankshaft Pulley – Remove and Install – Engines With an
– Crankshaft Front Seal – Remove and Install
– Crankshaft Wear Sleeve (Front) – Remove and Install
– Front Cover – Remove and Install
– Gear Group (Front) – Remove and Install
– Idler Gear – Remove
– Idler Gear – Install
– Housing (Front) – Remove
– Fuel Injection Pump – Install
– Housing (Front) – Install
– Accessory Drive – Remove and Install
– Crankcase Breather – Remove and Install – Naturally Aspirated
– Crankcase Breather – Remove and Install – Turbocharged
– Crankcase Breather – Remove and Install – Turbocharged
– Valve Mechanism Cover – Remove and Install
– Rocker Shaft and Pushrod – Remove
– Rocker Shaft – Disassemble
– Rocker Shaft – Assemble
– Rocker Shaft and Pushrod – Install
– Fuel Injection Pump Gear – Remove
– Cylinder Head – Remove
– Cylinder Head – Install
– Lifter Group – Remove and Install
– Camshaft – Remove and Install
– Camshaft Gear – Remove and Install
– Camshaft Bearings – Remove and Install
– Engine Oil Pan – Remove and Install – Cast Iron Oil Pan
– Balancer – Remove
– Balancer – Install
– Piston Cooling Jets – Remove and Install
– Fuel Injection Pump Gear – Install
– Pistons and Connecting Rods – Remove
– Pistons and Connecting Rods – Remove – Engines with a
– Pistons and Connecting Rods – Disassemble
– Pistons and Connecting Rods – Assemble
– Pistons and Connecting Rods – Install
– Pistons and Connecting Rods – Install – Engines with a
– Connecting Rod Bearings – Remove – Connecting rods in
– Connecting Rod Bearings – Install – Connecting rods in position
– Connecting Rod Bearings – Install – Connecting rods in position
– Crankshaft Main Bearings – Remove and Install – Crankshaft
– Fuel Injector – Remove
– Crankshaft – Remove
– Crankshaft – Install
– Crankshaft Gear – Remove and Install
– Bearing Clearance – Check
– Glow Plugs – Remove and Install
– V-Belts – Remove and Install – Engines Without an Automatic
– Alternator Belt – Remove and Install – Engines With an
– Fan – Remove and Install
– Fan Drive – Remove and Install
– Alternator – Remove – Engines Without an Automatic Belt
– Fuel Injector – Install
– Alternator – Remove – Engines With an Automatic Belt
– Alternator – Install – Engines Without an Automatic Belt
– Alternator – Install – Engines With an Automatic Belt Tensioner
– Electric Starting Motor – Remove and Install
– Air Compressor – Remove and Install
– Vacuum Pump – Remove and Install
– Turbocharger – Remove
– Fuel Priming Pump and Fuel Filter Base – Remove and Install
Schematic Caterpillar 416F Backhoe Loader Hydraulic System
– Features
– Cover Page
– Information
– Component Location
– Tap Location
– Fluid Power Symbols
– Electrical Symbols
– Schematic
– Machine Views
– Bucket Cylinder
– Chassis View
– Stick Cylinder
– Tilt and Lift Cylinder
Schematic Caterpillar 416F, 422F, 428F, and 434F Backhoe Loader Electrical System
Schematic Caterpillar 416F, 422F, and 428F Backhoe Loader Electrical System
Specifications 3054C Engines for Caterpillar Built Machines
– Fuel Injection Lines
– Cylinder Head
– Turbocharger
– Exhaust Manifold
– Camshaft
– Engine Oil Filter
– Engine Oil Pump
– Engine Oil Pressure
