Parts Manual BACKHOE Loader 416C CATERPILLAR

SEBP3706-30 September 2011 Parts Manual See “General Information” for New Parts Manual Features. 416C Backhoe Loader Single Tilt, Center Pivot CBD1-Up (Machine) MFG1-Up (Machine) C4Z1-Up (Engine) CRS1-Up (Engine) G4D1-Up (Engine) Powered By 3054C and C4.4 Engine SAFETY.CAT.COM

Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number: Dealer Information Name: Branch: Address: D e a l e r C o n t a c t P h o n e N u m b e r H o u r s Sales: Parts: Service:

MEMORANDA MEMORANDA SEBP3706-30

TABLE OF CONTENTS Name Page Name Page GENERAL INFORMATION ......... ......... A5 REPAIR ALTERNATIVES .......... .......... A8 SUPPLEMENTAL COOLANT ADDITIVES ... ... A9 MAINTENANCE PARTS ........... ........... A10 INDEX ................... ................... A14 MACHINE ARRANGEMENT ......... ......... 1 BACKHOE AR-EXTENDABLE STICK ... ... 1 BACKHOE AR-STANDARD STICK ..... ..... 1 CHASSIS AR ............... ............... 2 COMMON AR .............. .............. 3 DISTRIBUTION AR ............ ............ 4 DISTRIBUTION AR............. ............ 9 DISTRIBUTION AR ............ ............ 10 DRIVE AR-BACKHOE LOADER ...... ...... 16 LOADER AR ............... ............... 17 ENGINE ARRANGEMENT .......... .......... 19 ENGINE AR .............................. 19 ENGINE AR-PRIMARY .......... .......... 23 BASIC ENGINE ............... ............... 27 CAMSHAFT GP ............. ............. 27 COVER GP-VALVE MECHANISM ..... ..... 29 CRANKSHAFT GP ............ ............ 41 CYLINDER BLOCK GP .......... .......... 50 CYLINDER HEAD GP ........... ........... 57 DRIVE GP-FAN .............. .............. 63 FLYWHEEL GP .............. .............. 65 HOUSING GP-FLYWHEEL ........ ........ 67 HOUSING GP-FRONT .......... .......... 69 LIFTING GP-ENGINE ........... ........... 73 MOUNTING GP-ENGINE ......... ......... 75 MOUNTING GP-ENGINE & XMSN ..... ..... 77 PAN GP-OIL ............... ............... 79 PISTON & ROD GP ........................ 85 PLUG GP-CYLINDER HEAD ....... ....... 93 PLUG GP-ENGINE ............ ............ 94 PULLEY GP-CRANKSHAFT ........ ........ 99 ROCKER ARM GP ............ ............ 102 VALVE MECHANISM GP ......... ......... 104 LUBRICATION SYSTEM .......... .......... 107 BREATHER GP .............. .............. 107 FILLER GP-ENGINE OIL ......... ......... 110 GAUGE GP-OIL LEVEL & FILLER ..... ..... 