Cat 938G II Wheel Loader Parts Manual – PDF DOWNLOAD

GENERAL INFORMATION A27
REPAIR ALTERNATIVES A46
SUPPLEMENTAL COOLANT
ADDITIVES A51
LUBRICATION SYSTEM 69
ADAPTER GP-OIL LINE 69
BREATHER GP 70
FILTER GP-ENGINE OIL 71
FUMES DISPOSAL GP 72
GAUGE GP-OIL LEVEL (DIPSTICK) 73
LINES GP-ENGINE OIL 75
LINES GP-TURBOCHARGER OIL 76
PUMP GP-ENGINE OIL 77
VALVE GP-FLUJD SAMPLING 81
COOLING SYSTEM 82
COOLER GP-ENGINE OIL 82
GUARD GP-FAN 83
LINES GP-WATER 85
PUMP GP-WATER 94
RADIATOR & FAN GP 99
TANK GP-RADIATOR TOP 107
AIR INLET AND EXHAUST SYSTEM 109
AIR CLEANER GP 109
COVER GP-AIR INLET 112
ELBOW GP-AIR INLET 115
FILTER ELEMENT AS-AIR 116
LINES GP-AIR 117
MANIFOLD GP-EXHAUST 119
MUFFLER GP 120
PIPE AS-EXHAUST EXTENSION 121
PRECLEANER GP 122
TURBOCHARGER GP 125
FUEL SYSTEM 127
FILTER GP-WATER SEP & FUEL 127
LINES GP-FUEL 128
LINES GP-FUEL DRAIN 132
LINES GP-FUEL FILTER 133
LINES GP-INJECTOR HYD PUMP 145
PUMP GP-FUEL PRM & PRIM FILTER 147
PUMP GP-UNIT INJECTION 149
PUMP GP-UNIT INJECTOR HYD 151
REGULATOR GP-FUEL PRESSURE 154
TANK GP-FUEL 155
VALVE GP-SOLENOID 157
WATER SEP & FUEL PRM PUMP GP 158
ELECTRICAL AND STARTING SYSTEM 159
ALARM GP 159
ALTERNATOR AR-CHARGING 161
ALTERNATOR GP-CHARGING 162
BATIERY & WIRING GP 172
BLOCK GP-JUNCTION 175
CONTROL & MTG GPCOMMUNICATION
176
CONTROL & MTG GP-ENGINE ELEK 178
CONTROL GP-ENGINE ELECTRONIC 181
MAINTENANCE PARTS A56
INOEX “” A8S
MACHINE ARRANGEMENT 1
CHASSIS AR 1
GENERAL AR 1
SCRAP HANDLING AR 2
WASTE HANDLING AR 2
ENGINE ARRANGEMENT 4
ENGINE AR-COMPLETE 4
ENGINE AR-CORE 5
INSTALLATION AR-ENGINE 6
BASIC ENGINE 7
CAMSHAFT GP 7
CARRIER GP-SEAL 8
COVER GP-CYLINDER BLOCK 9
COVER GP-FRONT HOUSING 11
COVER GP-VALVE MECHANISM 13
CRANKSHAFT GP 14
CYLINDER BLOCK GP 16
CYLINDER HEAD AS 20
CYLINDER HEAD GP 27
DAMPER & PULLEY GP 39
DRAIN GP-ENGINE OIL 40
FASTENER GP-DAMPER & PULLEY 41
FASTENER GP-FLYWHEEL 42
FASTENER GP-FRONT HOUSING 43
FLYWHEEL GP 44
GEAR GP-FRONT 45
HOUSING GP-FLYWHEEL 47
HOUSING GP-FRONT 48
IDLER GP-BELT 49
LIFTER GP-VALVE 50
LIFTING GP-ENGINE 51
MOUNTING GP-AL TERNATOR 52
MOUNTING GP-ENGINE & TMSN 54
PAN GP-OIL 56
PISTON & ROD GP 57
PLUG GP-CYLINDER BLOCK 60
PLUG GP-ENGINE 61
PULLEY GP-IDLER 62
SEAL GP-CRANKSHAFT 64
SEAL GP-FLYWHEEL HOUSING 65
VALVE MECHANISM GP 66
SEBP3498-26 TABLE OF CONTENTS A 1
TABLE OF CONTENTS
Name Page Name Page
CONTROL GP-LiFT KICKOUT 186
CONTROL GP-POSITION 188
CONTROL GP-UNPROGRAMMED 189
ELECTRICAL AR 192
ELECTRONICS GP-MACHINE 193
ELECTRONICS GP-POWER TRAIN 194
HEATER GP-JACKET WATER 195
INSTALLATION ARCOMMUNICATION
199
INSTALLATION AR-SECURITY 199
INSTALLATION GP-SECURITY 200
LAMP GP-FLOOD 201
LAMP GP-HEAD & SIGNAL 205
LAMP GP-SIGNAL 209
LAMP GP-WARNING BEACON 212
LIGHTING AR-AUXILIARY 213
