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This is the compiled Caterpillar SIS repair set for the C-series backhoe loader family: 416C, 426C, 428C, 436C and 438C, all built around the Cat 3054 engine in turbocharged or naturally aspirated form. It is a five-model book, not a 416C-only book - the machine sections (Testing and Adjusting SENR1272, Hydraulic SENR1207/1208, Axles SENR1259/1205, Transmission SENR1204, Power Train SENR1273, and the 3054 engine supplement SENR1203) are titled for the whole family. You get engine, fuel, cooling, hydraulics, power train, brakes, steering, implements and operator station coverage, plus hydraulic, steering and electrical schematics for the 416C, 426C and 436C. Individual sections carry Cat publication dates from 1996 to 2013.
What's Inside This Caterpillar 416C, 426C, 428C, 436C, 438C Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Air Inlet and Exhaust System | 1-60 | Turbocharger, Inlet and Exhaust Manifolds, Air Cleaner |
| Basic Engine | 61-398 | Cat 3054 Engine, Cylinder Head, Crankshaft, Pistons, Flywheel, 3054 Engine Supplement for the Backhoe Family |
| Braking System | 399-475 | Service Brakes, Parking Brake, Brake Testing and Adjusting |
| Cooling System | 476-541 | Water Pump, Thermostat, Radiator, Fan Drive |
| Electrical and Starting System | 542-1672 | Bosch and Denso Alternators, Starting System, Batteries, Machine Security System, Product Link, EquipmentManager, Air Conditioning R134a |
| Engine Arrangement | 1673-1750 | Engine Mounting and Arrangement |
| Frame and Body | 1751-1768 | Frame, Body Panels |
| Fuel System | 1769-1903 | Fuel Injection Pump, Injectors, Fuel Filter, Priming |
| Hydraulic System | 1904-2511 | Pump Test and Adjust, Pump Flow Test, Line Relief Valve Test and Adjust, Ride Control, Makeup and Relief Valves, Pressure and Flow Compensator Valve, Cylinders |
| Implements | 2512-2553 | Loader and Backhoe Implement Linkage |
| Lubrication System | 2554-2595 | Engine Oil Pump, Oil Filter, Oil Relief Valve |
| Machine Arrangement | 2596-2607 | Machine Arrangement and Layout |
| Operator Station | 2608-2936 | Cab, Controls, Air Conditioning and Heating, Seat |
| Power Train | 2937-3587 | Transmission, Torque Converter, Axles, Differential, Final Drives |
| Schematic | 3588-3654 | 416C 426C 436C Hydraulic and Steering System Schematic, 416C 426C 436C Electrical System Schematics, Graphic Symbol Legends |
| Service Equipment and Supplies | 3655-3676 | Service Tooling and Supplies |
| Steering System | 3677-3800 | Steering Pump, Steering Cylinder, Steering Testing |
| Torque Specifications | 3801-3848 | Metric ISO Fasteners, English SAE Fasteners, Fittings, Plugs, Hose Clamps |
| Work Tools | 3849-3858 | Work Tool Hydraulics and Mounting |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Main relief valve system pressure limit | 20700 kPa (3000 psi) | |
| High pressure stall test system pressure | 20700 +/- 700 kPa (3000 +/- 100 psi) | |
| Line relief valve, auxiliary and loader tilt | 24200 +/- 350 kPa (3500 +/- 50 psi) | |
| Line relief valve, loader tilt (higher setting) | 26200 +/- 350 kPa (3800 +/- 50 psi) | |
| Low pressure standby | 2300 +/- 350 kPa (330 +/- 50 psi) | |
| Margin pressure | 2200 +/- 100 kPa (320 +/- 15 psi) at 1450 +/- 50 rpm | |
| Ride control accumulator charge | 1860 +/- 34.5 kPa (270 +/- 5.0 psi) | p. 2149 |
| Engine low idle | 950 +/- 50 rpm | |
| Hydraulic oil type | SAE 10W | |
| Hydraulic oil temperature for torque limiter test | 60 C (140 F) | |
| Torque limiter bolt torque | 12 +/- 3 N m (105 +/- 27 lb in) | |
| Engine fitted | Caterpillar 3054, turbocharged or naturally aspirated | |
| parallel lift machines | ||
| Loader tilt head end line relief | 15900 +/- 600 kPa (2300 +/- 90 psi) | |
| turbocharged machines | ||
| Hydraulic pump flow | 120 to 130 L/min | |
| naturally aspirated machines | ||
| Hydraulic pump flow | 100 to 120 L/min | |
Caterpillar 416C, 426C, 428C, 436C, 438C Common Problems This Manual Covers
Loader or backhoe is slow, weak, or a cylinder drifts down under load
Warm the oil to 60 C (140 F), then run the pump flow test and check the main relief against 20700 kPa (3000 psi) per the Testing and Adjusting section (SENR1272). It separates a relief valve out of spec from a worn pump or leaking cylinder before you throw parts at it.
