Product:BACKHOELOADER
Model:438DBACKHOELOADERBPN
Configuration:438DBackhoeLoaderBPN00001-00475(MACHINE)POWEREDBY3054Engine
OperationandMaintenanceManual 424D,428Dand438DBackhoeLoaders
MediaNumber-SEBU7400-02PublicationDate-01/06/2006DateUpdated-28/06/2006
Foreword
SMCS-7606
LiteratureInformation
Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.
Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.
Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbe differentfromyourmachine.Guardsandcoversmighthavebeenremovedforillustrative purposes.
Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machine.
Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.
Safety
Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.
Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingor performinglubrication,maintenanceandrepaironthismachine.
Operation
Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperienced operator.Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachment controls,transportationandtowinginformation.
Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.
Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.
Maintenance
Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS) liststheitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsare listedunderthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhe pagenumberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance. UsetheMaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenance procedures.
MaintenanceIntervals
Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily, weekly,monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemore convenientservicingschedulesandapproximatetheindicatedservicehourmeterreading. Recommendedserviceshouldalwaysbeperformedattheintervalthatoccursfirst.
Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanis specifiedinthemaintenanceintervalschartmightbenecessary.
Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500 servicehoursor3months,alsoservicethoseitemslistedunderevery250servicehoursor monthlyandevery10servicehoursordaily.
CaliforniaProposition65Warning
DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.
Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhands afterhandling.
CertifiedEngineMaintenance
Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformance oftherequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.
Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewiththe
regulations(40CFRPart89).Certainelementsofthemachineandenginesuchastheexhaust system,fuelsystem,electricalsystem,intakeairsystemandcoolingsystemmaybeemission relatedandshouldnotbealteredunlessapprovedbyCaterpillar.
MachineCapacity
Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcan adverselyaffectperformancecharacteristics.Includedwouldbestabilityandsystemcertifications suchasbrakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerfor furtherinformation.
CatProductIdentificationNumber
EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to 17characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandother constructionequipmentmanufacturersaremovingtocomplywiththelatestversionoftheproduct identificationnumberingstandard.Non-roadmachinePINsaredefinedbyISO10261.Thenew PINformatwillapplytoallCatmachinesandgeneratorsets.ThePINplatesandframemarking willdisplaythe17characterPIN.Thenewformatwilllooklikethefollowing:
1.Caterpillar'sWorldManufacturingCode(characters1-3)
2.MachineDescriptor(characters4-8)
3.CheckCharacter(character9)
4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.
This is the sample of the manual if you need complete manual Click Here to download
MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8character PINformat.
Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8 characterSerialNumber(S/N).
Copyright1993-2023CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees. TueSep1209:12:52UTC+05302023
Product:BACKHOELOADER
Model:438DBACKHOELOADERBPN
Configuration:438DBackhoeLoaderBPN00001-00475(MACHINE)POWEREDBY3054Engine
OperationandMaintenanceManual
Applylubricanttothegreasefittingsforthedriveshafttothefinaldrives.Therearetwogrease fittingsforeachdriveshaft.
Copyright1993-2023CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueSep1210:07:52UTC+05302023
Product:BACKHOELOADER
Model:438DBACKHOELOADERBPN
Configuration:438DBackhoeLoaderBPN00001-00475(MACHINE)POWEREDBY3054Engine
OperationandMaintenanceManual 424D,428Dand438DBackhoeLoaders
MediaNumber-SEBU7400-02PublicationDate-01/06/2006DateUpdated-28/06/2006
BackhoeBoom,Stick,Bucket,andCylinderBearingsLubricate
SMCS-6501;6502;6503;6510;6511;6512;6513;6533
Illustration1g00750900
Positionthebackhoeintotheservicepositionthatisshownabove.
Illustration2g00750901
Applylubricanttothegreasefitting(1)fortheheadendoftheboomcylinder.Applylubricantto thegreasefitting(2)fortherodendoftheboomcylinder.
Applylubricanttothegreasefitting(3)fortheboompivot.Thereisonegreasefittingoneach sideofthemachine.
Illustration3g00723265
Applylubricanttothegreasefitting(9)fortheheadendofthestickcylinder.Applylubricantto thegreasefitting(8)fortherodendofthestickcylinder.
Applylubricanttothegreasefitting(10)forthepivotpinforthestick.
