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Caterpillar 438d Backhoe Loader Service Manual - PDF Download

The Caterpillar 438d Backhoe Loader service manual provides detailed guidance for maintenance and repair, helping you keep your equipment running smoothly. This PDF download offers clear instructions and diagrams to support efficient troubleshooting and servicing, ensuring your loader performs reliably on the job. Ideal for operators and technicians seeking practical, easy-to-follow information.

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82 views32 pages

Caterpillar 438d Backhoe Loader Service Manual - PDF Download

The Caterpillar 438d Backhoe Loader service manual provides detailed guidance for maintenance and repair, helping you keep your equipment running smoothly. This PDF download offers clear instructions and diagrams to support efficient troubleshooting and servicing, ensuring your loader performs reliably on the job. Ideal for operators and technicians seeking practical, easy-to-follow information.

Uploaded by

Heavy-equipmentmanual
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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438D BACKHOE LOADER

Printed by Heavy Equipment Manuals Printed in U.S.A


v2.20

Heavy Equipment Manuals


This is the sample of the manual click on
the download link for complete manual
DOWNLOAD LINK
For some reason if link does not work
download this pdf and then click
 
 
 
 
 
 
 
 
 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 




Product: BACKHOE LOADER


Model: 438D BACKHOE LOADER BPN
Configuration: 438D Backhoe Loader BPN00001-00475 (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly


416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Engine
Supplement
Media Number -RENR3573-02 Publication Date -01/09/2009 Date Updated -30/09/2009

i01390521

Air Cleaner - Remove and Install


SMCS - 1051-010

Removal Procedure
Start By:

A. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic
System Pressure - Release".

Illustration 1 g00530249

1. Loosen hose clamp (1). Unhook three clips (2) and remove the air cleaner cover (3) .
Illustration 2 g00530250

2. Remove the air filter cartridge (4) .

Illustration 3 g00530251

3. Remove air filter cartridge (5), four bolts (6) and air filter housing (7) .

Installation Procedure
Illustration 4 g00530251

1. Install the filter housing (7). Install four bolts (6) and install the air filter cartridge (5) .

Illustration 5 g00530250

2. Install the air filter cartridge (4) .


Illustration 6 g00530249

3. Replace air cleaner cover (3) and secure cover (3) with three clips (2). Tighten the hose clamp
(1) .

Copyright 1993 - 2023 Caterpillar Inc. Tue Sep 12 10:15:34 UTC+0530 2023
All Rights Reserved.
Private Network For SIS Licensees.




Product: BACKHOE LOADER


Model: 438D BACKHOE LOADER BPN
Configuration: 438D Backhoe Loader BPN00001-00475 (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly


416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Engine
Supplement
Media Number -RENR3573-02 Publication Date -01/09/2009 Date Updated -30/09/2009

i01389679

Alternator - Remove and Install


SMCS - 1405-010

Removal Procedure
Start By:

A. Remove the left engine panel. Refer to Disassembly and Assembly, RENR3573, "Engine Cover
- Remove and Install".

Note: Put identification on all wires for installation purposes.

1. Disconnect the batteries.

Illustration 1 g00518929
2. Loosen bolt (1), bolt (2), and bolt (3). Slide the alternator toward the engine and disconnect the
alternator V-belts.

Illustration 2 g00518931

3. Disconnect electrical connection (5) and (6) .

Illustration 3 g00518932

4. Remove bolt (1), bolt (2), and bolt (3). Remove the alternator.

Installation Procedure
Illustration 4 g00518932

1. Slide the alternator toward the engine and connect the alternator V-belts. Install the alternator.
Install bolt (1), bolt (2), and bolt (3).

Illustration 5 g00518931

2. Connect electrical connection (5) and (6) .


Illustration 6 g00518929

3. Tighten bolt (1), bolt (2), and bolt (3) .

4. Connect the batteries.

Note: For the proper tightening procedures of the V-belt, refer to the Operation and Maintenance
Manual, SEBU7399, "V-Belts - Inspect/Adjust/Replace".,

End By: Install the right engine panel. Refer to Disassembly and AssemblyRENR3573, "Engine
Cover - Remove and Install".

Copyright 1993 - 2023 Caterpillar Inc. Tue Sep 12 10:07:54 UTC+0530 2023
All Rights Reserved.
Private Network For SIS Licensees.




Product: BACKHOE LOADER


Model: 438D BACKHOE LOADER BPN
Configuration: 438D Backhoe Loader BPN00001-00475 (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly


416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Engine
Supplement
Media Number -RENR3573-02 Publication Date -01/09/2009 Date Updated -30/09/2009

i01389778

Crankshaft Pulley - Remove and Install


SMCS - 1205-010

Removal Procedure
Start By:

A. Remove the right engine panel. Refer to Disassembly and Assembly, RENR3573, "Engine
Cover - Remove and Install" for the correct procedure.
B. Loosen the alternator. Refer to Disassembly and Assembly, RENR3573, "Alternator - Remove
and Install" for the correct procedure.

