Caterpillar cat 438 b backhoe loader (prefix 3kk) service repair manual (3kk03000 and up)

Service Repair Manual
Models
438B BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 438B BACKHOE LOADER 3KK
Configuration: 438B BACKHOE LOADER 3KK03000-UP (MACHINE) POWERED BY 3054 DIESEL ENGINE
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i04406238
Flywheel - Remove
SMCS - 1156-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1/3438B BACKHOE LOADER 3KK03000-UP (MACHINE) POWERED BY 3054 DIES...
2019/10/27https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g00546794
Typical Example. Different lifting device shown than what is called out in the Table.
1. Install Tool (A) and a suitable lifting device on flywheel (1) .
2. Remove bolts (3) and bearing housing (4) .
3. Remove six bolts (2) and the washers from the flywheel.
Note: The 3054 and 3056 marine engines used several bolt patterns to attach the flywheel to
the crankshaft. There are drilled holes that are not used in the crankshaft and in the
flywheel.
4. Use the suitable lifting device in order to remove flywheel (1) . The weight of flywheel (1)
and the flywheel ring gear is 53 kg (120 lb).
5. If removal of the flywheel ring gear is necessary, place an index mark on the chamfer of the
flywheel ring gear for the installation process.

6. Use a hammer and a punch in order to remove flywheel ring gear (5) from flywheel (1) .
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All Rights Reserved.
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Sun Oct 27 08:19:27 UTC+0800 2019

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i04406239
Flywheel - Install
SMCS - 1156-012
Installation Procedure
Table 1
Required Tools
Always wear protective gloves when handling parts that have been
heated.

Typical Example. Different Lifting device shown than what is called out in the table.
1. If flywheel ring gear (5) was removed, heat flywheel ring gear (5) to a temperature of 250 °
C (480 °F).
Note: Do not use a torch to heat the flywheel ring gear.
2. Install flywheel ring gear (5) on flywheel (1) .
Note: Ensure that the chamfer of the flywheel ring gear is in the correct position on the
flywheel.
3. Install Tool (A) and a suitable lifting device on flywheel (1) and position flywheel (1) in the
flywheel housing. The weight of flywheel (1) and flywheel ring gear (5) is 53 kg (120 lb).
4. Install six bolts (2) and the washers that hold flywheel (1) in position. Tighten the bolts to a
torque of 105 N·m (77 lb ft).
5. Put bearing housing (4) in position on the flywheel. Install four bolts (3) that fasten bearing
housing (4) to the flywheel.
6. Refer to the Specifications Module, "Flywheel" topic for information on inspecting the
flywheel.
Sun Oct 27 08:20:23 UTC+0800 2019

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i01741403
Crankshaft Rear Seal - Remove
SMCS - 1161-011
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
NOTICE
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 Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.

Engines with 14 Bolt Housing Assembly
The flywheel housing has been removed for photographic purposes only.
1. Remove bolts (1) from housing (3).
2. Remove socket head bolts (2) from housing (3).
3. Remove the crankshaft rear seal, the gasket, and housing (3) from the dowels in the cylinder
block.
Note: The 10 bolt housing assembly is manufactured as a one-piece assembly. The 10 bolt
housing assembly is NOT adaptable to engines that have the 14 bolt housing assembly.

1. Remove the bolts in reverse order of the numbered sequence. Refer to Illustration 2.
2. Remove the one-piece housing assembly from the cylinder block.
Sun Oct 27 08:21:18 UTC+0800 2019

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i01605362
Crankshaft Rear Seal - Install
SMCS - 1161-012
Table 1
Required Tools
A
9U-6205 Rear Seal Installer 1
1P-0510 Driver Group 1
B FT-2806 Alignment Tool 1
NOTICE
1. Inspect the condition of the gasket. Replace the gasket, if necessary.
2. Clean the areas of the parts that will contact each other.

3. Use Tool (A) and a suitable press to install the crankshaft rear seal into the housing. Make
sure that you install the seal to the correct depth in the housing. Refer to Specifications,
"Crankshaft Seals" for additional information.
4. Lubricate the crankshaft flange and the lip of the crankshaft rear seal with clean engine oil.
5. Install Tool (A) onto the crankshaft flange.
6. Put the new gasket for the housing in position on the dowels in the cylinder block.
7. Carefully place housing (3) and crankshaft rear seal (4) over Tool (A) .
8. Position housing (3) on the dowels in the cylinder block.
9. Remove Tool (A) .

The flywheel housing has been removed for photographic purposes only.
10. Install bolts (1) and socket head bolts (2) that fasten housing (3) to the cylinder block.
11. Tighten all of the bolts to a torque of 22 N·m (16 lb ft).
Note: The 10 bolt housing assembly is manufactured as a one-piece assembly. The 10 bolt
housing assembly is NOT adaptable to engines that have the 14 bolt housing assembly.
1. Ensure that all parts and surfaces of the engine block are clean and free from oil, grease, and
dirt.