Manual Section: Hydraulic System - Testing and Adjusting p. 2055Engine cranks hard, starts rough, or lacks power under load
The Fuel System section covers priming the system to clear air, fuel filter service, and injection pump and injector procedures. If a turbocharged machine is down on power, the Air Inlet and Exhaust System section covers turbocharger inspection and the inlet and exhaust manifolds.
Manual Section: Fuel System p. 1769Machine overheats on long digs or in hot weather
The Cooling System section covers the water pump, thermostat, radiator and fan drive with removal, inspection and test procedures, so you can confirm whether it is a plugged radiator core, a lazy thermostat or a failing water pump before ordering anything.
Manual Section: Cooling System p. 476Transmission shifts harsh, slips, or the machine crawls in gear
The Power Train coverage (SENR1204 transmission and SENR1273 power train) takes you through the torque converter, transmission clutch packs, axles, differential and final drives, with the checks to rule out oil level and converter problems before pulling the transmission.
Manual Section: Power Train p. 2937Frequently Asked Questions
Is my 426C or 438C actually covered, or is this just a 416C manual?
All five models are covered. Every machine section in this set - Testing and Adjusting, Hydraulic, Axles, Transmission, Power Train and the 3054 engine supplement - is Cat's family publication titled for the 416C, 426C, 428C, 436C and 438C. The schematic sheets cover the 416C, 426C and 436C.
What should the main relief pressure be when I test the hydraulics?
The main relief limits system pressure to 20700 kPa (3000 psi), and the high pressure stall test spec is 20700 +/- 700 kPa (3000 +/- 100 psi). Line reliefs on the auxiliary and loader tilt circuits run 24200 +/- 350 kPa (3500 +/- 50 psi), with 26200 +/- 350 kPa (3800 +/- 50 psi) on some circuits. The Testing and Adjusting section walks you through gauge hookup and the adjustment procedure for each valve.
How much flow should the hydraulic pump make?
On turbocharged machines the spec is 120 to 130 L/min; naturally aspirated machines run 100 to 120 L/min. The manual gives the full pump flow test and the low pressure standby (2300 +/- 350 kPa / 330 +/- 50 psi) and margin pressure (2200 +/- 100 kPa / 320 +/- 15 psi at 1450 +/- 50 rpm) checks, so you can tell a tired pump from a misadjusted compensator before you buy parts.
Does it cover ride control, and what should the accumulator charge be?
Yes. The hydraulic section covers ride control including the makeup and relief valves, and the accumulator charge spec is 1860 +/- 34.5 kPa (270 +/- 5.0 psi). Charging and test procedure are in the book. p. 2149
Which engine is in these machines, and is engine repair included?
The Cat 3054, either turbocharged or naturally aspirated. The set includes full basic engine coverage - cylinder head, crankshaft, pistons, flywheel - plus the SENR1203 engine supplement specific to the backhoe family, fuel injection pump and injector service, and the air inlet/exhaust section with the turbocharger. Low idle spec is 950 +/- 50 rpm.
