Caterpillar cat 938 g wheel loader (prefix 6ws) service repair manual (6ws00001 and up)

Service Repair Manual
Models
938G WHEEL LOADER

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Product: WHEEL LOADER
Model: 938G WHEEL LOADER 6WS
Configuration: 938G Wheel Loader 6WS00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
Flexxaire Fan
Media Number -RENR3699-07 Publication Date -01/02/2012 Date Updated -21/06/2016
i01742847
Mechanical Actuated Fan - Assemble
SMCS - 1356-016
Shifter Block − Assemble
Note: The following procedure should only be performed by persons that have taken the fan
rebuilding training course at FLEXXAIRE Manufacturing Inc. The shifter block assembly is sold
only as an assembly unless you have had the training.
Note: Proceed to “Hub - Assemble” if you have purchased a shifter block assembly.
Illustration 1 g00597621
1. Thread elbow (3) onto pickup tube (2). Then, thread pickup tube (2) into through shaft
bearing end (1).
Note: The orientation of pickup tube (2) in Illustration 2 is shown in the most common
direction. However, other applications may require pickup tube (2) to be rotated 180
degrees. Pickup tube (2) is stationary. Pickup tube (2) does not rotate. The arrows indicate
the direction of oil flow into pickup tube (2).
1/29938G Wheel Loader 6WS00001-UP (MACHINE) POWERED BY 3126 Engine(SEBP...
2020/3/20https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

2. Slide bearing cone (4) onto through shaft bearing end (1). Slide wave washer (5) and spacer
(6) onto through shaft bearing end (1).
3. Slide wave washer (7) onto through shaft bearing end (1).
4. Insert the races into the bores of shifter block plate (8).
5. Slide shifter block plate (8) onto through shaft bearing end (1).

6. Slide bearing cone (9) onto through shaft bearing end (1).
7. Install locking washer (10) and bearing locknut (11) onto through shaft bearing end (1).
Note: Once proper clearance is obtained, bend the tabs of locking washer (10) into the slots
in bearing locknut (11). Proper clearance is 0.0254 mm to 0.0762 mm
(0.001 inch to 0.003 inch). The shifter block assembly should spin freely.
Hub − Assemble
1. Lubricate O-Ring (1) with a light film of oil and insert O-Ring (1) into the hub insert.
Note: Clean the O-Ring groove thoroughly before installing O-Ring (1) in order to prevent
leakage.

2. Lubricate the shank of blade mounting shaft (2) with oil. Install nylon washer (3) onto blade
mounting shaft (2) and insert blade mounting shaft (2) into the hub insert.
3. Install the race of bearing (4) with the larger inside diameter onto blade mounting shaft (2).
4. Install the cage of bearing (4) onto blade mounting shaft (2).
5. Install the race of bearing (4) with the smaller inside diameter onto blade mounting shaft
(2).

6. Install collar (5) onto blade mounting shaft (2).
Note: The cut out of collar (5) should be facing upward.
7. Apply 9S-3263 Thread Lock Compound to capscrew (6). Install capscrew (6) into collar (5).
Hold blade mounting shaft (2) as you tighten capscrew (6). Tighten capscrew (6) to a torque
of 54 ± 5 N·m (40 ± 4 lb ft).
8. Repeat Steps 1 through 7 for each remaining blade mounting shaft.

9. Remove capscrews (7) and front plate (8) from the shifter block assembly.
10. Remove two spacers (9).
11. Place pivot blocks (10) onto the pins of collars (5).

12. Position shifter block assembly (11) in the hub.
Note: Verify that the machined surfaces of pivot blocks (10) are against the flange surface.
13. Put spacers (9) into position over the corresponding holes.
14. Install ring (12) and align the holes with spacers (9).
15. Apply 9S-3263 Thread Lock Compound to capscrews (13A) and (13B) and install the
capscrews. Tighten capscrews (13A) to a torque of 16 ± 4 N·m (12 ± 3 lb ft). Tighten
capscrews (13B) to a torque of 34 ± 4 N·m (25 ± 3 lb ft).
Note: The shifter block assembly should move freely over the pivot blocks. If the shifter
block is binding, it is possible that a pivot block needs to be turned by 90 degrees.

