Caterpillar Cat 438C BACKHOE LOADER (Prefix 1TR) Service Repair Manual (1TR01284-01549).pdf

Service Repair Manual
Model
438C BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 438C BACKHOE LOADER 1TR
Configuration: 438C Backhoe Loader Side Shift, Parallel Lift 1TR01284-01549 (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
i01082828
Water Temperature Regulator - Remove and Install
SMCS - 1355-010
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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. Drain the coolant from the cooling system into a suitable container for storage or disposal.
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Illustration 1 g00546643
Typical example of Type 1 and 9RM engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassembly
and Assembly, "Engine Design" topic.
2. Remove six bolts (1) that hold cover (2) and bracket (3) in position.
Note: Type 2 engines and 7BJ engines have four mounting bolts (1) that hold cover (2) in
position.
3. Remove bracket (3) and cover (2) from the water temperature regulator housing.
4. Remove water temperature regulator (4) and the gasket from water temperature regulator
housing (5) .
Note: Type 1 and 9RM engines may have two water temperature regulators for some engine
ratings. Type 2 and 7BJ engines will have one water temperature regulator for all engine
ratings.
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Note: Refer to the Testing and Adjusting Module for the correct procedure on testing the
water temperature regulator.
Installation Procedure
NOTICE
1. Inspect the condition of the gasket. Replace the gasket, if necessary.
Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassembly
and Assembly, "Engine Design" topic.
Note: Type 1 and 9RM engines may have two water temperature regulators for some engine
ratings. Type 2 and 7BJ engines will have one water temperature regulator for all engine
ratings.
2. Install water temperature regulator (4) and the gasket into housing (5) .
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3. Install bracket (3) and cover (2) on the water temperature regulator housing.
4. Install six bolts (1) that fasten cover (2) and bracket (3) to the water temperature regulator
housing.
Note: Type 2 engines and 7BJ engines have four mounting bolts (1) for the cover.
5. Install the upper radiator hose and fill the radiator to the correct level with coolant.
Note: Refer to the Operation and Maintenance Manual for the correct procedure.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Oct 13 00:08:43 UTC+0800 2019
4/4
2019/10/13

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i01082786
Water Outlet Manifold - Remove
SMCS - 1362-011
Removal Procedure
NOTICE
NOTICE
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
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Typical example
2. Remove clamp (1) for the boost line.
3. Loosen clamp (2) and disconnect hose (3) .
Typical example
4. Remove all bolts (4) that hold water outlet manifold (5) in position.
5. Remove water outlet manifold (5) and the gasket.
Sun Oct 13 00:09:39 UTC+0800 2019
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i01082822
Water Outlet Manifold - Install
SMCS - 1362-012
NOTICE
Typical example
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2. Put water outlet manifold (5) and the gasket in position on the engine.
3. Install bolts (4) that secure water outlet manifold (5) to the engine.
Typical example
4. Connect hose (3) and tighten clamp (2) .
5. Install clamp (1) for the boost line.
6. Install the upper radiator hose and fill the cooling system with coolant to the correct level.
Refer to the Operation and Maintenance Manual for the correct procedure.
Sun Oct 13 00:10:35 UTC+0800 2019
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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
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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.
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6. Use a hammer and a punch in order to remove flywheel ring gear (5) from flywheel (1) .
Sun Oct 13 00:11:30 UTC+0800 2019
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i04406239
Flywheel - Install
SMCS - 1156-012
Table 1
Required Tools
A 138-7575 Link Bracket 1
Always wear protective gloves when handling parts that have been
heated.
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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 13 00:12:26 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
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
1/3
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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.
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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 13 00:13:22 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
2. Clean the areas of the parts that will contact each other.
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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) .
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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.
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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 13 00:14:18 UTC+0800 2019
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2019/10/13

Caterpillar Cat 438C BACKHOE LOADER (Prefix 1TR) Service Repair Manual (1TR01284-01549).pdf

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Caterpillar Cat 438C BACKHOE LOADER (Prefix 1TR) Service Repair Manual (1TR01284-01549).pdf