Applylubricanttothegreasefitting(7)fortheheadendofthebucketcylinder.Applylubricantto thegreasefitting(6)fortherodendofthebucketcylinder.
Applylubricanttothegreasefitting(11)forthepivotpin.Thereisonegreasefittingoneachside ofthemachine.
Applylubricanttothegreasefitting(4)forthebucketpivotpin.
Applylubricanttothegreasefitting(5)forthelink.
Applylubricanttothegreasefitting(12)forthepivotpin. Thereisatotalofthirteengreasefittings.
Copyright1993-2023CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueSep1210:09:07UTC+05302023
Product:BACKHOELOADER
Model:438DBACKHOELOADERBPN
Configuration:438DBackhoeLoaderBPN00001-00475(MACHINE)POWEREDBY3054Engine
OperationandMaintenanceManual 424D,428Dand438DBackhoeLoaders
MediaNumber-SEBU7400-02PublicationDate-01/06/2006DateUpdated-28/06/2006
BackupAlarm-Test
SMCS-7406
TurntheenginestartswitchkeytoONinordertoperformthetest.
Applytheservicebrake.MovethetransmissiondirectioncontrollevertoREVERSEposition. Thebackupalarmshouldimmediatelysound.Thebackupalarmwillcontinuetosounduntilthe transmissiondirectioncontrolleverismovedtotheNEUTRALpositionortotheFORWARD position.
Copyright1993-2023CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees. TueSep1210:09:25UTC+05302023
Product:BACKHOELOADER
Model:438DBACKHOELOADERBPN
Configuration:438DBackhoeLoaderBPN00001-00475(MACHINE)POWEREDBY3054Engine
OperationandMaintenanceManual 424D,428Dand438DBackhoeLoaders
MediaNumber-SEBU7400-02PublicationDate-01/06/2006DateUpdated-28/06/2006
BatteryorBatteryCable-Inspect/Replace
SMCS-1401
i01833495
1.TurntheenginestartswitchtotheOFFposition.TurnallswitchestotheOFFposition.
2.Disconnectthenegativebatterycablefromtheframe.
Note:Donotallowthedisconnectedbatterycabletocontacttheframeofthemachine.
3.Disconnectthenegativebatterycableatthebattery.
4.Inspectthebatteryterminalsandinspectthebatterycables.Keeptheterminalscleanand keeptheterminalscoatedwithpetroleumjelly.
5.Performthenecessaryrepairs.Replacethecableorthebattery,asneeded.
6.Connectthenegativebatterycableatthebattery.
7.Connectthebatterycabletotheframeofthemachine.
8.Installtheenginestartswitchkey.
Copyright1993-2023CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueSep1210:09:43UTC+05302023
Product:BACKHOELOADER
Model:438DBACKHOELOADERBPN
Configuration:438DBackhoeLoaderBPN00001-00475(MACHINE)POWEREDBY3054Engine
OperationandMaintenanceManual 424D,428Dand438DBackhoeLoaders
MediaNumber-SEBU7400-02PublicationDate-01/06/2006DateUpdated-28/06/2006
Belts-Inspect/Adjust/Replace
SMCS-1357-025;1357-040;1357-510
Ifnewbeltsareinstalled,checkbeltadjustmentafter30minutesofoperation.Formultiplebelt driveapplications,alwaysreplacethebeltsinmatchedsets.Replacingonlyonebeltofamatched setwillcausethenewbelttocarrymoreloadbecausetheolderbeltsarestretched.Theadditional loadonthenewbeltcouldcausethenewbelttobreak.
1.Emptythebucket.Removethepinthatsecurestheloaderliftarmbracetotheleftloaderlift arm.Raisetheloaderarmtothemaximumheight.
2.Positiontheloaderliftarmbraceovertheleftliftcylinderrodwiththeflatendagainstthe cylinderend.
3.Pushthepinthroughtheholesoftheloaderliftarmbraceandinstallthecotterpin.
4.Slowlylowertheloaderarmsuntiltheloaderliftarmbracecontactsthetopofthelift cylinderandthebossesontheloaderarm.
5.Stoptheengineinordertoinspectthebelts.
Illustration1g00751273
6.Removetheengineaccesspanelontheleftsideofthemachine.