16. Clean the groove in the hub that holds the O-Ring for the cover plate. Install O-Ring (14)
into the groove.
17. Place cover plate (15) onto the hub and align the holes.
18. Install capscrews (16). Do not put any 9S-3263 Thread Lock Compound on capscrews (16).
Tighten capscrews (16) to a torque of 16 ± 4 N·m (12 ± 3 lb ft).

19. Flip the hub assembly. Clean the groove in the hub that holds the O-Ring for the flange
plate. Install O-Ring (17) into the groove.
20. Place hub flange (18) onto the hub and align the holes.
Note: There is a small capscrew in the flange plate that aligns with a counterbore in the hub.
21. Install capscrews (19). Do not put any 9S-3263 Thread Lock Compound on capscrews (19).
Tighten capscrews (19) to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
Actuator Bearings and Control Shaft Bushings − Install
1. Apply 4C-9507 Retaining Compound to bushing (1) and install bushing (1). The hole in
bushing (1) must line up with the hole in the bushing bore.

2. Install seals (2) and (3) so that the lips face outward.
Note: Some fans do not have seals (2) and (3).
3. Install all grease fittings and hoses.
4. Install spherical bearings (4) into actuator clevis (5).
10/29938G Wheel Loader 6WS00001-UP (MACHINE) POWERED BY 3126 Engine(SE...

5. Put actuator collar (6) into position. Apply 9S-3263 Thread Lock Compound to the threads
of shoulder bolts (7) and install bolts (7). Tighten bolts (7) to a torque of 54 ± 5 N·m
(40 ± 4 lb ft).
Note: Actuator collar (6) must be installed so that the four setscrews face outward.
Frost Plug and Main Shaft O-Ring − Install
1. Temporarily install main shaft extension (1) into main shaft (2).
Note: Main shaft extension (1) must be removed during installation of the O-Ring.

2. Use the former bushing as a template in order to create a slot in new bushing (3). Install new
bushing (3) into the rear of the main shaft.
3. Install bushing (4) into main shaft (2) or main shaft extension (1).
Note: Main shaft extension (1) may not be applicable in all cases. If this is true in your case,
bushing (4) will be required in main shaft (2).

4. Use the existing hole in bracket base (5) as a guide in order to drill a hole through the rear
bushing.
5. Clean the bore of the main shaft thoroughly. Verify that the bore for the internal O-Ring is
free of any foreign material.
6. Verify that through shaft (6) passes freely through both bushings (3) and (4).
Note: If through shaft (6) binds, reaming of bushings (3) and (4) may be required.
7. Remove main shaft extension (1) from main shaft (2).

8. Use through shaft (6) in order to push O-Ring (7) into the groove inside main shaft (2).
Note: You may want to insert through shaft (6) into main shaft (2) from both sides in order
to verify that O-Ring (7) has seated properly.
Main Bearing Cups − Install
1. Install bearing cup (1) into bearing carrier (2).

2. Install bearing cup (3) into the opposite side of bearing carrier (2).
3. Clean the bores of bearing cups (1) and (3). Verify that the grooves for the O-Rings are free
of any foreign material.
Carrier/Spool and Main Bearing − Install
1. Position bracket (1) so that main shaft (2) is vertical.
2. Slide fillet spacer (3) onto main shaft (2). The bevel on fillet spacer (3) must match the
radius on main shaft (2).
Note: Not all fan assemblies have fillet spacer (3).
3. Slide bearing cone (4) onto main shaft (2). Be careful not to damage the threads on main
shaft (2).
4. Set bearing carrier (5) on bearing cone (4).
5. Slide bearing spacer (6) onto main shaft (2).

