Caterpillar Cat 438D BACKHOE LOADER (Prefix BPE) Service Repair Manual Instant Download (BPE00664)

1
Service Repair Manual
Model 438D BACKHOE LOADER
2
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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.
3
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
• Loosen clamp (1) and (2). Disconnect hose (3) and
  (4) .
• Remove four bolts (5) .

Illustration 2
g00755958
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4. Loosen clamp (6) and disconnect hose (7) .

• Illustration 3 g00755960
• Loosen clamps (9) and (10). Disconnect hoses (11)
  and (12). Loosen clamp (13) and disconnect hose
  (14) .
• Remove the hydraulic tank assembly (8) .

Copyright 1993 - 2019 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Oct 5 011616 UTC0800 2019
6
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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
i01443704
Hydraulic Tank - Disassemble SMCS -
5056-015 Disassembly Procedure Start By A.
Remove the hydraulic tank. Refer to Disassembly
and Assembly, "Hydraulic Tank - 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
7
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.
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 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. 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.
Illustration 1 g00756180 1. Remove six bolts
(1). Remove diffuser assembly (2) and seal (3) .
8
Illustration 2 g00756181 2. Remove two bolts (4)
and sight gauge (5). Remove three fittings (6) .
Copyright 1993 - 2019 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
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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
i01443980
Hydraulic Tank - Assemble SMCS -
5056-016 Assembly Procedure 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. 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.
Illustration 1
g00756180
10
1. Use six bolts (1) in order to install diffuser
assembly (2) and seal (3) .
Illustration 2 g00756181 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 Nm (35 5 lb ft). End By
Install the hydraulic tank. Refer to Disassembly
and Assembly, "Hydraulic Tank - Install".
Copyright 1993 - 2019 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Oct 5 011809 UTC0800 2019
11
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Previous Screen
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
i01444175
Hydraulic Tank - Install SMCS -
5056-012 Installation Procedure 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.
12

• Illustration 1 g00755960
• Put hydraulic tank assembly (8) in position.
• Connect hoses (11) and (12). Tighten clamps (9)
  and (10). Connect hose (14) and tighten clamp
  (13) .

Illustration 2 g00755958 3. Connect hose (7) and
tighten clamp (6). Tighten clamp (6) to a torque
of 4.5 .5 Nm (40 5 lb in).
13

• Illustration 3 g00755957
• 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.
• Install four bolts (5) .
• Connect hose (3) and (4). Tighten clamp (1) and
  (2) .
• ,
• End By
• Install the cab. Refer to Disassembly and
  Assembly, "Cab - Install".
• Fill the hydraulic system with oil. Refer to
  Operation and MaintenanceSEBU7398, "Capacities"
  for the proper capacity.

Copyright 1993 - 2019 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Oct 5 011906 UTC0800 2019
14
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Previous Screen
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
i01429122
Steering Metering Pump - Remove SMCS -
4312-011 Removal Procedure
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 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 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.
15
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.
Illustration 1
g00748631
1. Remove torx screws (1) and cover (2) .
Illustration 2
g00748638
2. Remove torx screws (3) and cover (4) .
16
Illustration 3
g00748641
3. Remove torx screws (5) and plate (6) .
Illustration 4 g00748643 4. Remove two nuts (7)
and two bolts (8). Position steering column (9)
on the floor of the cab.
Illustration 5
g00748647
5. Disconnect two connectors (10) .
17
Illustration 6 g00748668 6. Disconnect five
lines (11) from metering valve (12) .
Illustration 7 g00748672 7. Remove four allen
head screws (13) from metering valve (12) .
Copyright 1993 - 2019 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sat Oct 5 012002 UTC0800 2019
18
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Previous Screen
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
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 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.
NOTICE Keep all parts clean from contaminants.
19
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.
Note Put identification marks on all lines, on
all hoses, on all wires, and on all tubes for
installation purposes.
Illustration 1
g00768563

• Steering metering pump
• Remove seven bolts (1) .
• Remove end cap (2) .

20
Illustration 2
g00768567

1. Remove O-ring seal (3) .
2. Remove housing (4) .

Illustration 3
g00768582
5. Remove O-ring seal (5) .
Illustration 4
g00768584
21

• Spacer plate
• Star
• Drive
• Drive spacer
• 6. Remove drive spacer (9), drive (8), star (7),
  and spacer plate (6) from the housing.

Illustration 5
g00768590
7. Remove O-ring seal (10) .
Illustration 6
g00768594
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.
22
Illustration 7 g00768615 9. Remove pin (12) from
the spool and sleeve assembly (11) .
Illustration 8 g00768619 10. Remove spool (13)
from the control end of sleeve (14) .
23
Illustration 9 g00768628 11. Remove centering
springs (15) from spool (13) . Note The steering
metering unit uses six centering springs.
Illustration 10 g00768635 Tapped plug (16)
retains the manual steering check valve. 12.
Remove tapped plug (16) .
Illustration 11
g00768638
Manual steering check valve 13. Remove roll pin
(18) and ball (17) .
24
Illustration 12
g00768645
Anticavitation valves 14. Remove two roll pins
(20) and two balls (19) from the bolt holes by
tipping the housing.
Illustration 13
g00768646

• Seal
• Spacer
• Needle bearing
• Spacer
• 15. Remove spacer (24), needle bearing (23),
  spacer (22), and seal (21) .

25
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Illustration 14
g00768651
16. Pry retaining ring (25) from the housing.
Illustration 15
g00768656

• Retaining ring
• O-ring seal
• Bushing
• Dust seal
• 17. Remove dust seal (28), bushing (27), and
  O-ring seal (26) .

27
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com