111 PUMP GP-ENGINE OIL .......... .......... 113 COOLING SYSTEM .......................... 115 CONNECTION GP-WATER ........ ........ 115 COOLER AS-OIL .......................... 118 COOLER GP-ENGINE OIL ........ ........ 119 COOLER GP-FLTR BASE & ENG OIL ... ... 122 FAN GP-SUCTION ............ ............ 128 LINES GP-POWER TRAIN COOLER .... .... 134 LINES GP-RADIATOR .......... .......... 136 LINES GP-TRANSMISSION COOLER ... ... 138 MOUNTING & LINES GP-RADIATOR ... ... 140 MOUNTING GP-RAD & OIL COOLER ... ... 141 PUMP GP-WATER ............ ............ 143 RADIATOR & HYD OIL COOLER GP .... .... 149 RADIATOR & OIL COOLER GP ...... ...... 151 TANK GP-EXPANSION .......... .......... 155 AIR INLET AND EXHAUST SYSTEM ..... ..... 156 AIR CLEANER GP ............ ............ 156 CONNECTION GP-INLET ......... ......... 167 COVER GP-INLET MANIFOLD ...... ...... 168 EXTENSION GP-EXHAUST ........ ........ 171 INDICATOR GP-AIR FILTER CHANGE ... ... 172 LINES GP-AIR .............. .............. 174 MANIFOLD GP-EXHAUST ........ ........ 175 MUFFLER & CONVERTER ........ ........ 176 MUFFLER GP .............. .............. 177 TURBOCHARGER GP .......... .......... 180 FUEL SYSTEM ............... ............... 184 CONTROL GP-GOVERNOR ........ ........ 184 FILTER GP-WATER SEP & FUEL ..... ..... 192 LINES GP-FUEL ............. ............. 193 LINES GP-FUEL FILTER ......... ......... 203 PUMP GP-FUEL INJECTION ....... ....... 204 PUMP GP-FUEL PRM & PRIM FILTER ... ... 214 TANK & MTG GP-FUEL .......... .......... 218 TANK GP-FUEL ............. ............. 219 ELECTRICAL AND STARTING SYSTEM ... ... 223 ALTERNATOR GP-CHARGING ...... ...... 223 BATTERY & WIRING GP ......... ......... 226 ELECTRONICS GP- COMMUNICATION ............ ............ 246 GLOW PLUG GP .......................... 247 HEATER GP-JACKET WATER ....... ....... 249 INSTALLATION GP-COMMUNICATION ... ... 250 LAMP GP-FLOOD ............ ............ 254 LAMP GP-WARNING BEACON ...... ...... 257 LIGHTING GP-FLOOD & SIGNAL ..... ..... 259 LIGHTING GP-WARNING BEACON .... .... 266 PANEL GP-FUSE ............. ............. 268 RELAY GP ................................ 269 STARTING MOTOR GP-ELECTRIC .... .... 273 SWITCH GP-ALL WHEEL DRIVE ..... ..... 277 SWITCH GP-DIFFERENTIAL LOCK .... .... 278 SWITCH GP-DISCONNECT ........ ........ 279 SWITCH GP-PRESSURE ......... ......... 280 WIRING GP-AIR CONDITIONER ...... ...... 282 SEBP3706-30 TABLE OF CONTENTS A1

