Caterpillar Cat 938K Wheel Loader (Prefix SWL) Service Repair Manual (SWL00001 and up)

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Service Repair Manual
Models 938K WHEEL LOADER
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Product WHEEL LOADER Model 938K WHEEL LOADER
SWL Configuration 938K Wheel Loader SWL00001-UP
(MACHINE) POWERED BY C6.6 Engine
Disassembly and Assembly 924K, 930K and 938K
Wheel Loaders Power Train Media Number
-UENR0281-03 Publication Date -01/04/2017
Date Updated -24/04/2017
i05142776
Transmission SMCS - 3030 Removal Procedure Table
1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-7505 Hydraulic Jack 1
B 138-7575 Link Bracket 3
B 1U-9200 Lever Puller Hoist Gp 1
Start By A. Remove the front hydrostatic piston
motor and the rear hydrostatic piston motor.
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Illustration 1 g02802456 1. Remove bolts (1) and
the caps in order to disconnect drive shaft (2)
from the yoke. Discard bolts (1) .
Illustration 2
g02802476
2. Remove cover (3) .
Illustration 3 g02802517 3. Disconnect harness
assemblies (4) and (5) . Reposition harness
assemblies (4) and (5) out of the way.
4
Illustration 4 g02802564 4. Disconnect harness
assembly (6) and reposition harness assembly (6)
out of the way.
Illustration 5
g02802576
5. Remove bracket (7) .
Illustration 6
g02802636
5
6. Disconnect harness assembly (8) . Disconnect
tube assembly (9) . Reposition filter base (10)
out of the way.
Illustration 7
g02802997
7. Disconnect harness assembly (11) .
Illustration 8
g02803036
8. Disconnect hose assembly (12) .
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Illustration 9 g02803097 9. Remove clamp (13)
and bolts (15) . Reposition tube assembly (14)
and hose assembly (16) out of the way.
Illustration 10 g02803276 10. Position Tooling
(A) under transmission (17) . The weight of
transmission (17) is approximately 145 kg (320
lb). Use suitable straps in order to secure
transmission (17) to Tooling (A) .
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Illustration 11
g02803363
11. Remove bolts (18) .
Illustration 12
g02803536
12. Remove bolts (19) .
Illustration 13
g02803541
13. Remove bolts (20) .
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Illustration 14 g02803577 14. Use Tooling (A) in
order to lower transmission (17) .
Illustration 15
g02803580
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Illustration 16
g02803606

• Illustration 17 g02803617
• Position a suitable bar across transmission
  mounts (21) . Attach Tooling (B) to the suitable
  bar and transmission (17) . The weight of
  transmission (17) is approximately 145 kg (320
  lb).
• Disconnect the straps that secure transmission
  (17) to Tooling (A) . Use Tooling (B) in order
  to raise transmission (17) off Tooling (A) .
  Remove Tooling (A) .
• Use Tooling (A) in order to lower transmission
  (17) to the ground.
• Installation Procedure
• 1. Install transmission (17) in the reverse order
  of removal.

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Illustration 18 g02802456 a. Install new bolts
(1) and tighten until snug. Tighten bolts (1) to
a torque of 71 10 Nm (52 7 lb ft) using an
X pattern. Disassembly Procedure Table 2
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-9200 Lever Puller Hoist Gp 1
A 138-7575 Link Bracket 3
B 308-3470 Jack Stand 3
C 138-7576 Link Bracket 2
D 6V-3009 Crossbar 1
D 6V-4832 Forcing Screw 1
D 8H-0663 Bearing Puller Gp 1
D 126-7181 Sliding Plate 4
D 126-7177 Puller Leg 2
D 1P-0510 Driver Gp 1
E 1P-0520 Driver Gp 1
F 4C-3652 Compressor Assembly 1
Start By A. Remove the transmission.
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Illustration 19 g02798341 1. Mark the clip
locations and connections. Remove harness
assembly (1) .
Illustration 20
g02798420
2. Remove valve assembly (2) .
Illustration 21 g02798422 3. Remove gasket (3)
from valve assembly (2) . Remove O-ring seals (4)
.
13
Illustration 22
g02798427
4. Remove nut (5) and remove coil (6) .
Illustration 23
g02798429
5. Remove valve (7) .
14
Illustration 24
g02798437
6. Remove O-ring seals (8) from valve (7) .
Illustration 25 g02798442 7. Remove temperature
sensor (9) from valve assembly (2) .
Illustration 26 g02798445 8. Remove O-ring seal
(10) from temperature sensor (9) .
15
Illustration 27 g02798448 9. Remove relief valve
(11) from valve assembly (2) .
Illustration 28 g02798449 10. Remove backup
rings (12) and O-ring seal (14) from relief valve
(11) . Remove backup rings (13) and O-ring seal
(15) . Remove O-ring seal (16) .
Illustration 29
g02798452
16
11. Remove fitting (17) and the O-ring seal from
valve assembly (2) . Remove the caps,
fittings (18) , and the O-ring seals. Remove the
cap, fitting (19) , and the O-ring seal.
Illustration 30
g02798457
12. Remove bolt (20) and yoke (21) .
Illustration 31
g02798458
13. Remove spacer (22) .
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Illustration 32 g02798461 14. Remove O-ring seal
(23) from yoke (21) .
Illustration 33 g02798465 15. Attach Tooling (A)
and a suitable lifting device to transmission
(24) . The weight of transmission (24) is
approximately 122 kg (270 lb). Use Tooling (A)
and the suitable lifting device in order to
position transmission (24) onto Tooling (B) as
shown on Illustration 33.
Illustration 34
g02798473
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16. Remove bolt (25) and remove yoke (26) .
Remove bolts (27) .
Illustration 35 g02798479 17. Remove O-ring seal
(28) from yoke (26) .
Illustration 36 g02798481 18. Attach Tooling (C)
and a suitable lifting device to housing (29) .
The weight of housing (29) is approximately 45
kg (100 lb). Use Tooling (C) and the suitable
lifting device in order to remove housing (29) .
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Illustration 37 g02798485 19. Remove bearing
cups (30) from housing (29) .
Illustration 38
g02798487
20. Remove shims (31) .
Illustration 39
g02798492
21. Remove bearing cup (32) .
20
Illustration 40
g02798494
22. Remove shims (33) .
Illustration 41
g02798495
23. Remove seal (34) .
21
Illustration 42 g02798498 24. Remove bolts (35)
and tube assembly (36) .
Illustration 43 g02798499 25. Remove O-ring seal
(37) from tube assembly (36) .
Illustration 44 g02798501 26. Remove drain plug
(38) and the O-ring seal from housing (29) .
22
Illustration 45
g02798503
27. Remove plug (39) and the O-ring seals.
Illustration 46
g02798506
28. Remove orifice (40) .
Illustration 47
g02798507
29. Remove plug (41) and the O-ring seal.
23
Illustration 48
g02798509
30. Remove orifice (42) .
Illustration 49
g02798510
31. Remove orifice (43) .
24