Illustration2g00287234
7.Inspecttheconditionoftheairconditionerbeltandtheadjustmentoftheairconditioner belt.Theairconditionerbeltshoulddeflect10mm(0.38inch)under110N(25lb)offorce.
Illustration3g00287235
8.Loosentheadjustinglocknut(1).Loosenthecompressorbracketmountingbolt(2).
9.Movethecompressoruntilthecorrectbelttensionisreached.
10.Tightentheadjustinglocknut(1).Tightenthecompressorbracketmountingbolt(2).
11.Recheckthebeltdeflection.Iftheamountofdeflectionisincorrect,repeatStep8toStep 10.
12.Installtheengineaccesspanelontheleftsideofthemachine.
13.Removetheengineaccesspanelontherightsideofthemachine.
14.Inspecttheconditionofthealternatorbeltsandtheadjustmentofthealternatorbelts.The alternatorbeltsshoulddeflect10mm(0.38inch)under110N(25lb)offorce.
Illustration5g00287243
15.Loosenthemountingbolt(1).Loosentheadjustinglocknut(2).
16.Movethealternatoruntilthecorrecttensionisreached.
17.Tightentheadjustinglocknut(2).Tightenthemountingbolt(1).
18.Recheckthebeltdeflection.Iftheamountofdeflectionisincorrect,repeatStep15toStep 17.
19.Installtheengineaccesspanel.
20.Starttheengine.Raisetheloaderarmstothemaximumheight.
21.Removethepinandreplacetheloaderliftarmbracetothestoredpositionontheloaderlift arm.
22.Lowerthebuckettotheground.
Product:BACKHOELOADER
Model:438DBACKHOELOADERBPN
Configuration:438DBackhoeLoaderBPN00001-00475(MACHINE)POWEREDBY3054Engine
OperationandMaintenanceManual 424D,428Dand438DBackhoeLoaders
MediaNumber-SEBU7400-02PublicationDate-01/06/2006DateUpdated-28/06/2006
BrakeReservoirOilLevel-Check
SMCS-4291-535
Illustration1g00751131
Pullthehoodreleaselever(1)inordertoopentheengineaccessdoor(2)onthetopofthe machine.Thehoodreleaseleverislocatedunderthecabdoorontheleftsideofthemachine.
Maintaintheoillevelbetweenthe"MIN"markand"MAX"markonthebrakereservoir.Addoil, ifnecessary.
Copyright1993-2023CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
TueSep1210:10:25UTC+05302023
Product:BACKHOELOADER
Model:438DBACKHOELOADERBPN
Configuration:438DBackhoeLoaderBPN00001-00475(MACHINE)POWEREDBY3054Engine
OperationandMaintenanceManual 424D,428Dand438DBackhoeLoaders
MediaNumber-SEBU7400-02PublicationDate-01/06/2006DateUpdated-28/06/2006 i04002955
BrakingSystem-Test
SMCS-4251;4267;7000
ServiceBrakeHoldingAbilityTest
Checktheareaaroundthemachine.Makesurethatthemachineisclearofpersonnelandclearof obstacles.
Testthebrakesonadry,levelsurface.
Fastentheseatbeltbeforeyoutestthebrakes.
Thefollowingtestsareusedtodetermineiftheservicebrakeisfunctional.Thesetestsarenot intendedtomeasurethemaximumbrakeholdingeffort.Thebrakeholdingeffortthatisrequired tosustainamachineataspecificenginerpmvariesdependingonthemachine.Thevariationsare thedifferencesintheenginesetting,inthepowertrainefficiency,andinthebrakeholdingability, etc.
1.Starttheengine.Raisethebucketslightly.
2.Applytheservicebrake.Releasetheparkingbrake.
3.MovethetransmissioncontrollevertoTHIRDSPEEDFORWARD.
4.Graduallyincreasetheenginespeedtohighidle.Themachineshouldnotmove.
Ifthemachinebeginstomove,reducetheenginespeedimmediatelyand engagetheparkingbrake.
5.Reducetheenginespeedtolowidle.MovethetransmissiontoNEUTRAL.Engagethe parkingbrake.Lowerthebuckettotheground.Stoptheengine.
NOTICE
Ifthemachinemovedwhiletestingthebrakes,contactyour Caterpillardealer.Havethedealerinspectand,ifnecessary,repairthe servicebrakebeforereturningthemachinetooperation.