TABLE OF CONTENTS Name Page Name Page WIRING GP-CONSOLE .......... .......... 291 WIRING GP-ENGINE ........... ........... 299 WIRING GP-HEATER ........... ........... 313 WIRING GP-KICKOUT & POSITIONER ... ... 317 WIRING GP-PLATFORM ......... ......... 323 WIRING GP-REAR ........................ 344 WIRING GP-RIDE CONTROL ....... ....... 345 POWER TRAIN .............................. 347 AXLE GP-DRIVE & STEERING ...... ...... 347 AXLE GP-REAR ............. ............. 350 CASE AS-TRANSMISSION ........ ........ 353 CASE GP-TRANSMISSION ........ ........ 360 DIFFERENTIAL & BEVEL GEAR GP .... .... 363 DIFFERENTIAL GP ........................ 365 DRIVE GP-FLEXIBLE COUPLING ..... ..... 367 FILLER GP-POWER TRAIN OIL ...... ...... 368 FLANGE GP-WHEEL ........... ........... 375 HOUSING & FLANGE GP-AXLE ...... ...... 377 HOUSING GP-AXLE ........... ........... 381 LINES GP-POWER TRAIN OIL ...... ...... 383 MOUNTING GP-AXLE .......... .......... 384 MOUNTING GP-TRANSMISSION ..... ..... 385 PLANETARY GP-FINAL DRIVE ...... ...... 386 POWER TRAIN AR ............ ............ 388 SHAFT GP-DRIVE ............ ............ 392 SHAFT GP-INPUT ............ ............ 393 SHAFT GP-OUTPUT ........... ........... 397 TRANSMISSION & MOUNTING GP .... .... 401 TRANSMISSION AR-DIRECT DRIVE .... .... 403 TRANSMISSION GP-DIRECT DRIVE ... ... 404 VALVE GP-RELIEF ............ ............ 424 VALVE GP-TIRE ............. ............. 425 WHEEL & TIRE AR ............ ............ 426 WHEEL & TIRE GP ........................ 428 BRAKING SYSTEM .......................... 440 CONTROL GP-PARKING BRAKE ..... ..... 440 CONTROL GP-SERVICE BRAKE ..... ..... 442 CYLINDER GP-BRAKE .......... .......... 448 LEVER GP-HAND CONTROL ....... ....... 450 RESERVOIR GP-BRAKE ......... ......... 451 STEERING SYSTEM ............ ............ 453 AXLE GP-FRONT ............. ............. 453 KNOB GP-STEERING .......... .......... 455 LINES GP-STEERING .......... .......... 456 PUMP GP-METERING .......... .......... 464 FRAME AND BODY ............. ............. 465 BOX GP-BATTERY ............ ............ 465 COUNTERWEIGHT GP .......... .......... 468 DOOR GP-BATTERY ........... ........... 471 DRAWBAR GP ............................ 472 EXTENSION GP-FENDER ........ ........ 473 FENDER GP-FRONT ........... ........... 474 FENDER GP-REAR ............ ............ 475 FLOORPLATE GP ............ ............ 480 FRAME AS-SWING ........................ 483 FRAME GP-LOADER ........... ........... 484 FRAME GP-SWING ............ ............ 494 GUARD GP-CYLINDER .......... .......... 500 GUARD GP-DRIVE SHAFT ........ ........ 502 GUARD GP-RADIATOR .......... .......... 503 HOOD & GUARD GP ........... ........... 504 HOOD GP-ENGINE ............ ............ 512 HYDRAULIC SYSTEM ........... ........... 520 ACCUMULATOR GP-RIDE CONTROL ... ... 520 CONTROL AR-RIDE ........... ........... 524 CONVERSION AR-CUSHION SWING ... ... 525 COOLER GP-HYD & XMSN OIL ...... ...... 527 CYLINDER & LINES GP-THUMB ..... ..... 528 CYLINDER GP-BACKHOE BUCKET .... .... 531 CYLINDER GP-BOOM .......... .......... 535 CYLINDER GP-HYDRAULIC ....... ....... 537 CYLINDER GP-LIFT ........... ........... 541 CYLINDER GP-MULTIPURPOSE BUKT .................. .................. 544 CYLINDER GP-STABILIZER ........ ........ 547 CYLINDER GP-STICK .......... .......... 553 CYLINDER GP-THUMB .......... .......... 555 CYLINDER GP-TILT ........... ........... 556 DRIVE & MTG GP-PUMP ......... ......... 558 FASTENER GP-VALVE .......... .......... 559 FILTER GP-OIL .............. .............. 560 FITTING GP-HYDRAULIC ......... ......... 561 HYDRAULIC AR ............. ............. 562 KICKOUT & POSITIONER GP ....... ....... 563 LINES GP-BACKHOE AUXILIARY ..... ..... 569 LINES GP-BOOM ............. ............. 599 LINES GP-BUCKET ............ ............ 605 LINES GP-CONNECTING ......... ......... 620 LINES GP-DRAIN ............. ............. 621 LINES GP-EXTENDABLE STICK ..... ..... 622 LINES GP-HYDRAULIC OIL COOLER ... ... 626 LINES GP-LIFT CYLINDER ........ ........ 630 LINES GP-LOADER AUXILIARY ...... ...... 634 LINES GP-MULTIPURPOSE BUCKET ... ... 638 LINES GP-PILOT .......................... 648 LINES GP-PUMP .......................... 652 LINES GP-RIDE CONTROL ........ ........ 654 LINES GP-STABILIZER .......... .......... 660 LINES GP-STICK .......................... 664 LINES GP-SWING ............ ............ 667 LINES GP-TILT CYLINDER ........ ........ 668 MANIFOLD GP-CONTROL ........ ........ 672 MANIFOLD GP-RIDE CONTROL ..... ..... 674 MOUNTING GP-BANK VALVE ....... ....... 675 MOUNTING GP-CYLINDER ........ ........ 679 A2 TABLE OF CONTENTS SEBP3706-30