LIGHTING AR-ROADING 213
LIGHTING AR-SIGNAL 214
LIGHTING GP-FLOOD 214
LIGHTING GP-FLOOD & SIGNAL 219
LIGHTING GP-ROADING 223
LIGHTING GP-SIGNAL 224
LIGHTING GP-WARNING BEACON 225
PANEL GP-CIRCUIT BREAKER 228
SENSOR GP-ENGINE 235
SENSOR GP-POSITION 237
SENSOR GP-PRESSURE 241
SENSOR GP-SPEED 250
SENSOR GP-TEMPERATURE 253
SERVICE GP-MACHINE 260
STARTING AID GP 261
STARTING AID GP-ETHER 263
STARTING MOTOR GP-ELECTRIC 264
SWITCH GP-DISCONNECT 267
SWITCH GP-MAGNETIC 268
SWITCH GP-QUICK COUPLER 276
SWITCH GP-SIGNAL 277
SWITCH GP-TOGGLE 278
SWITCH GP-WiPER 279
VALVE GP-ETHER STARTING 280
WARNING GP-BACKUP 281
WIRING AR-AXLE MONITORING 282
WIRING GP-AIR CONDITIONER 283
WIRING GP-AXLE MONITORING 284
WIRING GP-CAB 286
WIRING GP-COMMUNICATION 313
WIRING GP-COUPLER 315
WIRING GP-ELECTRIC CLUTCH 316
WIRING GP-ENGINE 317
WIRING GP-FRONT 335
WIRING GP-LiGHTING 344
WIRING GP-MACHINE 348
WIRING GP-POWER GUARD 356
WIRING GP-SECONDARY STEERING 358
WIRING GP-SENSOR 366
WIRING GP-STARTING AID 368
WIRING GP-TRACTION CONTROL 369
POWER TRAIN 374
AXLE AR-FIXED 374
AXLE AR-OSCILLATING 375
BRAKE & PLANETARY GP 377
CASE & PARTS GP-PLANETARY 379
CLUTCH GP 382
CONTROL GP-TRANSMISSION 388
COOLER & MTG GP- TRANSMISSION 390
COOLER AR-AXLE OIL 391
COVER GP-SHIPPING 392
COVER GP-TMSN OIL FILLER CAP 393
DIFFERENTIAL GP 394
DIFFERENTIAL GP-LiMITED SLIP 395
DIFFERENTIAL GP-NOSPIN 396
DRAIN GP-ECOLOGY 398
FILLER GP-POWER TRAIN OIL 399
FILTER GP-OIL 400
GEAR GP-BEVEL 402
GEAR GP-BEVEL & PINION 404
GEAR GP-OUTPUT TRANSFER 406
HOUSING GP-FIXED AXLE 408
HOUSING GP-OSCILLATING AXLE 412
INPUT GP-TRANSMISSION 416
LINES GP-AXLE OIL COOLER 417
LINES GP-POWER TRAIN FILTER 421
LINES GP-TORQUE CONV COOLER 425
MOUNTING GP-AXLE 427
MOUNTING GP-AXLE OIL COOLER 428
MOUNTING GP-RIM 430
POWER TRAIN AR 430
PUMP & MTG GP-AXLE OIL COOLER 431
PUMP GP-TRAN5MISSION 432
RIM AR 434
RIM GP-DEMOUNTABLE 435
SHAFT GP-DRIVE 439
SLIP JOINT GP 441
TIRE & RIM AR 442
TORQUE CONVERTER GP 453
TRANSMISSION AR 455
UNIVERSAL JOINT GP 457
VALVE GP-BYPASS 459
VALVE GP-MODULATING 460
VALVE GP-RELlEF 461
VALVE GP-TRANSMISSION
CONTROL 463
FRAME AND BODY 467
ACTUATOR AR-POWER GUARD 467
ACTUATOR GP-HOOD TILT 468
ACTUATOR GP-POWER 472
ACTUATOR GP-POWER GUARD 473
BAFFLE GP 475
A2 TABLE OF CONTENTS SEBP3498-26
TABLE OF CONTENTS
Name Page
COUNTERWEIGHT GP 476
COUNTERWEIGHT GP-REAR 477
DOOR GP-BAITERY 478
EXTENSION GP-FENDER 480
FENDER GP 481
FENDER GP-ROADING 483
FRAME AS-FRONT 485
FRAME AS-LOADER 488
FRAME AS-REAR 490
GRILL GP-RADIATOR 497
GUARD GP-ARTICULATION 501
GUARD GP-AXLE OIL COOLER 503
GUARD GP-AXLE SEAL 504
GUARD GP-BOITOM 505
GUARD GP-DRIVE SHAFT 513
GUARD GP-HITCH & STEERING 514
GUARD GP-LiGHTING 515
GUARD GP-POWER TRAIN 518
HINGE GP-ROADING FENDER 520
