Cat 938G II Wheel Loader Parts Manual VOLUME II – PDF DOWNLOAD

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Cat 938G II Wheel Loader Parts Manual VOLUME II – PDF DOWNLOAD

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Cat 938G II Wheel Loader Parts Manual VOLUME II – PDF DOWNLOAD

Language : English
Pages :678
Downloadable : Yes
File Type : PDF
Size:26.2 MB

DESCRIPTION:

Cat 938G II Wheel Loader Parts Manual VOLUME 1 – PDF DOWNLOAD

1. MACHINE IDENTIFICATION

Caterpillar machines are identified by Product Identification Numbers (PIN). Some components included in a machine may be identified by Serial Numbers (S/N). Typical components that will be serialized include engines, transmissions, bulldozers, and rippers. The machine and engine are further identified by arrangement numbers and in some cases modification numbers. These numbers are shown on the product identification plate(s) and on the master plate in the operator’s compartment. Caterpillar dealers need all of these numbers to determine accurate parts identification.

Effective First Quarter 2001 the Caterpillar Product Identification Number (PIN) will change from 8 to 17 characters. In an effort to provide uniform equipment identification, Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard. Non-road machine PINs are defined by ISO 10261. The new PIN format will apply to all Caterpillar machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following

Where:

Caterpillar’s World Manufacturing Code (characters 1-3)
Machine Descriptor (characters 4-8)
Check Character (character 9)
.Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17). These were previously referred to as the Serial Number

Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format. Components such as engines, transmissions, axles, etc. and work tools will continue to use an 8 character Serial Number (S/N).

2. ORDERING PARTS

WARNING

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

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.

3. PARTS MANUAL ORGANIZATION

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

5. MAINTENANCE PARTS INDEX

The Maintenance Parts Index, located near the beginning of the manual, references most frequently used maintenance part numbers, providing description, quantity, usage and page number. This information is organized alphabetically by part description

6. INDEX

The index located near the front of the manual is an alphabetical listing of all information elements included in the manual. Page numbers are provided for quick reference to detailed parts identification illustrations and serviceable consist lists.

7. PART NUMBER INDEX

A numerical index listing all part numbers and the corresponding page number(s) appears at the back of the manual.

8. CAPTIONS

Captions located at the top of each page of an information element identify the part number and part name along with additional descriptive information. PIN and S/N information found in each caption should be used to select correct information for a specific machine. Field replacement options, identification of optional attachment components, and where used (“part of”) information is also provided
The first line of a caption is shown in larger type font to indicate the beginning of an information element. Captions for additional pages that may be required to illustrate an information element will be shown in standard type font and will include the term (contd.)

9. NON-SERVICED PARTS

In some instances it is necessary to display non-serviced parts that are a link to a lower level serviceable consist lists. These non-serviced part numbers are shown in italic type indicating that they are not available

10. PARTS LIST REFERENCE NUMBERS

Numbers shown in the Ref No column correspond to numbers used in the associated graphic(s). An alphabetic suffix may be added to a reference number to identify lower level consist items. Numbers shown in the Graphic Ref column refer to the graphic number identifier displayed in the lower left corner of each illustration. The Graphic Ref number may be used in combination with the item Ref No to determine the correct part number. There may be intentional omission of a Ref No in a consist list as information is updated to reflect the latest serviceable part numbers.

11. INDENTED PART NAMES

When a part name is indented in a parts list, it is part of (included in) the group or assembly under which it is indented.

12. ILLUSTRATION REFERENCE LETTERS

When necessary, illustrations contain reference letters (A, B, C etc.) that are intended to track lines and harnesses from one point to another. They are also used to show where to reconnect illustrations that have been separated.

13. ABBREVIATIONS AND SYMBOLS

O.D. – Outside Diameter
I.D. – Inside Diameter
A – Not Part Of This Group
B – Use As Required
C – Change From Previous Type
D – Order By The Meter
E – Order By The Centimeter
F – Not Shown
G – Order By The Inch
I – See Hose Fabrication Guide
M – Metric Part
R – Remfg Part May Be Available
Y – Separate Illustration
Z – Not Serviced Separately

NOTE:

Continuing improvement and advancement of product design may cause changes to your machine which may not be included in this publication. Whenever a question arises regarding your Caterpillar product or this publication, please consult your Caterpillar dealer for the latest available information.