TABLE OF CONTENTS Name Page Name Page MOUNTING GP-LINES .......... .......... 681 PUMP GP-PISTON ............ ............ 684 SHAFT GP-PUMP DRIVE ......... ......... 691 TANK & MTG GP-HYDRAULIC ...... ...... 692 VALVE AR-BANK 2 ............ ............ 696 VALVE AR-BANK 3 ............ ............ 696 VALVE AR-BANK 6 ............ ............ 696 VALVE AR-BANK 7 ............ ............ 697 VALVE AR-BANK 8 ............ ............ 697 VALVE GP-BANK 2 ............ ............ 698 VALVE GP-BANK 3 ............ ............ 699 VALVE GP-BANK 6 ............ ............ 700 VALVE GP-BANK 7 ............ ............ 702 VALVE GP-BANK 8 ............ ............ 704 VALVE GP-CONTROL .......... .......... 706 VALVE GP-PUMP CONTROL ....... ....... 720 VALVE GP-SHUTTLE ........... ........... 721 IMPLEMENTS ............... ............... 722 ARM GP-LIFT .............. .............. 722 BOOM & BEARING AS .......... .......... 724 BOOM GP ................ ................ 725 BRACE GP-LIFT CYLINDER ....... ....... 726 GUARD GP-BOOM ............ ............ 727 LINKAGE GP-BACKHOE BUCKET ..... ..... 729 LINKAGE GP-LOADER BUCKET ..... ..... 731 LOCK GP-TRANSPORT .......... .......... 734 MOUNTING GP-STICK .......... .......... 738 PAD & GUARD GP-STABILIZER ...... ...... 739 PAD & MTG GP-STABILIZER ....... ....... 762 PAD GP-STABILIZER ........... ........... 769 STABILIZER GP-BACKHOE ........ ........ 771 STICK AS ................................ 773 STICK GP ................ ................ 774 STICK GP-HOE ............. ............. 778 WORK TOOLS ............... ............... 780 ADJUSTER GP-MANUAL ......... ......... 780 BUCKET AR-MULTIPURPOSE ...... ...... 781 BUCKET AS-GENERAL PURPOSE .... .... 783 BUCKET AS-HOE ............ ............ 788 BUCKET GP-GENERAL PURPOSE .... .... 827 BUCKET GP-HOE ............ ............ 832 BUCKET GP-MULTIPURPOSE ...... ...... 855 BULLDOZER AS ............. ............. 865 CLAM AS-MULTIPURPOSE BUCKET ... ... 869 COUPLER AR-QUICK .......... .......... 872 COUPLER GP-QUICK .......... .......... 873 EDGE GP-CUTTING ........... ........... 878 FORK GP ................................ 879 MOUNTING GP-BUCKET ......... ......... 880 PIN GP-COUPLER ........................ 881 THUMB AR ............... ............... 883 THUMB GP ............... ............... 894 TOOTH GP-UNI ............. ............. 896 OPERATOR STATION ........................ 897 ADJUSTER GP-SEAT ........... ........... 897 AIR CONDITIONER & MOUNTING GP ... ... 898 CAB AR-ENCLOSED ROPS ........ ........ 901 CAB AS ................. ................. 905 CAB GP-ENCLOSED ROPS ........ ........ 908 CANOPY AR-OPEN ROPS ........ ........ 922 CANOPY AS .............................. 926 CANOPY GP-OPEN ROPS ........ ........ 927 COMPARTMENT GP-LITERATURE .... .... 932 COMPRESSOR & MTG GP-REFRIG .... .... 933 COMPRESSOR GP-REFRIGERANT .... .... 937 CONDENSER & MTG GP- REFRIGERANT ............. ............. 940 CONSOLE GP-OPERATOR ........ ........ 942 CONTROL & MTG GP-STABILIZER .... .... 948 CONTROL GP-HYDRAULIC HAND .... .... 954 CONTROL GP-HYDRAULIC PEDAL .... .... 968 CONTROL GP-STEERING ........ ........ 974 CONTROL GP-TRANSMISSION ...... ...... 979 COVER GP-CAB ............. ............. 981 COVER GP-WIPER MOTOR ....... ....... 982 DOOR GP-CAB .............. .............. 983 FLOOR MAT GP ............. ............. 991 HEATER & AIR CONDITIONER GP .... .... 993 HEATER GP-CAB ............ ............ 995 LATCH GP-CAB DOOR & WINDOW .... .... 1003 LEVER GP-GOVERNOR ......... ......... 1005 LINER GP-CAB .............. .............. 1006 LINES GP-HEATER ............ ............ 1010 LINES GP-HEATER & AIR COND ..... ..... 1011 MIRROR GP-REAR VIEW ......... ......... 1015 MOTOR GP-WINDOW WIPER ....... ....... 1018 MOUNTING GP-CAB ........... ........... 1020 PEDAL GP-GOVERNOR ......... ......... 1021 RADIO GP-COMMUNICATION ...... ...... 1023 ROOF GP-CAB .............. .............. 1024 SEAT BELT GP .............. .............. 1027 SEAT GP ................ ................ 1029 SEAT GP-STATIC ............. ............. 1032 SEAT GP-SUSPENSION ......... ......... 1034 SUSPENSION GP-SEAT ......... ......... 1036 SWIVEL & SLIDE GP-SEAT ........ ........ 1043 SWIVEL GP-SEAT ............ ............ 1045 TACHOMETER GP-ELECTRIC ...... ...... 1046 TRIM GP-CAB .............. .............. 1047 WASHER GP-WINDOW .................... 1049 WINDOW GP-CAB ............ ............ 1053 WINDOW GP-DOOR ........... ........... 1062 WIPER & WASHER GP-WINDOW ..... ..... 1064 WIPER GP-WINDOW ........... ........... 1068 SERVICE EQUIPMENT AND SUPPLIES ... ... 1072 FILM GP .................................. 1072 LINK GP-SHIPPING ........... ........... 1074 SEBP3706-30 TABLE OF CONTENTS A3

