Caterpillar 938G Series II Wheel Loader & IT38G Series II Integrated Toolcarrier Repair Service Manual PDF - MCAT938G2IT38G2.zip
A full service and repair guide, complete with electrical wiring diagrams, covering the Caterpillar 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier — packed with every technical detail needed to service, troubleshoot, fix, and overhaul these machines the way professional technicians do.
Inside the Caterpillar 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
RENR6065 - Specifications (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train).pdf
RENR6066 - Systems Operation & Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train).pdf
RENR6068 - Disassembly and Assembly (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train).pdf
RENR6069 - 938G (Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Engine Supplement).pdf
RENR6070 - 938G (Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Steering System).pdf
RENR6071 - Systems Operation (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Steering System).pdf
RENR6072 - Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Steering System).pdf
RENR6073 - Specifications (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Braking System).pdf
RENR6074 - Systems Operation (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Braking System).pdf
RENR6075 - Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Braking System).pdf
RENR6076 - Specifications (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Hydraulic System).pdf
RENR6077 - Systems Operation & Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Hydraulic System).pdf
RENR6079 - Schematic (938G Series II Wheel Loader Hydraulic System).pdf
RENR6080 - Specifications (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems).pdf
RENR6080 - Systems Operation (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems).pdf
RENR6081 - Disassembly and Assembly (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems).pdf
RENR6082 - Schematic (938G Series II Wheel Loader IT38G Series II Integrated Toolcarrier Electrical System; Cab 201-8442; Chassis 201-8444-01 (CRD1-1175 CSX1-625).pdf
RENR6319 - Systems Operation & Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Monitor System).pdf
PRODUCT DETAILS:
Total Pages: 1,892 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
RENR6065 - Specifications (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train)...1
Torque Converter...3
Temperature Sensor (Torque Converter Oil)...5
Transmission Pump...6
Oil Filter (Power Train)...10
Bypass Switch (Power Train Oil Filter)...11
Pinout Specifications for Electronic Control (Power Train)...12
Transmission Control Valve...16
Relief Valve (Transmission Hydraulic Control)...18
Modulating Valve (Transmission Clutch)...20
Speed Sensor (Torque Converter Output and Transmission Output)...22
Speed Sensor (Transmission Intermediate Output)...23
Temperature Sensor (Transmission Oil)...24
Transmission...25
Clutch (Forward High and Forward Low)...28
Clutch (Reverse and Second)...32
Clutch (First and Third)...36
Transmission Case...38
Transmission Output Gears...44
Engine and Transmission Mounting...47
Drive Shaft...49
Bevel Gear and Pinion (Fixed and Oscillating Axles)...51
Differential...53
Limited Slip Differential...55
NoSPIN Differential...57
Fixed Axle Housing...59
Oscillating Axle Housing...61
Brake and Planetary...67
Axle Mounting...69
Rim Mounting...71
Gear Pump (Axle Oil Cooler)...73
Electric Clutch (Axle Oil Cooler Pump)...74
Check Valve (Axle Oil Cooler Bypass)...76
Temperature Switch (Axle Oil Monitoring)...77
Temperature Switch (Front and Rear Axle Oil)...78
RENR6066 - Systems Operation & Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train)...79
Introduction...81
Features...86
Location of Electrical Components...93
Location of Hydraulic Components...102
Electrical Input Components...112
Electronic Control Module (Power Train)...123
Electrical Output Components...128
Integrated Braking System...132
Data Link...142
Electrical Schematic (Transmission)...144
Transmission Pump...146
Oil Filter (Power Train)...148
Modulating Valve (Transmission Clutch)...149
Relief Valve (Transmission Hydraulic Control)...155
Torque Converter...157
Transmission Oil Cooler...159
Transmission Hydraulic System Schematic...160
Transmission Power Flow...163
Differential...188
Differential (Limited Slip)...190
Differential (NoSPIN)...196
Axle (Fixed and Oscillating)...205
Axle Oil Cooler...207
