Caterpillar cat 438 c backhoe loader (prefix 9kn) service repair manual (9kn01200 01418)

Service Repair Manual
Model
438C BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 438C BACKHOE LOADER 9KN
Configuration: 438C Backhoe Loader Center Pivot, Single Tilt 9KN01200-01418 (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
i01083913
Fuel Injection Pump - Install - Type 1 Engines and 9RM
Engines
SMCS - 1251-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
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
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Inspect the condition of the gasket for the fuel injection pump. Replace the gasket, if
necessary.
1/3438C Backhoe Loader Center Pivot, Single Tilt 9KN01200-01418 (MACHINE) POW...
2019/10/7https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g00545262
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".
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Oct 7 22:39:14 UTC+0800 2019

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i01051839
Turbocharger - Remove
SMCS - 1052-011
Removal Procedure
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 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.

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) .

7. Remove turbocharger (3) and the gaskets.
8. Plug all openings immediately.
Mon Oct 7 22:40:10 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.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain

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) .
Mon Oct 7 22:41:06 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

Typical example
2. Assemble cartridge (7) and turbine housing (10) .
3. Install three clamps (9) .
4. Apply 5P-3931 Anti-Seize Compound to six bolts (8). Tighten the bolts to a torque of 19 ±
1 N·m (14 ± 1 lb ft).
Typical example
5. Assemble compressor housing (6) and cartridge (7) .
6. Install three clamps (5) .
7. Apply 5P-3931 Anti-Seize Compound to six bolts (4). Tighten the bolts to a torque of 15 ±
4 N·m (11 ± 3 lb ft).

Typical example
8. Install hose assembly (3) and the gasket.
9. Install two bolts (2) .
10. Install elbow (1) and the O-ring seals.
End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
Mon Oct 7 22:42:02 UTC+0800 2019

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i06205331
Turbocharger - Install
SMCS - 1052-012
NOTICE
1. Inspect the condition of all gaskets. Replace the gaskets, if necessary.

Typical example
2. Install turbocharger (3) and the gaskets.
3. Install three bolts (7) .
Typical example
4. Apply 5P-3931 Anti-Seize Compound to nuts (5) . Tighten the nuts to a torque of 47 N·m
(35 lb ft).
5. Install the gasket and oil return line (6) .
6. Install two bolts (4) .

7. Slide hose (2) onto the turbocharger (3) .
8. Tighten two clamps (1) .
Mon Oct 7 22:42:57 UTC+0800 2019

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i01598347
Exhaust Manifold - Remove and Install - Type 2 Engines and
7BJ Engines
SMCS - 1059-010
Removal Procedure
Start By:
B. Remove the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold -
Remove and Install".
NOTICE

Typical example
1. Remove exhaust manifold nuts or bolts (1) in reverse order of the numbered sequence.
2. Remove exhaust manifold (2) from the engine.

Typical example
3. Remove exhaust manifold gaskets (3) from the engine.
4. Remove old sealant from stud threads.
NOTICE
Typical example

1. Inspect the condition of the gaskets. If the gaskets are damaged, use new parts for
replacement. Install exhaust manifold gaskets (3) on the cylinder head. Apply 4C-9507
Retaining Compound to the stud threads.
Typical example
NOTICE
Damage to the exhaust manifold can occur if the exhaust manifold is
not aligned and tightened correctly.

2. Install exhaust manifold (2) on the cylinder head.
Note: Some of the exhaust manifolds have large clearance holes for the bolts. If a new
exhaust manifold is installed ensure that the 148-7132 Ferrule mountings that are supplied
with the exhaust manifold are installed.
3. Install exhaust manifold nuts or bolts (1). Tighten the exhaust manifold nuts or bolts in the
numerical sequence to a torque of 44 N·m (33 lb ft).
End By:
a. Install the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold -
Remove and Install".
b. Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
Mon Oct 7 22:43:53 UTC+0800 2019

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i01068659
Exhaust Manifold - Remove and Install - Type 1 Engines and
9RM Engines
SMCS - 1059-010
Removal Procedure
Start By:
NOTICE

Typical example
1. Remove exhaust manifold nuts (1) .
2. Remove exhaust manifold (2) and the gasket.
NOTICE
Typical example

1. Inspect the condition of the gasket. Replace the gasket, if necessary.
2. Install the gasket and exhaust manifold (2) .
3. Install exhaust manifold nuts (1). Tighten the plated nuts to a torque of 44 N·m (32 lb ft).
Tighten the nuts that are not plated to a torque of 50 N·m (37 lb ft).
End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
Mon Oct 7 22:44:49 UTC+0800 2019

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i02870246
Inlet Manifold - Remove - Type 2 Engines and 7BJ Engines
SMCS - 1058-011
Removal Procedure
Note: For a complete description of Type 1 and Type 2 engines, refer to Disassembly and
Assembly, "Engine Design".
NOTICE
NOTICE
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain

Typical example
1. Disconnect tube (1) from the air inlet heater.
2. Loosen hose clamps (3) and slide the hose toward the turbocharger.
3. Remove four bolts (2) and remove elbow (4) from the air inlet manifold.
Typical example
4. Remove bolts (5) that fasten air inlet manifold (6) to the engine.
5. Remove air inlet manifold (6) .
Mon Oct 7 22:45:44 UTC+0800 2019

Caterpillar cat 438 c backhoe loader (prefix 9kn) service repair manual (9kn01200 01418)

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