TABLE OF CONTENTS Name Page Name Page LOCK GP-VANDALISM .......... .......... 1075 PLATE & FILM GP ............ ............ 1075 PROTECTION GP-VANDALISM ...... ...... 1081 TRANSPORT AR-MACHINE ........ ........ 1082 TRANSPORT GP-MACHINE ........ ........ 1083 PART NUMBER INDEX ........... ........... B1 A4 TABLE OF CONTENTS SEBP3706-30

GENERAL INFORMATION 1. MACHINE IDENTIFICATION Caterpillar machines are identified by Product Identification Numbers (PIN). Some components included in a machine may be identified by Serial Numbers (S/N). Typical components that will be serialized include engines, transmissions, bulldozers, and rippers. The machine and engine are further identified by arrangement numbers and in some cases modification numbers. These numbers are shown on the product identification plate(s) and on the master plate in the operator's compartment. Caterpillar dealers need all of these numbers to determine accurate parts identification. Effective First Quarter 2001 the Caterpillar Product Identification Number (PIN) changed from 8 to 17 characters. In an effort to provide uniform equipment identification, Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard. Non-road machine PINs are defined by ISO 10261. The new PIN format will apply to all Caterpillar machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following: Where: 1. Caterpillar's World Manufacturing Code (characters 1- 3) 2. Machine Descriptor (characters 4-8) 3. Check Character (character 9) 4. Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17). These were previously referred to as the Serial Number. Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format. Components such as engines, transmissions, axles, etc. and work tools will continue to use an 8 character Serial Number (S/N). 2. ORDERING PARTS Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world. Their parts inventories are up to date and include all parts normally required to protect your investment in Caterpillar machines. Dealers may offer repair kits or remanufactured parts to allow selection of the most effective repair alternative for a particular situation. When ordering parts, your order should specify the quantity, part number, part name, and the serial number/product identification number of the machine for which the parts are needed. 3. PARTS MANUAL ORGANIZATION Product information in this manual is presented as "information elements" that represent all of the components for the specific model. Engine Arrangement and Seat Group are examples of information elements. The information elements are organized alphabetically by part name and secondarily by part number within each major section of the manual. 4. TABLE OF CONTENTS A table of contents (TOC) is found at the beginning of the manual. The TOC lists each section of the manual with a complete list of all information elements organized as they appear in the manual. Page numbers are provided for quick reference to detailed parts identification illustrations and serviceable consist lists. 5. MAINTENANCE PARTS INDEX The Maintenance Parts Index, located near the beginning of the manual, references most frequently used maintenance part numbers, providing description, quantity, usage and page number. This information is organized alphabetically by part description. SEBP3706-30 GENERAL INFORMATION A5

