Caterpillar cat 438 c backhoe loader (prefix 1jr) service repair manual (1jr01107 01149)

Service Repair Manual
Model
438C BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 438C BACKHOE LOADER 1JR
Configuration: 438C Backhoe Loader Side Shift, Single Tilt 1JR01107-01149 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i02105278
Fuel Injection Pump - Remove - Type 2 Engines and 7BJ
Engines
SMCS - 1251-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
150-3992 Timing Pin (1)
1
150-3993 Timing Pin (2)
1
B
171-1085
or
173-9774
Tamper Resistant Tool Gp 1
( 1 )
Tool (A) is required in order to remove Bosch fuel injection pumps.
( 2 )
Tool (A) is required in order to remove Delphi (Lucas) and Stanadyne fuel injection pumps.
Start By:
A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
B. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines
- Remove and Install".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1/4438C Backhoe Loader Side Shift, Single Tilt 1JR01107-01149 (MACHINE) POWER...
2019/10/16https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Ensure that the No. 1 cylinder is at the top center position on the compression stroke. Refer
to the Testing and Adjusting, "Fuel System" topic for additional information.
Illustration 1 g00808245
2. Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. Move locking
spacer (1) into position (B). Tighten locking screw (2) to a torque of 10 N·m (7 lb ft).

Typical example
Note: Do not remove hub nut (4) from the shaft of the fuel injection pump. The hub of the
fuel injection pump is installed in the correct position from the factory in order to ensure
proper timing. If hub nut (4) is removed and the hub is removed, the hub will need to be
accurately installed on the shaft of the fuel injection pump by the use of special equipment.
Refer to your Caterpillar Dealer for more information.
Note: Do not release Torx screws (5) (if equipped). If the Torx screws are released and the
timing plate is moved, the timing position that is set at the factory will be lost. If the Torx
screws are released, the No. 1 cylinder must be set to the top center position on the
compression stroke before the Torx screws are tightened.
3. Slowly rotate the crankshaft until hole (6) in the timing gear and hole (7) in the hub are in
alignment with hole (8) in the fuel injection pump body.
Note: The location of Tool (A) for Bosch fuel injection pumps will be located toward the
top of the fuel injection pump. The location of Tool (A) for Delphi (Lucas) and Stanadyne
fuel injection pumps will be located toward the bottom of the fuel injection pump.
4. Install Tool (A) through hole (6) in the timing gear and hole (7) in the hub. Push Tool (A)
into position in hole (8) in the fuel injection pump body. If Tool (A) can be fully seated, the
fuel injection pump timing is correct. No resistance should be felt when the timing pin is
inserted into hole (8) of the fuel injection pump body.

Note: Some fuel injection pumps are installed with tamper proof bolts. Tool (B) may be
necessary in order to remove the tamper proof bolts.
5. Remove four bolts (3) that fasten the fuel injection pump gear to the fuel injection pump.
Timing gear (9) should be free from the fuel injection pump shaft.
Typical example
6. Remove three flange nuts (10) and fuel injection pump (11) from the engine.
Typical example
7. Remove O-ring seal (12) from fuel injection pump (11) .
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All Rights Reserved.
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Wed Oct 16 12:19:09 UTC+0800 2019

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i01083652
Fuel Injection Pump - Remove - Type 1 Engines and 9RM
Engines
SMCS - 1251-011
Removal Procedure
Table 1
Required Tools
A 173-9774 Bolt Remover (1)
1
B 9U-6198 Crankshaft Turning Tool 1
C
8S-2264 Puller Group 1
8S-4712 Bolt 2
( 1 )
The bolt remover is required in order to remove the tamper proof bolts on the access cover for the fuel injection
pump.
Start By:
A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
B. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines
- Remove and Install".
Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassembly and
Assembly, "Engine Design" topic.
NOTICE

NOTICE
containing fluids.
1. Remove four bolts (1) .
Note: Some engines may have four tamper proof bolts (1). Use Tool (A) in order to remove
the tamper proof bolts bolts.
2. Remove cover (2) .

3. Remove nut (3) and the lockwasher.
4. Use Tool (B) to rotate the crankshaft until keyway (X) is at 30 degrees from the vertical
centerline.

5. Install Tool (C) .
6. Disengage the gear from the fuel injection pump.
7. Disconnect hose (7) from the fuel injection pump.
8. Remove three nuts (6) that hold fuel injection pump (5) in position.
9. Remove fuel injection pump (5) and the gasket.
Note: Ensure that you do not lose the key when the fuel injection pump is removed. Also
notice the position of marks (4) in order to ensure proper alignment of fuel injection pump
(5) during installation.
Wed Oct 16 12:20:04 UTC+0800 2019

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i02046409
Fuel Injection Pump - Install - Type 2 Engines and 7BJ
Engines
SMCS - 1251-012
Installation Procedure
Table 1
Required Tools
A
150-3992 Timing Pin (1)
1
150-3993 Timing Pin (2)
1
B
171-1085
or
173-9774
Tamper Resistant Tool Gp 1
( 1 )
Tooling (A) is required in order to install Bosch fuel injection pumps.
( 2 )
Tooling (A) is required in order to install Dephi (Lucas) and Stanadyne fuel injection pumps.
NOTICE

