Caterpillar 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier workshop service repair manual includes:
* 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
Ride Control Accumulator...1073
Work Tool Control - Wheel Loader...1076
Ground Engaging Tool Torques...1080
RENR6077 - Systems Operation & Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Hydraulic System)...1082
Introduction - 938G Series II Wheel Loader...1083
Electrical Output Components...1097
Implement Hydraulic System - 938G Series II Wheel Loader...1102
Piston and Vane Pump (Implement Section)...1117
Pilot Valve...1120
Main Control Valve - 938G Series II Wheel Loader...1129
Relief Valve (Main)...1144
Relief Valve (Line)...1148
Ride Control System...1153
Kickout System - 938G Series II Wheel Loader...1163
Hydraulic Fan System...1168
Piston Pump (Hydraulic Fan)...1174
Gear Motor (Hydraulic Fan)...1180
General Testing and Adjusting Information...1186
System Pressure - Release...1191
Hydraulic Oil Contamination - Test...1194
Pump Performance (Implement) - Test...1198
Torque Converter Stall and Implement Pump Double Stall - Test...1203
Lift Cylinder - Isolation and Drift Check...1212
Tilt Cylinder - Isolation and Drift Check - 938G Series II Wheel Loader...1218
Pilot System Pressure - Test...1223
Relief Valve (Main) - Test and Adjust...1228
Relief Valve (Line) - Test and Adjust...1233
Kickout and Positioner - Adjust...1243
Ride Control Accumulator - Test and Charge...1248
Hydraulic Fan Speed - Test and Adjust...1258
RENR6079 - Schematic (938G Series II Wheel Loader Hydraulic System)...1268
Main...1269
Features...1269
Cover Page...1270
Information...0
Component Location...1271
Tap Location...1272
Fluid Power Symbols...1273
Electrical Symbols...1274
Schematic...1275
Machine View...0
Machine Comonent Locations...1276
Collage...1277
RENR6080 - Specifications (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems)...1292
Cab Mounting...1293
Window Wiper and Wiper Motor...1295
Governor Pedal...1302
Position Sensor (Throttle)...1304
Fuel Level Sender...1305
Hood Tilt Actuator...1307
Toggle Switch (Hood Tilt)...1309
Toggle Switch (Ground Level Shutdown)...1311
RENR6080 - Systems Operation (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems)...1313
Engine Starting Circuit...1314
Charging Circuit...1315
Backup Alarm Circuit...1317
Speed Limiting Function...1318
RENR6081 - Disassembly and Assembly (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems)...1319
Steering Frame Lock - Separate and Connect...1322
System Pressure - Release...1325
Hydraulic Tank - Remove...1328
Hydraulic Tank - Disassemble...1336
Hydraulic Tank - Assemble...1350
Hydraulic Tank - Install...1364
Pump Control Valve (Steering) - Remove and Install...1372
Piston and Vane Pump (Steering and Implement) - Remove...1375
Piston and Vane Pump (Steering and Implement) - Disassemble...1378
Piston and Vane Pump (Steering and Implement) - Assemble...1389
Piston and Vane Pump (Steering and Implement) - Install...1403
Secondary Steering Pump and Electric Motor - Remove and Install...1405
Steering Wheel - Remove and Install...1409
Metering Pump (HMU) - Remove...1413
Metering Pump (HMU) - Install...1417
Steering Control Valve - Remove...1421
Steering Control Valve - Disassemble...1424
Steering Control Valve - Assemble...1428
Steering Control Valve - Install...1432
Secondary Steering Valve - Remove...1435
Secondary Steering Valve - Disassemble...1438
Secondary Steering Valve - Assemble...1441
Secondary Steering Valve - Install...1444
Steering Cylinder - Remove and Install...1446
Vane Pump (Braking) - Remove...1452
Vane Pump (Braking) - Disassemble...1454
Vane Pump (Braking) - Assemble...1459
Vane Pump (Braking) - Install...1464
Brake Accumulator - Remove and Install...1465
Accumulator Charging Valve (Brake) - Remove and Install...1471
Brake Control Valve (Service) - Remove and Install...1477
Parking Brake - Remove and Install...1480
Brake Proportional Manifold (Traction Control System) - Remove...1485
Brake Proportional Manifold (Traction Control System) - Disassemble...1488
Brake Proportional Manifold (Traction Control System) - Assemble...1492
Brake Proportional Manifold (Traction Control System) - Install...1496
Pressure Reducing Valve (Traction Control System) - Remove and Install...1498
Fan and Gear Motor (Hydraulic Fan) - Remove...1502
Gear Motor (Hydraulic Fan) - Disassemble...1507
Gear Motor (Hydraulic Fan) - Assemble...1515
Fan and Gear Motor (Hydraulic Fan) - Install...1523
Piston Pump (Hydraulic Fan) - Remove...1527
Piston Pump (Hydraulic Fan) - Disassemble...1531
Piston Pump (Hydraulic Fan) - Assemble...1542
Piston Pump (Hydraulic Fan) - Install...1555
Pilot Operated Hydraulic Control - Remove...1557
Pilot Operated Hydraulic Control - Disassemble...1561
Pilot Operated Hydraulic Control - Assemble...1572
Pilot Operated Hydraulic Control - Install...1585
Pilot Operated Hydraulic Control (Joystick) - Remove...1588
Pilot Operated Hydraulic Control (Joystick) - Disassemble...1592
Pilot Operated Hydraulic Control (Joystick) - Assemble...1599
Pilot Operated Hydraulic Control (Joystick) - Install...1606
Selector and Pressure Control Valve (Pilot) - Remove and Install...1609
Diverter Valve (Quick Coupler) - Remove and Install...1612
Main Control Valve - Remove...1616
Main Control Valve - Disassemble...1622
Main Control Valve - Assemble...1630
Main Control Valve - Install...1639
Ride Control Accumulator - Remove and Install...1644
Solenoid Valve and Manifold (Ride Control; Head End) - Remove and Install...1650
Solenoid Valve and Manifold (Ride Control; Rod End) - Remove and Install...1656
Coupler Cylinder - Remove and Install...1661
Quick Coupler - Remove...1665
Quick Coupler - Install...1669
Lift Kickout Control - Remove and Install...1671
Bucket - Remove...1673
Bucket - Install...1678
Tilt Cylinder - Remove and Install...1682
Tilt Link - Remove...1690
Tilt Link - Install...1693
Lift Cylinder - Remove and Install...1695
Lift Arms - Remove...1706
Lift Arms - Install...1713
Window Wiper and Wiper Motor (Front) - Remove...1718
Window Wiper and Wiper Motor (Front) - Install...1725
Window Wiper and Wiper Motor (Rear) - Remove...1734
Window Wiper and Wiper Motor (Rear) - Install...1739
Cab - Remove...1745
Cab - Install...1758
Seat - Remove and Install...1770
Evaporator Coil - Remove and Install...1774
Heater Coil - Remove...1776
Heater Coil - Install...1781
Blower Motor (Air Conditioner; Heater) - Remove...1785
Blower Motor (Air Conditioner; Heater) - Install...1789
Loader Frame and Rear Frame - Separate...1793
Loader Frame and Rear Frame - Connect...1811
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)...1827
Main...1828
Collage...1832
RENR6319 - Systems Operation & Testing and Adjusting (938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Monitor System)...1864
Introduction...1865
Features...1868
Location of Electrical Components...1876
Component Description...1879
Data Link...1882
Warning Operation...1884
Diagnostic Operation...1886
Self Test...1889
Module - Replace...1890
Connector Contact Description...1892
System Schematic...1894
Caterpillar 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Repair Service Manual