GENERAL INFORMATION 6. INDEX The index located near the front of the manual is an alphabetical listing of all information elements included in the manual. Page numbers are provided for quick reference to detailed parts identification illustrations and serviceable consist lists. 7. PART NUMBER INDEX A numerical index listing all part numbers and the corresponding page number(s) appears at the back of the manual. 8. CAPTIONS Captions located at the beginning of each information element identify the part number and part name along with additional descriptive information. PIN and S/N information found in each caption should be used to select correct information for a specific machine. Field replacement options, identification of optional attachment components, and where used ("part of") information is also provided. The first line of a caption is shown in larger type font to indicate the beginning of an information element. Captions for additional pages that may be required to illustrate an information element will be shown in standard type font and will include the term (contd.) . 9. NON-SERVICED PARTS In some instances it is necessary to display non-serviced parts that are a link to a lower level serviceable consist lists. These non-serviced part numbers are shown in italic type indicating that they are not available. 10. PARTS LIST REFERENCE NUMBERS Numbers shown in the Ref No column correspond to numbers used in the associated graphic(s). An alphabetic suffix may be added to a reference number to identify lower level consist items. Numbers shown in the Graphic Ref column refer to the graphic number identifier displayed in the lower left corner of each illustration. The Graphic Ref number may be used in combination with the item Ref No to determine the correct part number. There may be intentional omission of a Ref No in a consist list as information is updated to reflect the latest serviceable part numbers. 11. INDENTED PART NAMES When a part name is indented in a parts list, it is part of (included in) the group or assembly under which it is indented. 12. ILLUSTRATION REFERENCE LETTERS When necessary, illustrations contain reference letters (A, B, C etc.) that are intended to track lines and harnesses from one point to another. They are also used to show where to reconnect illustrations that have been separated. 13. ABBREVIATIONS AND SYMBOLS O.D. – Outside Diameter I.D. – Inside Diameter A – Not Part Of This Group B – Use As Required C – Change From Previous Type D – Order By The Meter E – Order By The Centimeter F – Not Shown G – Order By The Inch I – Refer To Hydraulic Information System M – Metric Part R – Remfg Part May Be Available Y – Separate Illustration Z – Not Serviced Separately 14. DESCRIPTION OF TYPE CHANGES Type - A type is defined as any configuration change that requires an additional Information Element for an Arrangement, Group, or Assembly. If serial number breaks for types are not available, a type # ( Type 1, Type 2, etc.) will be displayed in the caption. These "type" changes are identified with a "C" note (change from previous type) in the Parts List. Only the "types" that apply to this Parts Manual will be included. Additional types may exist causing "C" notes to appear on an Information Element when no other types are shown. 15.<END> This symbol indicates the end of an information element. NOTE: Continuing improvement and advancement of product design may cause changes to your machine which may not be included in this publication. Whenever a question arises regarding your Caterpillar product or this publication, please consult your Caterpillar dealer for the latest available information. A6 GENERAL INFORMATION SEBP3706-30

Parts Manual BACKHOE Loader 416C CATERPILLAR

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