TABLE OF CONTENTS:

Cat 938G II Wheel Loader Parts Manual VOLUME II – PDF DOWNLOAD

GENERAL INFORMATION A27
REPAIR ALTERNATIVES A46
SUPPLEMENTAL COOLANT
ADDITIVES A51
MAINTENANCE PARTS
INDEX
MACHINE ARRANGEMENT,
CHASSIS AR
GENERAL AR ‘
SCRAP HANDLING AR,
WASTE HANDLING AR
ENGINE ARRANGEMENT
ENGINE AR-COMPLETE “”
ENGINE AR-CORE
INSTALLATION AR-ENGINE
BASIC ENGINE
CAMSHAFT GP ‘
CARRIER GP-SEAL “” ,
COVER GP-CYLINDER BLOCK
COVER GP-FRONT HOUSING
COVER GP-VALVE MECHANISM ‘
CRANKSHAFT GP
CYLINDER BLOCK GP
CYLINDER HEAD AS
CYLINDER HEAD GP
DAMPER & PULLEY GP
DRAIN GP-ENGINE OIL ,
FASTENER GP-DAMPER & PULLEY ,
FASTENER GP-FLYWHEEL ,
FASTENER GP-FRONT HOUSING
FLYWHEEL GP
GEAR GP-FRONT ‘
HOUSING GP-FLYWHEEL
HOUSING GP-FRONT
IDLER GP-BELT
LIFTER GP-VALVE ” ”
LIFTING GP-ENGINE
MOUNTING GP-ALTERNATOR
MOUNTING GP-ENGINE & TMSN ,
PAN GP-OIL ‘ ”
PISTON & ROD GP
PLUG GP-CYLINDER BLOCK
PLUG GP-ENGINE ‘
PULLEY GP-IDLER ‘
SEAL GP-CRANKSHAFT
SEAL GP-FLYWHEEL HOUSING
VALVE MECHANISM GP
LUBRICATION SYSTEM 69
ADAPTER GP-OIL LINE 69
BREATHER GP 7
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
COOLING SYSTEM
COOLER GP-ENGINE OIL
GUARD GP-FAN ”
LINES GP-WATER
PUMP GP-WATER , ” ,
RADIATOR & FAN GP
TANK GP-RADIATOR TOP
AIR INLET AND EXHAUST SYSTEM
AIR CLEANER GP
COVER GP-AIR INLET,
ELBOW GP-AIR INLET
FILTER ELEMENT AS-AIR
LINES GP-AIR ,
MANIFOLD GP-EXHAUST
MUFFLER GP
PIPE AS-EXHAUST EXTENSION
PRECLEANER GP
TURBOCHARGER GP ,
FUEL SYSTEM ‘
FILTER GP-WATER SEP & FUEL
LINES GP-FUEL
LINES GP-FUEL DRAIN
LINES GP-FUEL FILTER
LINES GP-INJECTOR HYD PUMP
PUMP GP-FUEL PRM & PRIM FILTER
PUMP GP-UNIT INJECTION,
PUMP GP-UNIT INJECTOR HYD
REGULATOR GP-FUEL PRESSURE
TANK GP-FUEL
VALVE GP-SOLENOID
WATER SEP & FUEL PRM PUMP GP ,
ELECTRICAL AND STARTING SYSTEM ‘
ALARM GP
ALTERNATOR AR-CHARGING ” , “,
ALTERNATOR GP-CHARGING
BATTERY & WIRING GP
BLOCK GP-JUNCTION
CONTROL & MTG
GP-COMMUNICATION ‘
CONTROL & MTG GP-ENGINE ELEK ,
CONTROL GP-ENGINE ELECTRONIC ,
TABLE OF CONTENTS A 1
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
AR-COMMUNICATION 199
INSTALLATION AR-SECURITY 199
INSTALLATION GP-SECURITY 2
LAMP GP-FLOOD 2 1
LAMP GP-HEAD & SIGNAL 2 5
LAMP GP-SIGNAL 2 9
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 o 235
SENSOR GP-POSITION ‘,’” 237
SENSOR GP-PRESSURE 241
SENSOR GP-SPEED 25
