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Caterpillar Cat 938G II Wheel Loader (Prefix CRD) Service Repair Manual (CRD00001 and up)

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Caterpillar Cat 938G II Wheel Loader (Prefix CRD) Service Repair Manual (CRD00001 and up)

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  1. Service Repair Manual Models 938G II WheelLoader

  2. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 1/47 Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 938G II WHEEL LOADER CRD Configuration: 938G II Wheel Loader CRD00001-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 i01879674 Transmission - Disassemble SMCS - 3030-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 1 3H-0465 Push-Puller Plate 4 5F-7344 Puller Block 1 B 5P-8715 Forcing Bolt 1 8B-7550 Push-Puller Leg 2 8H-0663 Bearing Puller 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 J 1U-6341 Threaded Rod 1 K 5P-7970 Nut 1 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  3. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 2/47 L 154-6182 Forcing Bolt 1 Start By: A. Separate the transmission from the torque converter. Refer to Disassembly and Assembly, "Transmission and Torque Converter - Separate". 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. 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. Illustration 1 g00984312 1. Install Tooling (A) to shaft (1). Attach a suitable lifting device to Tooling (A) . Note: Hold input shaft (2) away from shaft (1) for clearance. 2. Use a suitable lifting device to lift shaft (1) straight up out of transmission case. The weight of shaft (1) is approximately 50 kg (110 lb). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  4. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 3/47 Illustration 2 g00961151 3. Position shaft (1) on Tooling (C), as shown. Illustration 3 g00961189 4. Use Tooling (D) to remove retaining ring (3) and remove thrust disc (4) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  5. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 4/47 Illustration 4 g00961435 5. Remove gear and hub assembly (5) . Illustration 5 g00961444 6. Use Tooling (G) to remove retaining ring (6) . 7. Separate hub (7) from gear (5). If necessary, remove sleeve bearing (8) . Illustration 6 g00961455 8. Remove thrust disc (9) and retainer (10) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  6. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 5/47 Illustration 7 g00961468 9. Use Tooling (D) to remove retaining ring (11) . Illustration 8 g00961492 10. Use a screwdriver to remove retaining ring (12) . Illustration 9 g00961507 11. Remove one end plate (13), clutch plates (14), and friction discs (15) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  7. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 6/47 Illustration 10 g00961630 12. End plate (13), clutch plates (14), and friction plates (15) . Illustration 11 g00961639 13. Position the shaft assembly with retaining ring (16) in line with the opening in Tooling (F) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  8. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 7/47 Illustration 12 g00961647 14. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (D) to remove retaining ring (16). Remove Tooling (F) . Illustration 13 g00961656 15. Remove balance seal assembly (17) . Illustration 14 g00961678 16. Remove wave spring (18) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  9. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 8/47 Illustration 15 g00974947 17. Remove piston assembly (19) . Illustration 16 g00974948 18. Balance seal assembly (17). Wave spring (18) will be removed with piston (19). Check the lips on the seals for damage or wear. Replace the seals if it is necessary. Illustration 17 g00974949 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  10. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine(S... 9/47 19. Reposition the shaft assembly, as shown. Remove three seal rings (20). Use Tooling (D) to remove retaining ring (21) . Illustration 18 g00974950 20. Remove thrust disc (22) . Illustration 19 g00974951 21. Remove washer (23) and gear (24) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  11. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 10/47 Illustration 20 g00974953 22. Remove spacer assembly (25) . Illustration 21 g00974954 23. Remove thrust disc (26), the gear, and hub assembly (27) . Illustration 22 g00974955 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  12. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 11/47 24. Use Tooling (G) to remove retaining ring (28). Separate gear (27) from hub assembly (29). If necessary, remove sleeve bearing (30) . Illustration 23 g00974956 25. Remove thrust disc (31) and retainer (32) . Illustration 24 g00974957 26. Use Tooling (D) to remove retaining ring (33) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  13. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 12/47 Illustration 25 g00974958 27. Use a screwdriver to remove retaining ring (34) . Illustration 26 g00974959 28. Remove one end plate (35), clutch plates (36), and friction discs (37) . Illustration 27 g00974960 29. Exploded view of end plate (35), clutch plates (36), and friction discs (37) upon removal. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  14. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 13/47 Illustration 28 g00974961 Illustration 29 g00974962 30. Position the shaft assembly with the opening in retaining ring (38) in line with the opening in Tooling (F) . 31. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. The wave spring is not shown. 32. Use Tooling (D) to remove retaining ring (38) and remove Tooling (F) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  15. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 14/47 Illustration 30 g00974963 33. Remove balance seal assembly (39) . Illustration 31 g00974964 34. Remove wave spring (40) . Illustration 32 g00974965 35. Remove piston seal (41) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  16. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 15/47 Illustration 33 g00988356 36. Remove seal rings (41A) and (41B) from piston (41). Replace the seals, if necessary. Illustration 34 g00974967 37. Use Tooling (A) and a suitable lifting device in order to remove shaft assembly (42). The weight of shaft assembly is approximately 41 kg (90 lb). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  17. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 16/47 Illustration 35 g00975447 38. Position shaft (42) on Tooling (C), as shown. Illustration 36 g00975449 39. Use Tooling (D) to remove retaining ring (43) and remove thrust disc (44) . Illustration 37 g00975452 40. Remove gear and hub assembly (45) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  18. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 17/47 Illustration 38 g00975454 41. Use Tooling (G) to remove retaining ring (46). Separate gear (45) from hub assembly (47). Remove sleeve bearing (48), if necessary. Illustration 39 g00975456 42. Remove thrust disc (49) and retainer (50) . Illustration 40 g00975458 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  19. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 18/47 43. Use Tooling (D) to remove retaining ring (51) . Illustration 41 g00975463 44. Use a screwdriver to remove retaining ring (52) . Illustration 42 g00975467 45. Remove one end plate (53), clutch plates (54), and friction discs (55) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  20. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 19/47 Illustration 43 g00975553 46. Position the shaft so the opening in retaining ring (56) will line up with the opening in Tooling (F) . Illustration 44 g00975555 47. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. Use Tooling (D) to remove the retaining ring (56). Remove Tooling (F) . Illustration 45 g00975558 48. Remove balance seal assembly (57) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  21. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 20/47 Illustration 46 g00975562 49. Remove wave spring (58) . Illustration 47 g00975564 50. Remove piston assembly (59) . Illustration 48 g00988355 51. Remove seal rings (59A), and (59B) from piston (59). Replace the seals if it is necessary. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  22. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 21/47 Illustration 49 g00975570 52. Position the shaft assembly with the opposite end upward, as shown. Remove three seal rings (60). Use Tooling (D) to remove retaining ring (61) . Illustration 50 g00975576 53. Remove thrust disc (62) and gear assembly (63) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  23. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 22/47 Illustration 51 g00975578 54. Remove two sleeve bearings (64), if necessary. Illustration 52 g00975579 55. Remove thrust disc (65) and retainer (66) . Illustration 53 g00975584 56. Use Tooling (D) to remove retaining ring (67). Use a screwdriver to remove retaining ring (68) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

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  25. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 23/47 Illustration 54 g00975585 57. Remove one end plate (69), clutch plates (70), and friction discs (71) . Illustration 55 g00975587 58. End plate (69), clutch plates (70), and friction discs (71) upon removal. Illustration 56 g00975588 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  26. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 24/47 59. Position the shaft assembly so the opening in retaining ring (72) will be in line with the opening in Tooling (F) . Illustration 57 g00975810 60. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (G) to remove retaining ring (72). Remove Tooling (F) . Illustration 58 g00975811 61. Remove balance seal assembly (73) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

  27. 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine... 25/47 Illustration 59 g00975812 62. Remove wave spring (74) . Illustration 60 g00975818 63. Remove piston seal (75) . Illustration 61 g00988354 64. Remove seal rings (76) and (77) from piston (75). Replace the seals if it is necessary. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 2020/5/2

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