Fill Time for the Transmission Clutch - Calibrate...210
Engagement Pressure for the Transmission Clutch - Calibrate...220
Position Sensor (Left Brake Pedal) - Calibrate...229
Transmission Control (Shift Lever) - Test...234
Torque Converter Stall - Test...241
Transmission Pressures - Test and Adjust...244
Transmission Clutch Running Clearance - Check...255
Differential Pinion Preload - Adjust...259
Differential Backlash and Bearings - Adjust...266
Limited Slip Differential Disc End Play - Check...272
NoSPIN Differential - Test...275
Axle Housing and Bearing Preload - Adjust...277
RENR6068 - Disassembly and Assembly (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train)...280
Steering Frame Lock - Separate and Connect...282
System Pressure - Release...285
Bottom Guard (Engine) - Remove and Install...288
Power Train Guard (Transmission) - Remove and Install...291
Transmission Oil Pump - Remove...294
Transmission Oil Pump - Disassemble...296
Transmission Oil Pump - Assemble...302
Transmission Oil Pump - Install...308
Relief Valve (Transmission Hydraulic Control) - Remove...310
Relief Valve (Transmission Hydraulic Control) - Disassemble...313
Relief Valve (Transmission Hydraulic Control) - Assemble...316
Relief Valve (Transmission Hydraulic Control) - Install...319
Modulating Valve (Transmission Clutch) - Remove...321
Modulating Valve (Transmission Clutch) - Disassemble...323
Modulating Valve (Transmission Clutch) - Assemble...324
Modulating Valve (Transmission Clutch) - Install...326
Manifold (Transmission Control Valve) - Remove...328
Manifold (Transmission Control Valve) - Install...329
Transmission and Torque Converter - Separate...331
Torque Converter - Disassemble - Fixed...335
Torque Converter - Disassemble - Free Wheel...342
Torque Converter - Assemble - Free Wheel...351
Torque Converter - Assemble - Fixed...359
Transmission - Disassemble...365
Transmission - Assemble...411
Transmission and Torque Converter - Connect...470
Parking Brake - Remove and Install...473
Drive Shaft (Front) - Remove and Install...478
Drive Shaft (Center) - Remove and Install...481
Drive Shaft (Rear) - Remove and Install...484
Tire and Rim (Front) - Remove and Install...486
Tire and Rim (Rear) - Remove and Install...490
Fixed Axle (Front) - Remove and Install...496
Oscillating Axle (Rear) - Remove and Install...501
Trunnion Support (Oscillating Axle; Front) - Remove and Install...508
Trunnion Support (Oscillating Axle; Rear) - Remove and Install...513
Axle Housing - Disassemble...522
Duo-Cone Conventional Seals - Install...529
Axle Housing - Assemble...536
Service Brakes - Remove and Install...545
Differential and Bevel Gear - Remove...556
Differential Pinion - Disassemble...562
Differential Pinion - Assemble...567
Differential - Disassemble...574
Differential - Assemble...577
Differential and Bevel Gear - Install...580
Limited Slip Differential - Disassemble...590
Limited Slip Differential - Assemble...598
NoSPIN Differential - Disassemble...609
NoSPIN Differential - Assemble...612
RENR6069 - 938G (Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Engine Supplement)...615
Steering Frame Lock - Separate and Connect...617
System Pressure - Release...620
Hood - Remove...623
Hood - Install...627
Hood Tilt Actuator - Remove and Install...631
Belt Tensioner - Remove and Install...637
Alternator - Remove and Install...640
Electric Starting Motor - Remove and Install...644
Fuel Priming Pump and Primary Filter (Water Separator) - Remove and Install...648
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install...651
Unit Injector Hydraulic Pump - Remove...655
Unit Injector Hydraulic Pump - Install...659
Unit Injector - Remove...663
Unit Injector - Install...665
Fuel Tank - Remove...667
Fuel Tank - Install...669
Water Temperature Regulator - Remove and Install...671
Water Pump - Remove...674
Water Pump - Install...677
Refrigerant Condenser - Remove and Install...679
Hydraulic Oil Cooler - Remove and Install...684
Fan and Gear Motor (Hydraulic Fan) - Remove...688
Fan and Gear Motor (Hydraulic Fan) - Install...693
Radiator Top Tank - Remove and Install...697
Radiator Core - Remove and Install...703
Radiator and Fan Group - Remove...707
Radiator and Fan Group - Install...713
Aftercooler - Remove and Install...718
Radiator Bottom Tank - Remove and Install...724
Crankshaft Front Seal - Remove...729
Crankshaft Front Seal - Install...732
Engine Oil Cooler - Remove...735
Engine Oil Cooler - Install...738
Turbocharger - Remove...740
Turbocharger - Install...743