– -SENSOR-GP-TEMPERATURE -:- – 253
SERVICE GP-MACHINE ‘ ” 26
STARTING AID GP 261
STARTING AID GP-ETHER 263
STARTI NG 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 28
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-L1GHTING 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 o 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 39
COOLER AR-AXLE OIL 391
COVER GP-SHIPPING 392
COVER GP-TMSN OIL FILLER CAP 393
DIFFERENTIAL GP 394
DIFFERENTIAL GP-L1MITED SLIP 395
DIFFERENTIAL GP-NOSPIN 396
DRAIN GP-ECOLOGY ” ‘ 398
FILLER GP-POWER TRAIN OIL ‘” 399
FILTER GP-OIL 4
GEAR GP-BEVEL 4 2
GEAR GP-BEVEL & PINION ‘ o 4 4
GEAR GP-OUTPUT TRANSFER o 4 6
HOUSING GP-FIXED AXLE 4 8
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 43
POWER TRAIN AR ‘” o 43
PUMP & MTG GP-AXLE OIL COOLER o ‘ 431
PUMP GP-TRANSMISSION 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 ” ‘” 46
VALVE GP-RELIEF 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
COUNTERWEIGHT GP
COUNTERWEIGHT GP-REAR
DOOR GP-BATTERY , “”
EXTENSION GP-FENDER
FENDER GP
FENDER GP-ROADING
FRAME AS-FRONT,
FRAME AS-LOADER
FRAME AS-REAR
GRILL GP-RADIATOR
GUARD GP-ARTICULATION
GUARD GP-AXLE OIL COOLER
GUARD GP-AXLE SEAL
GUARD GP-BOTTOM
GUARD GP-DRIVE SHAFT
GUARD GP-HITCH & STEERING
GUARD GP-LIGHTING
GUARD GP-POWER TRAIN
HINGE GP-ROADING FENDER
HITCH GP-ARTICULATING
HOOD & GUARD GP
LADDER GP
LINES GP-GREASE
LINK GP-STEERING FRAME LOCK
SHIELD GP-ENGINE COMPARTMENT
SUPPORT GP-AIR INLET
TILT GP-HOOD
ROTATING GP-PUMP
STEERING AR-SECONDARY
STEERING COLUMN GP
VALVE GP-PUMP CONTROL
VALVE GP-RELIEF
VALVE GP-SECONDARY STEERING
VALVE GP-STEERING
HYDRAULIC SYSTEM ‘
ACCUMULATOR GP-RIDE CONTROL
BODY GP-PILOT VALVE
CARTRIDGE GP-VANE PUMP
CONTROL GP-HANDLE
CONTROL GP-PILOT OPERATED
HYD
COVER GP-HYDRAULIC TANK CAP
CYLINDER & SEAL GP-LiFT
CYLINDER & SEAL GP-TILT
CYLINDER GP-COUPLER
CYLINDER GP-L1FT
CYLINDER GP-TILT
HANDLE GP-MODULAR
HYDRAULIC AR
HYDRAULIC AR-3 VALVE
HYDRAULIC AR-4 VALVE
KICKOUT & POSITIONER GP
LINES GP-COUPLER
LINES GP-FRONT
LINES GP-HYDRAULIC
LINES GP-HYDRAULIC OIL COOLER
LINES GP-LiFT CYLINDER
LINES GP-PILOT
LINES GP-RIDE CONTROL
LINES GP-TILT CYLINDER
MOTOR GP-GEAR
PIVOT GP-PILOT VALVE ‘
PLATE GP-PILOT VALVE
PUMP & MTG GP-HYDRAULIC
PUMP & MTG GP-HYDRAULIC FAN
PUMP GP-PISTON