HITCH GP-ARTICULATING 522
HOOD & GUARD GP 524
LADDER GP 527
LINES GP-GREASE 528
LINK GP-STEERING FRAME LOCK 532
SHIELD GP-ENGINE COMPARTMENT 533
SUPPORT GP-AIR INLET 534
TILT GP-HOOD 535
ROTATING GP-PUMP 590
STEERING AR-SECONDARY 591
STEERING COLUMN GP 592
VALVE GP-PUMP CONTROL 593
VALVE GP-RELIEF 595
VALVE GP-SECONDARY STEERING ‘ 596
VALVE GP-STEERING 597
HYDRAULIC SYSTEM ‘ 600
ACCUMULATOR GP-RIDE CONTROL 600
BODY GP-PILOT VALVE 603
CARTRIDGE GP-VANE PUMP 606
CONTROL GP-HANDLE 607
CONTROL GP-PILOT OPERATED
HYD 609
COVER GP-HYDRAULIC TANK CAP 621
CYLINDER & SEAL GP-LiFT 622
CYLINDER & SEAL GP-TILT 623
CYLINDER GP-COUPLER 624
CYLINDER GP-LiFT 626
CYLINDER GP-TILT 627
HANDLE GP-MODULAR 635
HYDRAULIC AR 636
HYDRAULIC AR-3 VALVE 636
HYDRAULIC AR-4 VALVE 637
KICKOUT & POSITIONER GP 641
LINES GP-COUPLER 645
LINES GP-FRONT 659
LINES GP-HYDRAULIC 667
LINES GP-HYDRAULIC OIL COOLER 669
LINES GP-LiFT CYLINDER 678
LINES GP-PILOT ; 682
LINES GP-RIDE CONTROL 687
LINES GP-TILT CYLINDER 702
MOTOR GP-GEAR 708
PIVOT GP-PILOT VALVE 709
PLATE GP-PILOT VALVE 712
PUMP & MTG GP-HYDRAULIC 720
PUMP & MTG GP-HYDRAULIC FAN 721
PUMP GP-PISTON 723
PUMP GP-PISTON & VANE 725
ROTATING GP-PUMP 726
TANK & FILTER GP-HYDRAULIC 727
TANK & MTG GP-HYDRAULIC 732
VALVE & MTG GP-MAIN CONTROL 734
VALVE GP-CHECK 736
VALVE GP-CONTROL 738
VALVE GP-DEMAND FAN 741
VALVE GP-DIVERTER 742
VALVE GP-MAIN CONTROL 745
VALVE GP-MANUAL 751
VALVE GP-PILOT 752
VALVE GP-PILOT CARTRIDGE 768
VALVE GP-PUMP CONTROL 774
VALVE GP-RELIEF 776
BRAKING SYSTEM 539
ACCUMULATOR GP-BRAKE 539
BASE GP-FOOT BRAKE 542
BRAKE GP-PARKING 545
CONTROL AR-TRACTION 546
CONTROL GP-FOOT BRAKE 547
CONTROL GP-PARKING BRAKE 549
CONTROL GP-SERVICE BRAKE 555
CONVERSION AR-TRACTION
CONTROL 564
MANIFOLD GP-BRAKE
PROPORTIONAL 565
PUMP GP-VANE 566
VALVE GP-SOLENOID 567
STEERING SYSTEM 569
CONTROL GP-STEERING 569
CYLINDER & MTG GP-STEERING 573
CYLINDER & SEAL GP-STEERING 575
CYLINDER GP-STEERING 576
LINES GP-SECONDARY STEERING 578
LINES GP-STEERING 580
PUMP & MOTOR GP-SEC STEERING 584
PUMP & MTG GP-SECONDARY
STEER 585
PUMP GP-METERING 586
PUMP GP-PISTON ” 588
SEBP3498-26 TABLE OF CONTENTS A3
Name Page
TABLE OF CONTENTS
Page Name
VALVE GP-SELECTOR & PRESS
CONT 780
VALVE GP-SHUTOFF 781
VALVE GP-SHUTTLE 783
VALVE GP-SOLENOID 785
VALVE GP-SOLENOID & MANIFOLD 790
IMPLEMENTS 791
ARM AS-LIFT 791
CONTROL GP-BUCKET 792
LIFT AR 799
WORK TOOLS 800
ADAPTER GP-TIP 800
ARM GP-MATERIAL HANDLING 801
BUCKET AS-GENERAL PURPOSE 802
BUCKET AS-MATERIAL HANDLING 805
BUCKET GP-GENERAL PURPOSE 810
BUCKET GP-MATERIAL HANDLING 814
CONTROL AR-QUICK COUPLER 814
COUPLER AR-QUICK 815
COUPLER GP-QUICK 818
EDGE GP-CUTTING 820
EDGE-CUTTING 822
EDGE-END 823
FORK GP-PALLET 824
FRAME GP-QUICK COUPLER 825
TIP GP 828