Typical example
1. Check the condition of O-ring seal (13) on fuel injection pump (12). If the seal is worn or
damaged, replace the seal.
2. Lightly lubricate O-ring seal (13) with clean engine oil. Install O-ring seal (13) on fuel
injection pump (12) .
NOTICE
The No. 1 cylinder must be at the top center position on the
compression stroke before the fuel injection pump is installed. If the
crankshaft needs to be rotated, the fuel injection pump must be
mounted temporarily or the loose gear could cause damage to the front
housing.
Typical example

3. Put fuel injection pump (12) in position on the engine. Ensure that the timing gear is aligned
with the hub of fuel injection pump (12). Install three flange nuts (11) and tighten the flange
nuts to a torque of 28 N·m (21 lb ft).
Typical example
4. Position gear (9) on the shaft of the fuel injection pump.
Note: Some fuel injection pumps are installed with tamper proof bolts. Tooling (B) may be
necessary in order to install the tamper proof bolts.
5. Put the timing gear plate in position and install four bolts (3). Tighten the four bolts finger
tight.
Note: The fuel injection pump gear will only fit in one position. Install the gear with the
letters "C" and "M" facing away from the engine.

Typical example
6. Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. Move locking
spacer (1) into position (A). Tighten locking screw (2) to a torque of 10 N·m (7 lb ft).
Note: The location of Tooling (A) for Bosch fuel injection pumps will be located toward the
top of the fuel injection pump. The location of Tooling (A) for Dephi (Lucas) and
Stanadyne fuel injection pumps will be located toward the bottom of the fuel injection
pump.
7. Install Tooling (A) through hole (6) in the timing gear and hole (7) in the hub. Push Tooling
(A) into position in hole (8) in the fuel injection pump body. If Tooling (A) can be fully
seated, the fuel injection pump timing is correct. No resistance should be felt when the
timing pin is inserted into hole (8) of the fuel injection pump body.
NOTICE
The fuel injection pump may be supplied with the fuel injection pump
shaft in the locked position. The drive shaft of the fuel injection pump
must not be rotated without the spacer in position under the locking
screw. Damage to the drive shaft of the fuel injection pump will result.
8. When the timing plate is installed, rotate gear (9) by hand in a counterclockwise direction in
order to remove the backlash between gear (9) and the idler gear. Do not rotate the
crankshaft or the fuel injection pump shaft. Tighten bolts (3) to a torque of 28 N·m (21 lb
ft).
9. Remove Tooling (A) from the fuel injection pump gear.

End By:
a. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines -
Remove and Install".
b. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
Wed Oct 16 12:21:00 UTC+0800 2019

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i01083913
Fuel Injection Pump - Install - Type 1 Engines and 9RM
Engines
SMCS - 1251-012
Installation Procedure
Table 1
Required Tools
A 173-9774 Bolt Remover (1)
1
( 1 )
The bolt remover is required in order to install the tamper proof bolts on the access cover for the fuel injection
pump.
Note: For a complete description of Type 1 and Type 2 Engines, refer to the Disassembly and
Assembly, "Engine Design" topic.
NOTICE
1. Inspect the condition of the gasket for the fuel injection pump. Replace the gasket, if
necessary.

2. Install the gasket and fuel injection pump (5) .
Note: Align marks (4) that are on fuel injection pump (5) and the timing gear cover.
3. Install the key.
4. Install three nuts (6) that hold fuel injection pump (5) in position.
5. Connect hose (7) to fuel injection pump (5) .
6. Engage the gear with the fuel injection pump.
7. Install the lockwasher and nut (3) .

8. Install cover (2) and four bolts (1) .
Note: Some engines have four tamper proof bolts (1). Use Tool (A) in order to install the
four bolts.
9. Set the timing of the fuel injection pump. Refer to the Testing and Adjusting Module for the
correct procedure.
End By:
a. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines -
Install".
b. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
Wed Oct 16 12:21:56 UTC+0800 2019

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i01051839
Turbocharger - Remove
SMCS - 1052-011
Removal Procedure
NOTICE
NOTICE
containing fluids.

Typical example
1. Loosen two clamps (1) .
2. Slide hose (2) away from turbocharger (3) .
3. Remove two bolts (4) and the gasket.
4. Disconnect oil return line (6) from the cylinder block and remove the gasket.
5. Remove nuts (5) .
Typical example
6. Remove three bolts (7) .

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7. Remove turbocharger (3) and the gaskets.
8. Plug all openings immediately.
Wed Oct 16 12:22:51 UTC+0800 2019

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i01051906
Turbocharger - Disassemble
SMCS - 1052-015
Disassembly Procedure
Start By:
A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
NOTICE
NOTICE
containing fluids.

1. Place an index mark on all of the components for the assembly procedure.
Typical example
2. Remove elbow (1) and the O-ring seal.
3. Remove two bolts (2) .
4. Remove hose assembly (3) and the gasket.
Typical example
5. Remove six bolts (4) .
6. Remove three clamps (5) .
7. Separate compressor housing (6) from cartridge (7) .

Typical example
Typical example
8. Remove six bolts (8) .
9. Remove three clamps (9) .
10. Separate cartridge (7) from turbine housing (10) .
Wed Oct 16 12:23:47 UTC+0800 2019

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i01051989
Turbocharger - Assemble
SMCS - 1052-016
Assembly Procedure
NOTICE
1. Inspect the condition of the gaskets. Replace the gaskets, if necessary.
Typical example

Caterpillar cat 438 c backhoe loader (prefix 1jr) service repair manual (1jr01107 01149)

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