Caterpillar Cat 438D BACKHOE LOADER (Prefix BPE) Service Repair Manual (BPE00664-00742).pdf

Service Repair Manual
Model
438D BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 438D BACKHOE LOADER BPE
Configuration: 438D Backhoe Loader BPE00664-00742 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Machine
Systems
Media Number -RENR3585-11 Publication Date -01/09/2009 Date Updated -28/09/2009
i01442986
Hydraulic Tank - Remove
SMCS - 5056-011
Removal Procedure
Start By:
A. Remove the cab. Refer to Disassembly and Assembly, "Cab - Remove".
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
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.
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438D Backhoe Loader BPE00664-00742 (MACHINE) POWERED BY 3054 Engine(...
2019/10/5
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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.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, all hoses and all tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the system.
1. Drain the hydraulic oil into a suitable container. The capacity of the hydraulic tank is 38 L
(10 US gal).
Illustration 1 g00755957
2. Loosen clamp (1) and (2). Disconnect hose (3) and (4) .
3. Remove four bolts (5) .
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4. Loosen clamp (6) and disconnect hose (7) .
5. Loosen clamps (9) and (10). Disconnect hoses (11) and (12). Loosen clamp (13) and
disconnect hose (14) .
6. Remove the hydraulic tank assembly (8) .
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Oct 5 01:16:16 UTC+0800 2019
3/3
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Systems
i01443704
Hydraulic Tank - Disassemble
SMCS - 5056-015
Disassembly Procedure
Start By:
A. Remove the hydraulic tank. Refer to Disassembly and Assembly, "Hydraulic Tank -
Remove".
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
NOTICE
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containing fluids.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the
same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the
assembly procedure.
1. Remove six bolts (1). Remove diffuser assembly (2) and seal (3) .
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2. Remove two bolts (4) and sight gauge (5). Remove three fittings (6) .
Sat Oct 5 01:17:13 UTC+0800 2019
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Systems
i01443980
Hydraulic Tank - Assemble
SMCS - 5056-016
Assembly Procedure
Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the
same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the
assembly procedure.
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
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1. Use six bolts (1) in order to install diffuser assembly (2) and seal (3) .
2. Use two bolts (4) in order to install sight gauge (5). Install three fittings (6). Tighten three
fittings (6) to a torque of 45 ± 5 N·m (35 ± 5 lb ft).
End By: Install the hydraulic tank. Refer to Disassembly and Assembly, "Hydraulic Tank -
Install".
Sat Oct 5 01:18:09 UTC+0800 2019
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Systems
i01444175
Hydraulic Tank - Install
SMCS - 5056-012
Installation Procedure
NOTICE
containing fluids.
1/3
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1. Put hydraulic tank assembly (8) in position.
2. Connect hoses (11) and (12). Tighten clamps (9) and (10). Connect hose (14) and tighten
clamp (13) .
3. Connect hose (7) and tighten clamp (6). Tighten clamp (6) to a torque of 4.5 ± .5 N·m (40 ±
5 lb in).
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Note: There must be 31 mm (1.22 inch) between the front surface of the bracket and the
rear face of the engine block. There must be 7 mm (0.275 inch) between the outlet on the
hydraulic tank and the filter head on the transmission.
4. Install four bolts (5) .
5. Connect hose (3) and (4). Tighten clamp (1) and (2) .
,
End By:
a. Install the cab. Refer to Disassembly and Assembly, "Cab - Install".
b. Fill the hydraulic system with oil. Refer to Operation and MaintenanceSEBU7398,
"Capacities" for the proper capacity.
Sat Oct 5 01:19:06 UTC+0800 2019
3/3
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Systems
i01429122
Steering Metering Pump - Remove
SMCS - 4312-011
Removal Procedure
Make sure all of the work tools have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
NOTICE
containing fluids.
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1. Remove torx screws (1) and cover (2) .
2. Remove torx screws (3) and cover (4) .
2/4
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3. Remove torx screws (5) and plate (6) .
4. Remove two nuts (7) and two bolts (8). Position steering column (9) on the floor of the cab.
5. Disconnect two connectors (10) .
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6. Disconnect five lines (11) from metering valve (12) .
7. Remove four allen head screws (13) from metering valve (12) .
Sat Oct 5 01:20:02 UTC+0800 2019
4/4
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Systems
i01473776
Steering Metering Pump - Disassemble
SMCS - 4312-015
Disassembly Procedure
Start By:
A. Remove the steering metering pump. Refer to Disassembly and Assembly, "Steering
Metering Pump - Remove" in this manual.
NOTICE
containing fluids.
NOTICE
Keep all parts clean from contaminants.
1/9
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Contamination of the hydraulic system with foreign material will
reduce the service life of the hydraulic system components.
To prevent contaminants from entering the hydraulic system, always
plug or cap the lines, fittings, or hoses as they are disconnected. Cover
any disassembled components and clean them properly before
assembly.
Clean the hydraulic system properly after any major component
exchange or especially after a component failure, to remove any
contamination.
installation purposes.
Steering metering pump
1. Remove seven bolts (1) .
2. Remove end cap (2) .
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3. Remove O-ring seal (3) .
4. Remove housing (4) .
3/9
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(6) Spacer plate
(7) Star
(8) Drive
(9) Drive spacer
6. Remove drive spacer (9), drive (8), star (7), and spacer plate (6) from the housing.
8. Remove spool and sleeve assembly (11) .
Note: Do not bind the spool and sleeve assembly in the housing. Rotate the spool and sleeve
assembly slowly in order to remove the assembly from the housing.
Note: During removal, the pin may slide outward from the spool and sleeve assembly which
will lock these parts in the housing. If this occurs, center the pin and continue to remove the
spool and sleeve assembly.
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9. Remove pin (12) from the spool and sleeve assembly (11) .
10. Remove spool (13) from the control end of sleeve (14) .
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11. Remove centering springs (15) from spool (13) .
Note: The steering metering unit uses six centering springs.
Tapped plug (16) retains the manual steering check valve.
12. Remove tapped plug (16) .
Manual steering check valve
13. Remove roll pin (18) and ball (17) .
6/9
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Anticavitation valves
14. Remove two roll pins (20) and two balls (19) from the bolt holes by tipping the housing.
(21) Seal
(22) Spacer
(23) Needle bearing
(24) Spacer
15. Remove spacer (24), needle bearing (23), spacer (22), and seal (21) .
7/9
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16. Pry retaining ring (25) from the housing.
(25) Retaining ring
(26) O-ring seal
(27) Bushing
(28) Dust seal
17. Remove dust seal (28), bushing (27), and O-ring seal (26) .
8/9
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Caterpillar Cat 438D BACKHOE LOADER (Prefix BPE) Service Repair Manual (BPE00664-00742).pdf

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Caterpillar Cat 438D BACKHOE LOADER (Prefix BPE) Service Repair Manual (BPE00664-00742).pdf