Caterpillar cat 438 c backhoe loader (prefix 9kn) service repair manual (9kn00001 01060)

Service Repair Manual
Model
438C BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 438C BACKHOE LOADER 9KN
Configuration: 438C Backhoe Loader Side Shift, Single Tilt 9KN00001-01060 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
G3B, K3A and L3A Denso Alternators
Media Number -SENR5841-00 Publication Date -01/10/1998 Date Updated -09/10/2001
i00937307
Alternator - Disassemble
SMCS - 1405-015
Procedure
Illustration 1 g00477507
(1) G3B Alternator Pulley Nut. (2) L3A Alternator Pulley Nut. (3) K3A Alternator Pulley Nut.
1. Remove the nut that secures the pulley to the rotating shaft. An impact wrench can be used
to loosen the nut. Use a deep well socket (six point). Do not use a twelve point socket.
1/6438C Backhoe Loader Side Shift, Single Tilt 9KN00001-01060 (MACHINE) POWER...
2019/10/6https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Alternator (55 Ampere) With Securing Screws (Front Cover) (4) and B Terminal (5) .
Alternator (90 Ampere) With Securing Nuts (Rear Cover) (4) , B Terminal (5) , And Additional Fastener (6) .
2. Remove the three bolts (4) that attach the rear end cover to the alternator. Also remove the
B terminal nut and plastic shroud (5) . On 90 amp alternators, remove the screw (6) .

3. Remove the two screws (7) that secure the brush holder. Note that the rubber seal that is
covering the brush holder in illustration 4 is for 90 amp alternators. The 55 amp alternator
has a slightly different seal.
4. Remove the three screws (8) that secure the IC regulator. The screws are different lengths,
and the screws must be put back in the same hole.
Alternator (55 Ampere) With Wire Type Leads From Stator

Alternator (90 Ampere) With Terminal Type Leads From Stator
5. On 55 ampere alternators, remove the four screws that are holding the stator leads. Use
needle nose pliers to straighten the stator leads. On 90 ampere alternators, remove the four
screws that are attaching the terminal type leads to the rectifier. Remove the rectifier.
55 Amp Alternator

90 Amp Alternator
A Puller Is Used To Separate The Two Halves Of The Alternator.
6. A puller (14) is used to separate the two halves of the alternator. Use a puller with an end
that is pointed. Do not use a puller with a flat shaft end. Hook the arms of the puller around
the inner portion of the case (13) . See illustration 10. Use puller arms with thin, flat bottom
hooks (15) .
Note: As the case comes apart, ensure that the washer between the rear bearing and the case
of the alternator is accounted for. The washer will be reused during reassembly of the
alternator.

7. Use a press to remove the rotor from the front case. Use blocking in order to ensure that the
alternator and the press are properly aligned. Ensure that the rotor does not fall to the floor
as the rotor is pressed out of the case.
8. If necessary, remove the front bearing (17) by removing the screws (18) and the retainer
plate.
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All Rights Reserved.
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Sun Oct 6 09:30:41 UTC+0800 2019

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G3B, K3A and L3A Denso Alternators
i00942054
Alternator - Assemble
SMCS - 1405-016
Procedure
1. If the front bearing (17) has been removed or replaced, install the bearing. Secure the
bearing by attaching the retainer plate with four screws (18) .

2. Slide the rotor shaft into the front bearing.
3. Slide the rear case of the alternator over the rear of the rotor shaft. Ensure that the washer
(16) that is shown in illustration 3 is in position (A) . Position (A) is between the rear
bearing and the case of the alternator. Ensure that the stator leads go through the proper
slots in the rear case. The two halves of the case will probably not be able to be pushed
together. Initially, use hand pressure in order to press the case together.

4. Insert the four screws or bolts (11) and tighten finger tight. Tighten each screw or bolt with
a socket wrench. Tighten the screws or bolts in a cross pattern until the two halves of the
case are brought together. Push the rubber bushings (12) into position over the stator leads
on 90 amp alternators.
Alternator (55 Ampere) With Wire Type Leads From Stator
Alternator (90 Ampere) With Terminal Type Leads From Stator
5. Place the rectifier in position. On 55 ampere alternators, use needle nose pliers in order to
bend the lead wire (9) into position. A screw then secures the leads to the rectifier. On 90
ampere alternators, align the terminals of the rectifier with the terminal type leads from the
stator (10) . Use four screws to secure the two terminals together.