Illustration 1 g00732453

1. Remove the V-Belts (1) .


Illustration 2 g00732465

2. Remove three bolts (2) and remove crankshaft pulley (3) .

Installation Procedure

Illustration 3 g00732465

1. Install crankshaft pulley (2) and install three bolts (3). Evenly tighten the bolts to 115 N·m (85
lb ft).
This is the sample of the manual click on
the download link for complete manual
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download this pdf and then click
Illustration 4 g00732453

2. Install V-Belts (1) .

Note: For the proper tightening procedure of the V-Belts, refer to Operation and Maintenance,
SEBU7399, "V-Belts - Inspect/Adjust/Replace".

End By: Install the engine cover. Refer to Disassembly and AssemblyRENR3573, "Engine Cover-
Remove and Install" for the correct procedure.

Copyright 1993 - 2023 Caterpillar Inc. Tue Sep 12 10:10:51 UTC+0530 2023
All Rights Reserved.
Private Network For SIS Licensees.




Product: BACKHOE LOADER


Model: 438D BACKHOE LOADER BPN
Configuration: 438D Backhoe Loader BPN00001-00475 (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly


416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Engine
Supplement
Media Number -RENR3573-02 Publication Date -01/09/2009 Date Updated -30/09/2009

i01389659

Electric Starting Motor - Remove and Install


SMCS - 1453-010

Removal Procedure
Start By:

A. Remove the right engine panel. Refer to Disassembly and Assembly, RENR3573, "Engine
Cover - Remove and Install".

Note: Put identification tags on all wires for installation purposes.

1. Disconnect the batteries.

Illustration 1 g00518861
2. Remove wire (1) from starter (2) .

Note: The photograph for Step 3 was taken from the bottom of the starter.

Illustration 2 g00518862

3. Remove wire (3) and wire (4) from the starter.

Illustration 3 g00518863

4. Remove three bolts (5) and remove starter (2) .

Installation Procedure
Illustration 4 g00518863

1. Install the starter (2). Install three bolts (5) .

Note: The photograph for Step 2 was taken from the bottom of the starter.

Illustration 5 g00518862

2. Install wire (4) and wire (3) on the starter.


Illustration 6 g00518861

3. Install wire (1) on the starter (2) .

4. Connect the batteries.

End By: Install the right engine panel. Refer to Disassembly and AssemblyRENR3573, "Engine
Cover - Remove and Install".

Copyright 1993 - 2023 Caterpillar Inc. Tue Sep 12 10:06:45 UTC+0530 2023
All Rights Reserved.
Private Network For SIS Licensees.




Product: BACKHOE LOADER


Model: 438D BACKHOE LOADER BPN
Configuration: 438D Backhoe Loader BPN00001-00475 (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly


416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Engine
Supplement
Media Number -RENR3573-02 Publication Date -01/09/2009 Date Updated -30/09/2009

i01439767

Engine and Transmission - Install


SMCS - 1000-012; 1004-012; 3030-012; 3101-012

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 4
B 6V-3145 Load Leveler 1

Illustration 1 g00753080
1. Attach tool (B) to a suitable lifting device. Attach tool (B) to the engine and to the transmission.

2. Install the engine and the transmission. The weight of the engine and transmission is 680 kg
(1500 lb).

Illustration 2 g00753725

3. Install two bolts (59). Tighten bolts (59) to 220 ± 30 N·m (160 ± 20 lb ft).

Illustration 3 g00753634

4. Remove straps (58) and wood block (57) .


Illustration 4 g00753623

5. Connect three electrical connectors (56) and install strap (55) .

Illustration 5 g00753606

6. Connect seven electrical connectors (54) and install three straps (53).
Illustration 6 g00753596

7. Install the valve and two bolts (52) .

Illustration 7 g00753591

8. Connect electrical connector (51) .

Illustration 8 g00753552

9. Install the washers and two engine mounting bolts (50). Tighten bolts (50) to 220 ± 30 N·m
(160 ± 20 lb ft).
Illustration 9 g00753546

10. Install the washers and engine mounting bolt (49). Tighten bolt (49) to 220 ± 30 N·m (160 ± 20
lb ft).

Illustration 10 g00753362

11. Install the washers and engine mounting bolt (48). Tighten bolt (48) to 220 ± 30 N·m (160 ± 20
lb ft).
Illustration 11 g00753335

12. Remove tool (A) and two straps (47) from hydraulic tank (46) .

Illustration 12 g00753331

13. Install two bolts (45) .


Illustration 13 g00753330

14. Install two bolts (44) .

Illustration 14 g00753329

15. Connect connector (43) .

Illustration 15 g00753305

16. Connect test line (42) .


Illustration 16 g00753227

17. Install fitting (41) and six screws (40) .

Illustration 17 g00753213

18. Install the bolt and clamp (39) .


Illustration 18 g00753201

19. Install the bolt and clamp (38) .

Illustration 19 g00753198

20. Connect hoses (36) and (37) .

Illustration 20 g00753185

21. Install bolt (35) .


Illustration 21 g00752950

22. Connect line (34) .

Illustration 22 g00752935

23. Connect connector (33) and install strap (32) .


Illustration 23 g00752929

24. Connect two wires (31) .

Illustration 24 g00752919

25. Connect two wires (30). Connect three connectors (29) and install two straps (28) .

Illustration 25 g00752916

26. Connect two lines (25) and governor cable (27). Tighten nut (26) to 38 ± 2 N·m (28 ± 1.5 lb ft).

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