Caterpillar Cat 938G Wheel Loader (Prefix 4YS) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
938G WHEEL LOADER

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Product: WHEEL LOADER
Model: 938G WHEEL LOADER 4YS
Configuration: 938G Wheel Loader 4YS00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
IT38G Integrated Toolcarrier and 938G Wheel Loader Power Train
Media Number -SENR6787-07 Publication Date -01/08/2007 Date Updated -06/08/2007
i01382038
Transmission - Disassemble
SMCS - 3030-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
B 8B-7548 Push-Puller Tool Gp 1
C 1P-2420 Transmission Repair Stand 1
D 2P-8312 Retaining Ring Pliers 1
E 8S-2328 Dial Indicator Gp 1
F 9U-7480 Compressing Tube 1
G 1P-1863 Retaining Ring Pliers 1
H 9U-7479 Compressing Tube 1
I 1U-6341 Threaded Rod 1
J 5P-7970 Nut 1
Start By:
A. Separate the transmission from the torque converter. Refer to Disassembly and Assembly,
"Transmission and Torque Converter - Separate".
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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: Put identification marks on all sections of the transmission for assembly purposes.
NOTICE
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.
1. Drain the transmission fluid into a suitable container for storage or disposal. The capacity of
the transmission is 30 L (8 US gal).
Illustration 1 g00730160
2. Remove bolt (2), retainer (3), and yoke (4) .
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3. Remove bolts (5) and remove retainer (6). Check O-ring seal (7) for damage or wear.
Replace the seal, if it is necessary. The O-ring seal (7) is located behind retainer (6).
Remove brake drum (8) .
4. Remove four bolts (9). Remove tube assembly (10) .
5. Check O-ring seal (11) for damage or wear. The O-ring seal (11) is located on each end of
the tube assembly. Replace the seal if it is necessary.
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6. Remove the transmission cover.
7. Install Tooling (A) to shaft (13). Attach a hoist and a suitable lifting sling to Tooling (A) .
Note: Hold input shaft (12) away from shaft (13) for clearance.
8. Use the hoist to lift shaft (13) straight up out of transmission case. The weight of shaft (13)
is 41 kg (90 lb).
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9. Install Tooling (A) to shaft (15). Attach a hoist and a suitable lifting sling to Tooling (A) .
Note: Hold input shaft (1) away from shaft (4) for clearance.
10. Use the hoist to lift shaft (4) straight up out of transmission case. The weight of shaft (15) is
46 kg (101 lb).
11. Install Tooling (A) to input shaft (12). Attach a hoist and a suitable lifting sling to Tooling
(A) .
12. Use the hoist to carefully remove input shaft (1) from transmission case (3). The weight of
the input shaft is 17 kg (37.5 lb).
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13. Install Tooling (A) to output shaft (16). Attach a hoist and a suitable lifting sling to Tooling
(A) .
14. Use the hoist to carefully remove output shaft (17) from transmission case. The weight of
the output shaft is 80 kg (176 lb).
15. Remove thrust disc (150) from transmission case (14) .
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16. Install Tooling (B). Remove bearing (17) from output shaft (18) .
17. Position shaft assembly (16) on Tooling (C) .
18. Use Tooling (D) to remove retaining ring (19). Remove thrust disc (20) .
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19. Remove gear (21) .
20. Use Tooling (D) to remove retaining ring (22) .
21. Separate hub assembly (23) from gear (21). Remove sleeve bearing (24), if it is necessary.
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22. Remove thrust disc (25) and retainer (26) .
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Typical Example
(W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.
24. Use Tooling (E), a suitable air supply and the following procedure to measure the running
clearance of the clutch pack:
a. Place the shaft in the vertical position. End plate (W) that will be measured should be
facing upward.
b. Make sure that end plate (W) is free.
c. Position the tip of Tooling (E) on end plate (W). Zero Tooling (E) .
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Personal injury can result from applying air pressure without the lock
ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come
out with great force.
Make sure lock ring is securely in place before applying air pressure to
clutch pack.
d. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (Z) in the
shaft for the clutch that is being checked.
e. End plate (W) should move upward and end plate (W) should contact retaining ring
(X). The dial indicator will display the distance between end plate (W) and retaining
ring (X). This is the running clearance of the clutch pack. For the proper running
clearance, refer to the Testing and Adjusting, "Transmission Clutch Running
Clearance - Check" for the machine that is being serviced.
25. Use a screwdriver to remove retaining ring (28) .
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26. Remove one end plate (29), clutch plates (31), and disc assembly (30) .
27. Install Tooling (F), Tooling (I), and Tooling (J) in order to compress the wave spring. The
wave spring is not shown.
28. Use Tooling (D) to remove retaining ring (32). Release the pressure on the wave spring and
remove Tooling (F) .
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29. Remove balance seal assembly (33) .
30. Remove wave spring (34) .
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31. Apply suitable air pressure to the passage in order to move piston (35) upward. Remove
piston (35) from shaft (2) .
32. Balance seal assembly (33), wave spring (34), and piston (35) upon removal. Check the lips
on the seals for damage or wear. Replace the seals if it is necessary.
33. Use a lifting eyebolt, and a hoist in order to turn the shaft to the opposite side.
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34. Remove four seal rings (36) .
35. Remove the thrust disc (37) .
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37. Remove gear (39) .
38. Remove thrust disc (40) .
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39. Remove gear and hub assembly (41) .
40. Use Tooling (G) to remove retaining ring (42) .
41. Separate hub assembly (43) from gear (41) .
42. If necessary, remove sleeve bearing (44) .
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43. Remove thrust disc (45) and ring retainer (46) .
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Typical Example
(Z) Oil passage. (W) End plate. (X) Retaining ring. (Y) Running clearance.
44. Use Tooling (E), a suitable air supply and the following procedure to measure the running
clearance of the clutch pack:
a. Place the shaft in the vertical position. End plate (W) that will be measured should be
facing upward.
b. Make sure that end plate (W) is free.
c. Position the tip of Tooling (E) on end plate (W). Zero Tooling (E) .
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Personal injury can result from applying air pressure without the lock
ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come
out with great force.
Make sure lock ring is securely in place before applying air pressure to
clutch pack.
d. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (Z) in the
shaft for the clutch that is being checked.
e. End plate (W) should move upward and end plate (W) should contact retaining ring
(X). The dial indicator will display the distance between end plate (W) and retaining
ring (X). This is the running clearance of the clutch pack. For the proper running
clearance, refer to the Testing and Adjusting, "Transmission Clutch Running
Clearance - Check" for the machine that is being serviced.
45. Use a screwdriver to remove retaining ring (47) .
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46. Remove one end plate (48), clutch plates (49) and friction discs (50) .
47. End plate (48), clutch plates (49), and friction discs (50) upon removal.
48. Use Tooling (G) to remove snap ring (51) .
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Caterpillar Cat 938G Wheel Loader (Prefix 4YS) Service Repair Manual Instant Download.pdf

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Caterpillar Cat 938G Wheel Loader (Prefix 4YS) Service Repair Manual Instant Download.pdf