6. Place the voltage regulator in position and secure the regulator with screws (8) . Use screws
that are the proper length, which was noted during disassembly of the alternator.
7. Attach the brush to the voltage regulator by using two screws (7) . Push back the spring-
loaded brushes as the brush assembly slides over the rotor. Ensure that the rubber seal is in
the proper position.

8. Place the rear alternator cover in position and secure the cover with three screws (4) (55
amp alternators). Secure the cover with three nuts on 90 amp alternators.
9. Slide the insulator (5) onto the B terminal and secure the insulator with a nut.
Sun Oct 6 09:31:37 UTC+0800 2019

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3054 ENGINE SUPPLEMENT FOR 416C, 426C, 428C, 436C & 438C BAC
SENR12030001
Introduction
SMCS - 1405-016
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with
suitable containers before opening any compartment or disassembling any component containing
fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to
collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations
and mandates.
Sun Oct 6 09:32:59 UTC+0800 2019

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SENR12030002
Tire Explosion Prevention
SMCS - 1405-016
Explosions of air inflated tires have resulted from heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated by welding, by heating rim components, by
external fire or by excessive use of brakes.
A tire explosion is much more violent than a blowout. The explosion can propel the tire, the rim
components, and the axle components as far as 500 m (1500 ft) or more from the machine. Both
the force of the explosion and the flying debris can cause property damage, personal injury, or
death.
Do not approach a warm tire. Maintain a minimum distance, as shown. Stay outside the shaded
area in illustration 1.
Dry nitrogen gas is recommended for inflation of tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure. Nitrogen mixes properly with air.

Nitrogen inflated tires reduce the potential of a tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation of the rubber, deterioration of rubber, and
corrosion of rim components.
To avoid overinflation, proper nitrogen inflation equipment and training in the usage of the
equipment are necessary. A tire blowout or a rim failure can result from improper equipment or
from misused equipment.
When you inflate a tire, stand behind the tread and use a self-attaching chuck.
Sun Oct 6 09:33:55 UTC+0800 2019

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SENR12030003
Hood
SMCS - 7251-010
Remove & Install Hood
Start By:
a. remove left engine panel
b. remove right engine panel
1. Open hood and remove four bolts (1). Remove the left side of the hood.
2. Remove bolt (2) from the rear of the right side of the hood.

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3. Remove bolt (3) from the front of the right side of the hood.
4. Remove three bolts (4) from the right side of the hood. Remove the right side of the hood.
NOTE: Install hood in reverse order.
End By:
a. install left engine panel
b. install right engine panel
Sun Oct 6 09:34:51 UTC+0800 2019

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SENR12030004
Right Engine Panel
SMCS - 2411-010
Remove & Install Right Engine Panel
1. Remove three bolts (1) and right engine panel (2).
NOTE: Install the right engine panel in the reverse order.
Sun Oct 6 09:35:46 UTC+0800 2019

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SENR12030005
Left Engine Panel
SMCS - 2411-010
Remove & Install Left Engine Panel
1. Open hood (1).
2. Remove bolts (2) and left engine panel (3).
NOTE: Install the left engine panel in the reverse order.
Sun Oct 6 09:36:42 UTC+0800 2019

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SENR12030006
Counterweight
SMCS - 7056-010
Remove & Install Counterweight
1. Remove four bolts (1) and two bumpers (2). Remove screw (3) and grill (4).
2. Using tooling (A), remove four nuts (5) and two u-bolts (6). Remove two counterweights (7).
The weight of the two counterweights is 101.7 Kg (224 lb).

Caterpillar cat 438 c backhoe loader (prefix 9kn) service repair manual (9kn00001 01060)

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Caterpillar cat 438 c backhoe loader (prefix 9kn) service repair manual (9kn00001 01060)