PUMP GP-PISTON & VANE
ROTATING GP-PUMP
TANK & FILTER GP-HYDRAULIC
TANK & MTG GP-HYDRAULIC
VALVE & MTG GP-MAIN CONTROL ,
VALVE GP-CHECK
VALVE GP-CONTROL
VALVE GP-DEMAND FAN
VALVE GP-DIVERTER
VALVE GP-MAIN CONTROL
VALVE GP-MANUAL
VALVE GP-PILOT
VALVE GP-PILOT CARTRIDGE
VALVE GP-PUMP CONTROL
VALVE GP-RELlEF
BRAKING SYSTEM
ACCUMULATOR GP-BRAKE
BASE GP-FOOT BRAKE
BRAKE GP-PARKING
CONTROL AR- TRACTION
CONTROL GP-FOOT BRAKE
CONTROL GP-PARKING BRAKE
CONTROL GP-SERVICE BRAKE,
CONVERSION AR-TRACTION
CONTROL
MANIFOLD GP-BRAKE
PROPORTIONAL ,
PUMP GP-VANE
VALVE GP-SOLENOID
STEERING SYSTEM
CONTROL GP-STEERING
CYLINDER & MTG GP-STEERING ,
CYLINDER & SEAL GP-STEERING
CYLINDER GP-STEERING
LINES GP-SECONDARY STEERING
LINES GP-STEERING ,
PUMP & MOTOR GP-SEC STEERING
PUMP & MTG GP-SECONDARY
STEER
PUMP GP-METERING
PUMP GP-PISTON
SEBP3498-26 TABLE OF CONTENTS A3
Page Name
TABLE OF CONTENTS
Name Page
VALVE GP-SELECTOR & PRESS
CONT
VALVE GP-SHUTOFF
VALVE GP-SHUTTLE
VALVE GP-SOLENOID , ” ,
VALVE GP-SOLENOID & MANIFOLD
IMPLEMENTS
ARM AS-LIFT
CONTROL GP-BUCKET
LIFT AR
WORK TOOLS
ADAPTER GP-TIP
ARM GP-MATERIAL HANDLING
BUCKET AS-GENERAL PURPOSE ,
BUCKET AS-MATERIAL HANDLING
BUCKET GP-GENERAL PURPOSE
BUCKET GP-MATERIAL HANDLING
CONTROL AR-QUICK COUPLER
COUPLER AR-QUICK
COUPLER GP-QUICK
EDGE GP-CUTTING
EDGE-CUTTING
EDGE-END
FORK GP-PALLET
FRAME GP-QUICK COUPLER
TIPGP
TIP GP-SHORT
OPERATOR STATION
ADJUSTER GP-SEAT
AIR COMPRESSOR GP-SEAT
AIR CONDITIONER & MOUNTING GP ‘
AIR CONDITIONER AR
AIR CONDITIONER GP
ARMRESTGP
CAB AR ,
CAB GP
CAB GP-ENCLOSED ROPS
CANOPY AR-OPEN ROPS
COMPRESSOR GP-REFRIGERANT
CONDENSER & MTG
GP-REFRIGERANT
CONTROL GP-MONITOR
DASH GP
DOOR GP-CAB
DUCT GP-AIR
EXTENSION GP-BACKREST ,
FILTER GP-CAB AIR
GUARD GP-VANDALISM
GUARD GP-WINDOW
HEATER & MTG GP-CAB 89
HEATER GP-CAB 891
HORN GP-ELECTRIC 893
INSTALLATION GP-RADIO 895
LINER GP-CAB 896
LINER GP-OPEN ROPS 9 3
LINES GP-AIR CONDITIONER 9 4
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 92
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 95
SEAT & MOUNTING GP 951
SEAT BELT GP 954
SEAT GP 958
SEAT GP-SUSPENSION 966
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 1
PART NUMBER INDEX B1

CAT 938G II WHEEL LOADER PARTS MANUAL VOLUME II – PDF DOWNLOAD:

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