Note: The crankshaft rear seal is lubricated. There is no need to lubricate the seal or the
crankshaft flange before installation.
2. Place housing assembly (3) on crankshaft flange (1) until the housing assembly contacts the
cylinder block face. Plastic sleeve (2) will push out of the housing assembly. Discard the
plastic sleeve after the housing assembly is installed.
3. Place Tool (B) over housing assembly (3). This will center the housing assembly onto the
crankshaft flange.
4. Install the bolts with Tool (B) in position in order to fasten housing assembly (3) to the
cylinder block. Tighten bolts 1 and 2 to a torque of 22 N·m (16 lb ft).
5. Remove Tool (B). Tighten the remaining bolts in sequence to a torque of 22 N·m (16 lb ft).
End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
Sun Oct 27 08:22:14 UTC+0800 2019

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i01741450
Flywheel Housing - Remove and Install
SMCS - 1157-010
Removal Procedure
Table 1
Required Tools
Start By:
a. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
b. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
NOTICE
NOTICE

containing fluids.
1. Support the engine with blocks or with a suitable lifting device on a flat level surface.
Typical example
2. Remove mounting bolts (1) from the top of flywheel housing (2).
Typical example
3. Attach Tooling (A) and a suitable lifting device to flywheel housing (2).
4. Remove mounting bolts (3) that attach the flywheel housing to the cylinder block.

5. Remove flywheel housing (2). If necessary, hit flywheel housing (2) with a soft faced
hammer in order to separate flywheel housing (2) from the cylinder block. The weight of
flywheel housing (2) is approximately 32 kg (70 lb).
Table 2
Required Tools
NOTICE
1. Clean the rear face of the cylinder block and the mating surface of the flywheel housing.
Inspect the felt seal on the rear flange of the engine oil pan. Replace the felt seal, if
necessary. Inspect the dowels in the cylinder block that align the flywheel housing. Replace
the dowels, if necessary.
2. Use Tooling (A) and a suitable lifting device to position flywheel housing (2) on the dowels
that are on the cylinder block. The weight of flywheel housing (2) is approximately 32 kg
(70 lb).
3. Install mounting bolts (3).

Typical example
4. Install mounting bolts (1) that attach flywheel housing (2) to the cylinder block.
Tighten the bolts for an aluminum flywheel housing to a torque of 70 N·m (52 lb ft).
Tighten the cast iron flywheel housing bolts to the following torque:
M10 "8.8" ... 44 N·m (33 lb ft)
M10 "10.9" ... 63 N·m (46 lb ft)
M12 "8.8" ... 75 N·m (55 lb ft)
M12 "10.9" ... 115 N·m (85 lb ft)
5. Remove Tooling (A) from the flywheel housing.
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
b. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
Sun Oct 27 08:23:10 UTC+0800 2019

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i01461242
Crankshaft Pulley - Remove and Install
SMCS - 1205-010
Removal Procedure
Start By:
A. Remove the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Typical example
1. Remove three bolts (2) that hold thrust block (3) in position.
2. Remove thrust block (3) from the end of the crankshaft. The thrust block holds the
crankshaft pulley in position on the end of the crankshaft.
3. Remove crankshaft pulley (1) from the engine.

Note: Some engines have a water immersion seal that is placed on the front cover. The seal has a
flexible lip on the front. The plastic mandrel that is supplied with the seal must be installed in the
seal when the crankshaft pulley is removed. This will ensure that the lip maintains the correct
shape.
Typical example
1. Remove the plastic mandrel, if necessary.
2. Put crankshaft pulley (1) in position on the crankshaft.
3. Apply 9S-3263 Thread Lock Compound to the threads of three bolts (2) .
4. Put thrust block (3) in position and align the holes with the holes in the end of the
crankshaft.
Note: It may be necessary to keep the crankshaft from rotating while you torque bolts (3).
Use the appropriate tools in order to keep the crankshaft from rotating.
5. Install three bolts (2) that hold the thrust block in position. Tighten bolts (2) to a torque of
115 N·m (85 lb ft).
End By: Install the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Sun Oct 27 08:24:05 UTC+0800 2019

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i01742537
Crankshaft Front Seal - Remove
SMCS - 1160-011
Removal Procedure
Table 1
Required Tools
A 1U-8145 Drill Bit 1
B 1U-7600 Slide Hammer Puller 1
Start By:
a. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".
NOTICE
NOTICE

containing fluids.
Typical example
1. Use Tooling (A) to drill three evenly spaced holes in crankshaft front seal (1).
2. Place Tooling (B) in the holes in order to remove crankshaft front seal (1). Use Tooling (B)
in each of the three holes to evenly remove the crankshaft front seal.
Note: Do not damage the flange of the crankshaft during the removal process for the
crankshaft front seal.
NOTICE
Ensure that the main lip is used in order to remove the crankshaft
front seal. Do not damage the edge of the housing for the crankshaft
front seal.
Sun Oct 27 08:25:01 UTC+0800 2019

Caterpillar cat 438 b backhoe loader (prefix 3kk) service repair manual (3kk03000 and up)

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Caterpillar cat 438 b backhoe loader (prefix 3kk) service repair manual (3kk03000 and up)