TIP GP-LONG 828
TIP GP-SHORT 829
OPERATOR STATION 831
ADJUSTER GP-SEAT 831
AIR COMPRESSOR GP-SEAT 832
AIR CONDITIONER & MOUNTING GP 833
AIR CONDITIONER AR 835
AIR CONDITIONER GP 836
ARMREST GP 839
CABAR 844
CAB GP 845
CAB GP-ENCLOSED ROPS 847
CANOPY AR-OPEN ROPS 849
COMPRESSOR GP-REFRIGERANT 850
CONDENSER & MTG GPREFRIGERANT
852
CONTROL GP-MONITOR 854
DASH GP 855
DOOR GP-CAB 856
DUCT GP-AIR 880
EXTENSION GP-BACKREST 882
FILTER GP-CAB AIR 883
GUARD GP-VANDALISM 885
GUARD GP-WINDOW 887
HEATER & MTG GP-CAB 890
HEATER GP-CAB 891
HORN GP-ELECTRIC 893
INSTALLATION GP-RADIO 895
LINER GP-CAB 896
LINER GP-OPEN ROPS 903
LINES GP-AIR CONDITIONER 904
LINES GP-CAB HEATER 912
LITERATURE GP 914
MIRROR GP-REAR VIEW 915
MONITOR AR-PAYLOAD 917
MONITOR GP-PAYLOAD 918
MOTOR GP-WINDOW WIPER 920
MOUNTING GP-CAB 922
OPERATOR AR 926
PAN GP-BACKREST 928
PAN GP-SEAT 931
PANEL GP-INSTRUMENT 933
PEDAL GP-GOVERNOR 939
RADIO GP 941
RECLINER GP-SEAT 943
ROPS GP-ENCLOSED 944
ROPS GP-OPEN 947
SCREEN GP-SUN 950
SEAT & MOUNTING GP 951
SEAT BELT GP 954
SEATGP 958
SEAT GP-SUSPENSION 966
SUPPORT GP-SEAT 974
SUSPENSION GP-SEAT 975
VISOR GP-CAB 981
WASHER GP-WINDOW 982
WINDOW GP-DOOR 984
WIPER GP-WINDOW 986
SERVICE EQUIPMENT AND SUPPLIES 989
FILM GP 989
LINES GP-DIAGNOSTIC 991
LOCK GP-VANDALISM 998
MOUNTING GP-LUBRICATION
CHART 999
PLATE & FILM GP 1000
PART NUMBER INDEX B1

CRD1-Up (Machine)
5GG1-Up (Engine)
FWS1-Up (Transmission)
WNF1-Up (Transmission)
TCC1-Up (Transmission)
TCT1-Up (Torque Converter)

2. ORDERING PARTS :

Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world. Their parts inventories are up to date and include all parts normally required to protect your investment in Caterpillar machines. Dealers may offer repair kits or remanufactured parts to allow selection of the most effective repair alternative for a particular situation. When ordering parts, your order should specify the quantity, part number, part name, and the serial number/product identification number of the machine for which the parts are needed.

Product information in this manual is presented as “information elements” that represent all of the components for the specific model. Engine Arrangement and Seat Group are examples of information elements. The information elements are organized alphabetically by part name and secondarily by part number within each major section of the manual.

4. TABLE OF CONTENTS:

A table of contents (TOC) is found at the beginning of the manual. The TOC lists each section of the manual with a complete list of all information elements organized as they appear in the manual. Page numbers are provided for quick reference to detailed parts identification illustrations and serviceable consist lists.