6. Slide shims (7) and (8) onto main shaft (2).
7. Slide bearing cone (9) onto main shaft (2). Thread bearing locknut (10) onto main shaft (2).
Tighten bearing locknut (10) to the correct torque. Refer to Table 1 for the correct torque.
Note: The use of a torque multiplier is recommended when you tighten bearing locknut
(10).
Table 1
Torque Values for Bearing Locknut (10)
Identification Inside Diameter Torque Value
N09 44.45 mm (1.75 inch) 230 ± 41 N·m (170 ± 30 lb ft)
N14 69.85 mm (2.75 inch) 353 ± 54 N·m (260 ± 40 lb ft)
8. Use a dial indicator to verify bearing clearance. Add or remove shims in order to obtain the
correct bearing clearance. Refer to Table 2 for the correct clearance.
Table 2
Bearing Clearances

Inside Diameter Clearance
44.45 mm (1.75 inch) 0.025 mm to 0.076 mm (0.001 inch to 0.003 inch)
69.85 mm (2.75 inch) 0.076 mm to 0.127 mm (0.003 inch to 0.005 inch)
9. Remove all components except for fillet spacer (3) after the correct bearing clearance has
been obtained. The components will be reinstalled later in the procedure.
10. Place bearing carrier (5) so that the seal end faces upward.
11. Apply 4C-9507 Retaining Compound to the seal bore and the outside diameter of seal (11).
12. Place main bearing cone (12) into the cup. Press seal (11) into the seal bore of bearing
carrier (5) until the face of seal (11) is flush with the edge of bearing carrier (5).
13. Lubricate the double seal with oil.
14. Attach pulley (13) to bearing carrier (5) with capscrews (14). Tighten capscrews (14) to a
torque of 54 ± 5 N·m (40 ± 4 lb ft).
Note: Verify correct orientation of pulley (13).

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15. Position pulley (13) and bearing carrier (5) onto main shaft (2). Use care when you slide the
seal over the shoulder of the main shaft in order to not damage the seal. Be careful not to
damage the threads on the main shaft.
16. Install spacer (14) and shim (15). Shim (15) is the thinnest shim.
17. Install remaining shims (16) and bearing cone (17).

18. Thread bearing locknut (18) onto main shaft (2) so that the end with the bevel faces away
from bearing cone (17). Tighten bearing locknut (18) to the correct torque. Refer to Table 3
for the correct torque.
Note: The use of a torque multiplier is recommended when you tighten bearing locknut
(18).
Table 3
N09 44.45 mm (1.75 inch) 230 ± 41 N·m (170 ± 30 lb ft)
N14 69.85 mm (2.75 inch) 353 ± 54 N·m (260 ± 40 lb ft)
19. Install locking washer (19). Install bearing locknut (20) so that the end with the bevel faces
toward bearing cone (17). Tighten bearing locknut (20) to the correct torque. Refer to Table
4 for the correct torque.
Note: Not all models of fan have two locknuts.
Table 4

N09 44.45 mm (1.75 inch) 61 ± 11 N·m (45 ± 8 lb ft)
N14 69.85 mm (2.75 inch) 75 ± 11 N·m (55 ± 8 lb ft)
20. Bend the tabs of locking washer (19) into the slots in bearing locknut (20).
21. Apply 7M-7456 Compound to the threads of main shaft extension (21). Thread main shaft
extension (21) into main shaft (2). Tighten main shaft extension (21) to a torque of
136 ± 11 N·m (100 ± 8 lb ft).
Note: Not all fan assemblies have main shaft extension (21).
22. Inspect the groove for O-Ring (22) for any foreign material. Install O-Ring (22) into the
groove in bearing carrier (5). You can use grease in order to hold O-Ring (22) in place.

23. Position spool (23) so that the bolt holes are aligned with the holes in bearing carrier (5).
Install capscrews (14).
Hub Kit − Install
1. Apply 9S-3263 Thread Lock Compound to the threads of through shaft bearing end (1).
Thread through shaft (2) onto through shaft bearing end (1).
2. Lubricate the entire length of through shaft (2) with a film of oil.

Caterpillar cat 938 g wheel loader (prefix 6ws) service repair manual (6ws00001 and up)

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Caterpillar cat 938 g wheel loader (prefix 6ws) service repair manual (6ws00001 and up)