Air Cleaner - Remove and Install...745
Muffler - Remove and Install...751
Refrigerant Compressor - Remove and Install...756
Engine; Torque Converter and Transmission - Remove...760
Engine from Torque Converter and Transmission - Separate...771
Engine to Torque Converter and Transmission - Connect...774
Engine; Torque Converter and Transmission - Install...777
Engine - Remove...787
Engine - Install...793
RENR6070 - 938G (Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Steering System)...799
Hydraulic Tank and Filter...800
Breaker Relief Valve...802
Temperature Sensor (Hydraulic Oil)...804
Piston Pump (Steering)...806
Secondary Steering Pump and Electric Motor...809
Relay (Secondary Steering Motor)...811
Relay (Secondary Steering Intermediate)...812
Steering Control...813
Metering Pump (HMU)...815
Steering Control Valve...817
Relief Valve (Pump Backup)...819
Relief Valve (Steering Cylinder Crossover)...820
Secondary Steering Valve...821
Pressure Switch (Primary Steering Oil and Secondary Steering Oil)...822
Steering Cylinder...823
Articulated Hitch...825
RENR6071 - Systems Operation (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Steering System)...827
General Information (Steering)...828
Piston Pump (Steering)...834
Metering Pump (HMU)...842
Steering Control Valve...845
Secondary Steering System...855
Secondary Steering Pump and Electric Motor...859
Secondary Steering Valve...861
RENR6072 - Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Steering System)...863
System Pressure - Release...864
Hydraulic Oil Contamination - Test...867
Pump Performance (Steering) - Test...871
Steering System Pressure (High Pressure Stall) - Test...873
Piston Pump (Steering) Low Pressure Standby - Test...876
Piston Pump (Steering) Margin Pressure - Test and Adjust...878
Relief Valve (Pump Backup) - Test and Adjust...883
Relief Valve (Steering Cylinder Crossover) - Test and Adjust...887
Steering Time - Check...890
Steering Control Valve - Adjust...892
RENR6073 - Specifications (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Braking System)...894
Hydraulic Tank and Filter...895
Breaker Relief Valve...897
Temperature Sensor (Hydraulic Oil)...899
Vane Pump (Braking)...900
Brake Accumulator...903
Accumulator Charging Valve (Brake)...906
Foot Brake Control...908
Position Sensor (Left Brake Pedal)...910
Limit Switch (Stop Light) (Left Brake Pedal)...912
Brake Control Valve (Service)...913
Pressure Switch (Service Brake Oil)...915
Parking Brake Control...917
Limit Switch (Parking Brake)...918
Service Brakes...919
Parking Brake...923
RENR6074 - Systems Operation (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Braking System)...925
General Information (Braking)...926
Vane Pump (Braking)...928
Brake Accumulator...931
Accumulator Charging Valve (Brake)...934
Brake Control Valve (Service)...937
Position Sensor (Left Brake Pedal)...941
Service Brakes...942
Service Brake Disc Wear Indicator...945
Parking Brake...949
RENR6075 - Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Braking System)...951
System Pressure - Release...952
Hydraulic Oil Contamination - Test...955
Pump Performance (Braking) - Test...959
Brake Accumulator - Test and Charge...962
Accumulator Charging Valve (Brake) - Test and Adjust...967
Service Braking System Pressure - Test...975
Limit Switch (Stop Light) - Adjust...977
Service Brakes - Test...980
Brake System Air - Purge...982
Service Brake Wear Indicator (New Brake Disc) - Check...985
Service Brake Wear Indicator (Existing Brake Disc) - Check...996
Parking Brake - Test...1005
Parking Brake - Manual Release...1007
Parking Brake Control - Adjust...1009
RENR6076 - Specifications (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Hydraulic System)...1012
Hydraulic Tank and Filter...1013
Breaker Relief Valve...1015
Temperature Sensor (Hydraulic Oil)...1017
Check Valve (Hydraulic Oil Cooler Bypass)...1018
Piston and Vane Pump (Implement Section)...1019
Piston Pump (Hydraulic Fan)...1021
Solenoid Valve (Demand Fan)...1025
Gear Motor (Hydraulic Fan)...1026
Selector and Pressure Control Valve (Pilot)...1028
Ball Switch (Hydraulic Lockout Detent Override)...1030
Pilot Valve...1031
Pilot Valve (Joystick)...1039
Diverter Valve (Quick Coupler)...1049
Main Control Valve - Wheel Loader...1051
Relief Valve (Main)...1057
Relief Valve (Line)...1059
Lift Cylinder - Wheel Loader...1062
Tilt Cylinder - High Lift...1064
Tilt Cylinder - Wheel Loader...1066
Coupler Cylinder...1068
Solenoid Valve (Ride Control)...1070
Check Valve (Ride Control)...1072