– Engine Oil Bypass Valve
– Engine Oil Pan
– Crankcase Breather
– Fuel Injection Pump
– Water Temperature Regulator
– Water Pump
– Cylinder Block
– Crankshaft – Spheroidal Graphite Iron (SGI) Crankshaft
– Crankshaft – Steel Crankshaft
– Crankshaft Seals
– Connecting Rod Bearing Journal – Spheroidal Graphite Iron
– Connecting Rod Bearing Journal – Steel Crankshaft
– Main Bearing Journal – Spheroidal Graphite Iron (SGI)
– Main Bearing Journal – Steel Crankshaft
– Fuel Injection Pump
– Connecting Rod – For Use With Spheroidal Graphite Iron
– Connecting Rod – For Use With Steel Crankshaft
– Piston and Rings
– Piston Cooling Jet
– Balancer – If Equipped
– Front Housing and Covers
– Gear Group (Front)
– Flywheel
– Flywheel Housing
– Crankshaft Pulley
– Fuel Injection Nozzles
– Fan Drive
– Engine Lifting Bracket
– Alternator and Regulator
– Electric Starting Motor
– Glow Plugs
– Fuel Transfer Pump
– Lifter Group
– Rocker Shaft
– Valve Mechanism Cover
– Cylinder Head Valves
– Engine Design
Specifications 416F, 420F and 430F Backhoe Loaders Hydraulic and Steering System
– Backhoe Control Mounting
– Bank Valve (Eight) (Mechanically Operated)
– Bank Valve (Eight) (Pilot Operated)
– Bank Valve (Seven) (Mechanically Operated)
– Bank Valve (Seven) (Pilot Operated)
– Bank Valve (Six)(Mechanically Operated)
– Bank Valve (Six)(Mechanically Operated)
– Bank Valve (Three)(Mechanically Operated)
– Bank Valve (Three)(Mechanically Operated)
– Bank Valve (Three)(Pilot Operated)
– Bank Valve (Two)(Mechanically Operated)
– Boom Cylinder
– Boom Cylinder
– Boom Cylinder
– Bucket Cylinder (Backhoe)
– Bucket Cylinder (Backhoe)
– Bucket Positioner and Lift Kickout
– Control Manifold (Inlet)
– Control Manifold and Solenoid (Boom, Stick, Pattern Switch)
– Control Valve (Auxiliary) (Mechanically Operated)
– Control Valve (Auxiliary) (Pilot Operated)
– Control Valve (Backhoe Bucket) (Pilot Operated)
– Control Valve (Backhoe Bucket)(Mechanically Operated)
– Control Valve (Boom)(Mechanically Operated)
– Control Valve (Boom)(Pilot Operated)
– Control Valve (Lift)(Mechanically Operated)
– Control Valve (Lift)(Pilot Operated)
– Control Valve (Stabilizer) (Mechanically Operated)
– Control Valve (Stabilizer) (Pilot Operated)
– Control Valve (Stick)(Mechanically Operated)
– Control Valve (Stick)(Mechanically Operated)
– Control Valve (Stick)(Pilot Operated)
– Control Valve (Stick)(Pilot Operated)
– Control Valve (Swing)(Mechanically Operated)
– Control Valve (Swing)(Pilot Operated)
– Control Valve (Tilt)(Mechanically Operated)
– Control Valve (Tilt)(Pilot Operated)
– Crossover Relief Valve (Swing Cushion)
– Extendable Stick Cylinder
– Hydraulic Accumulator (Pilot Oil)
– Hydraulic Accumulator (Pilot Oil)
– Hydraulic Hand Control
– Hydraulic Hand Control
– Hydraulic Hand Control (Loader) (Mechanically Operated)
– Hydraulic Hand Control (Loader) (Mechanically Operated)
– Hydraulic Hand Control – Stabilizer
– Hydraulic Pedal Control
– Hydraulic Tank and Mounting
– Joystick Control Mounting
– Lift Arm
– Lift Arm
– Lift Cylinder
– Lift Cylinder Brace
– Lift Cylinder Brace
– Limit Switch (Service Brake)
– Metering Pump (Steering)
– Multipurpose Bucket Cylinder
