Cat 938G II parts manual

CMERPILLAR® SEBP3498-26 May 2005 VOLUME I Pages 1-466 Parts Manual 93°SG II Wheel Load SIS6 Se;' "General Information" or New Parts Manual Features. er CR01-Up (Machine) 5GG1-Up (Engine) FWS1-Up (TI . W ransrnisaien] T~~1-UP {Transmission} TCT~ 1:P(Torque Converter) p (Torque Converter)

Product and Dealer Information Note: For product identification plate locations, see the section "Product Identification Information" in the Operation and Maintenance Manual. Delivery Date: _ Product Information Model: _ Engine Serial Number: _ Generator Serial Number: _ Attachment Serial Numbers: _ Attachment Information: _ .~ Dealer Equipment Number: -----------------::--- . Dealer Information . ;- Name: Branch: _ Address: Dealer Contact Phone Number Sales: Parts: Service:

Informations produit et concessionnaire Nota: Voir I'emplacement de la plaque siqnaletique du produit au chapitre "Informations produit" du guide d'utilisation et d'entretien. Date de livraison: _ Informations produit Modele: _ Nurnero de sene du moteur: _ Numero de serie de la boite de vitesses: _ Nurneros de sene d'equipement; _ Nurnero materiel client: 00 "_0_ Nurnero materiel concessionnaire: _ Informations concessionnaire Nom: Agence: _ Adresse: Contact concessionnaire Numero de telephone Heures Ventes: Pieces: Service:

Informacion del Producto/Distribuidor Nota: Para saber la ubicaci6n de las placas de identificaci6n del producto, ver la secci6n "Informaci6n sobre identificaci6n del producto" en el Manual de Operaci6n y Mantenimiento. Fecha de entrega: _ Informacion del producto Modelo: __ Numero de identificaci6n del producto: __ Nurnero de serie del motor: _ Numero de serie de la transmisi6n: ,. _ Nurneros de serie de los accesorios: _ Informaci6n sobre 105 accesorios: _ Nurnero del equipo del cliente: _ Nurnero del equipo del distribuidor: _ Informacion del distribuidor Nombre: Sucursal: _ Direcci6n: Comunicaci6n con el distribuidor Numero de telefono Horas Ventas: --._--_-.---- .. ---- Piezas: Servicio:

lnformacoas Sobre Produto e Revendedor Nota: Para localizacces da placa de identificayao do produto, consulte a secao, "lnformacoes Sobre tdentiflcacac do Produto" no Manual de operscao e Manuten~o. Data de Entrega: _ Informacoes Sobre 0 Produto Modelo: _ Nurnero de Identifica~o do Produto: _ Numero de Serie do Motor: _ Nurnero de Serie da Transmissao: , Numeros de sene de Acess6rios: _ lnformacoes Sobre Acess6rios: _ Nurnero do Equipamento do Cliente: _ Numero do Equipamento do Revendedor: _ lnformacoes Sobre 0 Revendedor Nome: Filial: _ Endereco: Contato do Revendedor Telefone Vendas: Pecas: Servico:

Produkt- und Handlerlntorrnatlon Anmerkung: Fur die Lage der Produkt-Identnummer und Seriennummern siehe Abschnitt "Produkt-ldenfinformation" im 8etriebs- und Wartungshandbuch. Lieferdatum: _ Produkt-Identinformation Modell: _ Produkt-Identnummer: _ Seriennummer des Motors: _ Seriennummer des Getriebes: _ Seriennummer des Generators: _ Seriennummern der Arbeitsqerate: _ Arbeitsger3teinformation: _ Kundennummer: _ Handlernurnrner: _~ . .. _ Handlerlnformatlon Name: Niederlassung: _ Adresse: .._- ._ .. _._ .. _ .. ---------------- Kontaktperson beim Handler Telefon Dienststunden Verkauf: Ersatzteile: _ Service:

MEMORANDA MEMORANDA SEBP3498-26

Page TABLE OF CONTENTS Namo Page Name 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 GP- COMMUNICATION. ........ 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 A1

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 AR- COMMUNICATION. ........ 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

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Cat 938G II parts manual

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