• Illustration 50 g02798511
• Remove bolt (45) . Remove sensor (44) and the
  O-ring seal.
• Remove bolt (46) . Remove sensor (47) and the
  O-ring seal.
• Remove plug (48) and the O-ring seal.

Illustration 51
g02798512
35. Remove shaft assembly (49) .
Illustration 52 g02798514 36. Use Tooling (D) in
order to remove bearing cone (50) from shaft
assembly (49) .
25
Illustration 53 g02798517 37. Use Tooling (D) in
order to remove bearing cone (51) from shaft
assembly (49) .
Illustration 54
g02798519
38. Remove bearing cup (52) .
Illustration 55
g02798520
39. Remove shaft assembly (53) .
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Illustration 56 g02798521 40. Use Tooling (D) in
order to remove bearing cone (54) from shaft
assembly (53) .
Illustration 57 g02798522 41. Use Tooling (D) in
order to remove bearing cone (55) from shaft
assembly (53) .
27
Illustration 58
g02798523
42. Remove bearing cup (56) .
Illustration 59 g02798524 43. Remove bolts (57)
and remove plate (58) .
Illustration 60 g02798526 44. Remove bolts (59)
from plate (58) . Remove seal assembly (60) .
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Illustration 61 g02798527 45. Use Tooling (E)
and a suitable press in order to remove seal (61)
(not shown) from seal assembly (60) .
Illustration 62
g02798529
46. Remove shaft assembly (62) .
Illustration 63
g02798530
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47. Use Tooling (D) in order to remove gear
assembly (63) from shaft assembly (62) .
Illustration 64 g02798531 48. Remove bearing
cone (64) from gear assembly (63) .
Illustration 65
g02798532
49. Remove thrust washer (65) .
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Illustration 66
g02798533
50. Remove thrust bearing (66) .
Illustration 67 g02798534 51. Remove needle
bearing (67) from shaft assembly (62) .
Illustration 68 g02798535 52. Remove spacer (68)
and needle bearing (69) from shaft assembly (62) .
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Illustration 69
g02798701
53. Remove thrust bearing (70) .
Illustration 70 g02798703 54. Remove thrust
washer (71) and retaining ring (72) .
Illustration 71
g02798709
55. Remove end plate (73) .
32
Illustration 72
g02798714
Illustration 73
g02798715
Illustration 74 g02798976 56. Remove friction
discs (74) and plates (75) ending with end plate
(76) .
33
Illustration 75
g02798719
Illustration 76
g02798724
Personal injury can result from being struck by
parts propelled by a released spring force. Make
sure to wear all necessary protective
equipment. Follow the recommended procedure and
use all recommended tooling to release the
spring force.
57. Use Tooling (F) and a suitable press in order
to compress spring (77) (not shown) in shaft
assembly (62) .
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58. With spring (77) compressed, remove retaining
ring (78) .
Illustration 77
g02798744
59. Remove washer (79) and spring (77) .
Illustration 78
g02798750
60. Remove sleeve (80) .
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Illustration 79
g02798764
61. Remove piston (81) .
Illustration 80
g02798768
62. Remove seal rings (82) from piston (81) .
Illustration 81
g02798775
63. Remove seal rings (83) and (84) .
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Illustration 82
g02798781
64. Remove bearing cone (85) .
Illustration 83
g02798793
65. Remove shaft assembly (86) .
Illustration 84 g02798796 66. Use Tooling (D) in
order to remove bearing cone (87) .
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Illustration 85 g02798798 67. Position shaft
assembly (86) onto a suitable press. Use the
suitable press in order to separate shaft (88)
from bearing cone (89) , spacer (90) , and gear
(91) .
Illustration 86
g02798808
68. Remove bearing cups (92) .
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Friend! Thank you very much for visiting. Full
manual if required, please enter the following
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