Caterpillar Cat 938G II Wheel Loader (Prefix PHN) Service Repair Manual (PHN00001 and up).pdf

Service Repair Manual
Models
938G II Wheel Loader

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Product: WHEEL LOADER
Model: 938G II WHEEL LOADER PHN
Configuration: 938G II Wheel Loader PHN00001-UP (MACHINE) POWERED BY 3126B Engine
Disassembly and Assembly
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power
Train
Media Number -RENR6068-03 Publication Date -01/12/2008 Date Updated -19/12/2008
i01380984
Transmission Oil Pump - Disassemble
SMCS - 3066-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
Illustration 1 g00742335
1. Remove two bolts (1) and cover (2) .
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938G II Wheel Loader PHN00001-UP (MACHINE) POWERED BY 3126B Engine(S...
2020/5/4
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2. Remove seven bolts (3). Remove O-ring seal (4) .
3. Install two forcing screws, as shown.
4. Install Tooling (A), a hoist, and a suitable lifting device. Use a hoist to remove gear pump
(5) .
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5. Remove six bolts (6) .
6. Remove shaft (7) .
7. Remove retaining ring (8) .
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8. Remove gear (9) and ball bearing (10) as a unit from the body assembly.
9. Use a suitable press to remove ball bearing (10) from gear (9) .
10. Remove five bolts (11) .
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Note: Only the bolt which is marked with an X has a washer.
11. Turn over the gear pump (5) and remove one bolt (12) .
12. Separate pump cover assembly (13) from gear pump (5) .
13. Remove two bearings (14) .
14. Remove O-ring seal (15) .
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Note: Identify two oil pump gears and mark the location of the gears for assembly purposes.
15. Remove two oil pump gears (16) .
16. Check the condition of two dowels (17) and replace the dowels, if necessary.
17. Check the condition of two dowels (18) and replace the dowels, if necessary.
18. Remove two bearings (19) .
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All Rights Reserved.
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Mon May 4 10:39:21 UTC+0800 2020
6/6
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Train
i01381042
Transmission Oil Pump - Assemble
SMCS - 3066-016
Assembly Procedure
Table 1
Required Tools
A 138-7573 Link Bracket 2
1. Install two bearings (19) to a depth of 1.5 ± .5 mm (0.059 ± 0.02 inch) below the machined
surface of the body assembly. The bearing joints should be 30 ± 15 degrees from the
centerline that runs through the bearing bores.
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2. Install two oil pump gears (16) .
3. Install two dowels (17), if the dowels were removed in assembly.
4. Install two dowels (18), if the dowels were removed in assembly.
5. Install two bearings (14) to a depth of 1.5 ± .5 mm (0.059 ± 0.02 inch) below the machined
surface of the body assembly. The bearing joints should be 30 ± 15 degrees from the
centerline that runs through the bearing bores.
6. Install O-ring (15) .
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7. Turn over gear pump (5) .
8. Connect pump cover assembly (13) to gear pump (5) and install one bolt (12) .
9. Install five bolts (11) .
Note: Only one bolt which is marked has a washer.
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10. Heat up bearing (10) to 135 °C (275 °F). Install the bearing in gear (9) .
11. Install gear (9) and bearing (10) as a unit on the body assembly.
12. Install retaining ring (8) .
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13. Install shaft (7) .
14. Install six bolts (6). The torque for bolts (6) is 55 ± 10 N·m (41 ± 7 lb ft).
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15. Install Tooling (A), a hoist, and a suitable lifting device. Use a hoist to install gear pump
(5) .
16. Remove two forcing screws that were used in the disassembly.
17. Install seven bolts (3). Install O-ring seal (4) .
18. Install two bolts (1) and cover (2) .
Mon May 4 10:40:18 UTC+0800 2020
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Train
i01886316
Transmission Oil Pump - Install
SMCS - 3066-012
Installation Procedure
Table 1
Required Tools
B 138-7575 Link Bracket 2
C 10 mm by 1.5 by 6 (Guide Bolt) 2
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.
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1. Install transmission oil pump (4) on Tooling (C). The weight of transmission oil pump (4) is
approximately 30 kg (65 lb).
2. Remove Tooling (B) and install bolts (3). Remove Tooling (C) .
3. Install tube assembly (2). Connect tube assembly (1) .
End By: Install the implement and the steering pumps. Refer to Disassembly and Assembly,
"Piston and Vane Pump (Steering and Inplement) - Install".
Mon May 4 10:41:14 UTC+0800 2020
2/2
2020/5/4

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Train
i01886348
Relief Valve (Transmission Hydraulic Control) - Remove
SMCS - 3210-011
Removal Procedure
Table 1
Required Tools
ZZ
6V-9507 Face Seal Plug 1
6V-9508 Face Seal Plug 1
6V-9828 Cap As 1
6V-9829 Cap As 1
Start By:
A. Remove the cab. Refer to Disassembly and Assembly, "Cab - Remove".
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: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN
PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS
SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
NOTICE
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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.
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.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this
helps to keep contaminants from entering the system.
1. Disconnect hose assemblies (1) and (2) .
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2. Remove bolts (3) and remove relief valve (4) .
Mon May 4 10:42:11 UTC+0800 2020
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Train
i01886519
Relief Valve (Transmission Hydraulic Control) - Disassemble
SMCS - 3210-015
Disassembly Procedure
Table 1
Required Tools
A 1P-1853 Retaining Ring Pliers 1
Start By:
A. Remove the relief valve. Refer to Disassembly and Assembly, "Relief Valve (Transmission
Hydraulic Control) - Remove".
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.
1/3
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1. Remove bolts (1) and remove cover (2) .
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
2. Remove bolts (3) and remove cover (4) .
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3. Remove load piston (10), spring (9), spool assembly (8), and slug (11) from body (12) .
4. Use Tooling (A) to remove retaining ring (13). Remove retainer (5), spring (6), and ball (7)
from spool (8) .
5. Remove fitting (14), fitting (15), and plug (16) from body (12) .
Mon May 4 10:43:08 UTC+0800 2020
3/3
2020/5/4

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Train
i06649649
Relief Valve (Transmission Hydraulic Control) - Assemble
SMCS - 3210-016
Assembly Procedure
Table 1
Required Tools
A 1P-1853 Retaining Ring Pliers 1
1. Install plug (16), fitting (15), and fitting (14) in body (12).
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2. Install ball (7), spring (6), and retainer (5) in spool (8). Use Tooling (A) to install retaining
ring (13).
3. Install slug (11), spool assembly (8), spring (9), and load piston (10) in body (12).
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
4. Install cover (4) and install bolts (3). Tighten bolts (3) to a torque of 28 ± 7 N·m
(21 ± 5 lb ft).
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5. Install cover (2) and install bolts (1). Tighten bolts (1) to a torque of 28 ± 7 N·m
(21 ± 5 lb ft).
End By:
a. Install the relief valve. Refer to Disassembly and Assembly, "Relief Valve (Transmission
Hydraulic Control) - Install".
Mon May 4 10:44:05 UTC+0800 2020
3/3
2020/5/4

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Train
i02840644
Relief Valve (Transmission Hydraulic Control) - Install
SMCS - 3210-012
Installation Procedure
1. Install relief valve (4) . Install bolts (3) . Tighten bolts (3) to a torque of 30 ± 4 N·m (22 ± 3
lb ft).
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2020/5/4

Caterpillar Cat 938G II Wheel Loader (Prefix PHN) Service Repair Manual (PHN00001 and up).pdf

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