– Oil Filter (Hydraulic)
– Pin Coupler Cylinder
– Pin Coupler Cylinder
– Pin Coupler Cylinder
– Pin Coupler Cylinder
– Piston Pump (Work Tool and Steering)
– Piston Pump (Work Tool and Steering)
– Radiator and Hydraulic Oil Cooler
– Radiator and Hydraulic Oil Cooler
– Ride Control Accumulator
– Ride Control Accumulator
– Ride Control Manifold
– Service Brake Control
– Service Brake Control
– Stabilizer Cylinder
– Stabilizer Cylinder
– Steering Control
– Steering Cylinder (2WD)
– Stick Cylinder
– Stick Cylinder
– Stick Cylinder
– Swing Cylinder
– Tilt Cylinder
– Tilt Cylinder
– Transport Lock
– Transport Lock
Specifications 416F, 420F, 422F, 428F, 430F, 432F, 434F and 444F Backhoe Loaders Axles, Differential and Brakes
– Axle (Front)
– Axle (Front) – Two-Wheel Drive
– Axle (Rear)
– Axle (Rear)
– Drive and Steering Axle (Front)
– Drive and Steering Axle (Rear)
– Drive Shaft
– Parking Brake Control
– Service Brake Control
– Service Brake Control
– Solenoid Valve and Mounting (Differential Lock)
– Switch (Differential Lock)
– Wheel and Tire (Front)
– Wheel and Tire (Rear) Wheel and Tire (Rear)
Systems Operation & Testing and Adjusting 416F, 420F, 422F, 428F, 430F, 432F, 434F and 444F Backhoe Loaders Axles, Differential and Brakes
– Axle (Front)
– Axle (Front) – Adjust
– Axle (Rear)
– Axle Housing and Bearing Preload – Adjust
– Brake System Air – Purge
– Differential (Standard)
– Differential Backlash and Bearings – Adjust
– Differential Lock – If Equipped
– Differential Pinion Bearing – Adjust
– Drive and Steering Axle (Front)
– Drive and Steering Axle (Front) – Adjust
– Drive and Steering Axle (Rear)
– Drive and Steering Axle (Rear) – Adjust
– Parking Brake Control
– Service Brake Control
– Service Brake Control – Adjust
Systems Operation, Testing and Adjusting 3054C Engines for Caterpillar Built Machines
– Fuel System
– Finding Top Center Position for No. 1 Piston
– Fuel Injection Nozzle – Test
– Fuel Injection Pump Timing – Adjust
– Fuel Quality – Test
– Fuel System – Prime
– Fuel System Pressure – Test
– Air Inlet and Exhaust System – Inspect
– Turbocharger – Inspect
– Exhaust Temperature – Test
– Engine Crankcase Pressure (Blowby) – Test
– Air Inlet and Exhaust System
– Compression – Test
– Engine Valve Lash – Inspect/Adjust
– Valve Depth – Inspect
– Valve Guide – Inspect
– Engine Oil Pressure – Test
– Engine Oil Pump – Inspect
– Excessive Bearing Wear – Inspect
– Excessive Engine Oil Consumption – Inspect
– Increased Engine Oil Temperature – Inspect
– Cooling System – Check – Overheating
– Lubrication System
– Cooling System – Inspect
– Cooling System – Test
– Engine Oil Cooler – Inspect
– Water Temperature Regulator – Test
– Piston Ring Groove – Inspect
– Connecting Rod – Inspect
– Connecting Rod Bearings – Inspect
– Main Bearings – Inspect
– Cylinder Block – Inspect
– Cylinder Head – Inspect
– Cooling System
– Piston Height – Inspect
– Flywheel – Inspect
– Flywheel Housing – Inspect
– Gear Group – Inspect
– Alternator – Test
– Battery – Test
– Electric Starting System – Test
– Glow Plugs – Test
– Basic Engine
– Electrical System
– Troubleshooting
– Fuel System – Inspect
– Air in Fuel – Test
– General Information