Caterpillar Cat 938H Wheel Loader (Prefix JKM) Service Repair Manual (JKM00001 and up).pdf

Service Repair Manual
Models
938H Wheel Loader

Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 938H WHEEL LOADER JKM
Configuration: 938H Wheel Loader JKM00001-UP (MACHINE) POWERED BY C6.6 Engine
Disassembly and Assembly
C6.6 Engines for Caterpillar Built Machines
Media Number -KENR6081-15 Publication Date -01/03/2014 Date Updated -04/03/2014
i02786857
Cylinder Head - Install
SMCS - 1100-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A -
Guide Bolt
(M16 by 115mm)
2
B 8T-3052 Degree Wheel 1
C 1U-6396 O-Ring Assembly Compound 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not
damage the mating surfaces of the cylinder head of the cylinder block. Ensure that no debris
enters the cylinder bores, the coolant passages, or the lubricant passages.
2. Inspect the mating surface of the cylinder head for distortion. Refer to Specifications,
"Cylinder Head" for more information. If the mating surface of the cylinder head is distorted
beyond maximum permitted limits, replace the cylinder head.
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938H Wheel Loader JKM00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP...
2020/5/7
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3. If necessary, install the inlet manifold to the cylinder head. Refer to Disassembly and
Assembly, "Inlet manifold - Remove and Install".
Illustration 1 g01340176
4. Inspect dowels (18) for damage. If necessary, replace the dowels in the cylinder block.
5. Install Tooling (A) to the cylinder block.
6. Align cylinder head gasket (17) with dowels (18). Install cylinder head gasket (17) onto the
cylinder block.
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Typical example
7. Use a suitable lifting device (16) to lift cylinder head (15). The weight of the cylinder head
is approximately 66 kg (145.5 lb).
Note: A spreader bar must be used in order to distribute the weight of the cylinder head
during the lifting operation.
8. Use Tooling (A) to align the cylinder head with the cylinder block. Install the cylinder head
to the cylinder block.
Note: Ensure that the cylinder head is correctly positioned on dowels (18).
9. Remove Tooling (A).
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10. Clean bolts (14). Follow Steps 10.a for the procedure to inspect the bolts.
a. Use a straight edge to check the threads of the bolts. Refer to Illustration 3. Replace
any bolts that show visual reduction in the diameter of the thread over length (Y).
11. Lubricate the threads and the shoulder of bolts (14) with clean engine oil.
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12. Install bolts (14) to cylinder head (16).
13. Tighten the bolts to a torque of 50 N·m (37 lb ft) in the numerical sequence. Refer to
Illustration 5.
14. Tighten the bolts to a torque of 100 N·m (74 lb ft) in the numerical sequence. Refer to
Illustration 5.
15. Turn the bolts through an additional 225 degrees in the numerical sequence. Refer to
Illustration 5. Use Tooling (B) to achieve the correct final torque.
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Typical example
16. Use Tooling (C) in order to lubricate the O-ring seals. Install new O-ring seals (12) and (13)
to bypass tube (11). Install the bypass tube in the cylinder head. Install bolts (10). Tighten
the bolts to a torque of 22 N·m (16 lb ft).
Typical example
17. Remove the plugs and caps from the ports and tube assemblies.
18. Install tube assembly (8) for the fuel return to the cylinder head and to the transfer pump.
Secure the tube clips for tube assembly (8).
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19. If the engine has a wastegate solenoid, install tube assembly (9) for the wastegate solenoid
to the cylinder head. Secure the tube clips for tube assembly (9).
Typical example
20. Follow Steps 20.a and 20.b in order to connect harness assembly (4) to inlet air temperature
sensor (7).
a. Connect harness assembly (4) to inlet air temperature sensor (7).
b. Slide the locking tab into the locked position.
21. Follow Steps 21.a and 21.b in order to connect harness assembly (4) to boost pressure
sensor (6).
a. Connect harness assembly (4) to boost pressure sensor (6).
22. Follow Steps 22.a and 22.b in order to connect harness assembly (4) to coolant temperature
sensor (5).
a. Connect harness assembly (4) to coolant temperature sensor (5).
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23. Use new cable straps in order to secure the harness assembly to the cylinder head and to the
inlet manifold. Ensure that the harness assembly is not strained.
Note: Ensure that the harness assembly is clear of other engine components.
24. Install the inlet hose to inlet connection (3) on inlet manifold (2).
Typical example
25. If necessary, install water temperature regulator housing (1) to the cylinder head. Refer to
Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install".
26. Connect the upper radiator hose to water temperature regulator housing (1) on the cylinder
head.
27. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change" for the correct filling procedure.
28. If necessary, fill the engine oil pan to the correct level that is indicated on the engine oil
level gauge. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check".
End By:
a. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit
Injector - Remove".
b. Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft
and Pushrods - Install".
c. Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve
Mechanism Cover Base - Install".
d. Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and
Install".
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e. Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold - Remove
and Install".
f. Install the electronic control module and the mounting bracket. Refer to Disassembly and
Assembly, "Electronic Control Module - Remove and Install".
g. If necessary, install the fuel filter base and the secondary fuel filter. Refer to Disassembly
and Assembly, "Fuel Filter Base - Remove and Install".
h. If necessary, install the fuel priming pump and the primary fuel filter. Refer to Disassembly
and Assembly, "Fuel Priming Pump - Remove and Install".
i. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold -
Remove and Install".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu May 7 13:02:13 UTC+0800 2020
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Shutdown SIS
Previous Screen
i02786866
Lifter Group - Remove and Install
SMCS - 1209-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Name Qty
A(1)
9U-6198 Crankshaft Turning Tool 1
A(2)
9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 1U-7262 Telescoping Magnet 1
(1)
The Crankshaft Turning Tool is used on the front pulley.
(2)
This Tool is used in the aperture for the electric starting motor.
Start By:
a. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".
b. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and
Install".
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
NOTICE
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1. If the crankshaft is installed, use Tooling (A) to rotate the crankshaft in order to gain access
to appropriate lifters (1).
2. Use Tooling (B) in order to remove lifters (1).
Note: Place a temporary identification mark on each lifter in order to identify the correct
location.
3. Repeat Steps 1 and 2 in order to remove the remaining lifters.
Table 2
Required Tools
A(1)
A(2)
9U-7336 Housing 1
B 1U-7262 Telescoping Magnet 1
(1)
(2)
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NOTICE
NOTICE
It is strongly recommended that all lifters should be replaced when a
new camshaft is installed.
1. Clean the lifters. Follow Steps 1.a through 1.c in order to inspect the lifters. Replace any
worn lifters or damaged lifters.
a. Inspect the seat of the pushrod in the lifter for visual wear or damage.
b. Inspect the shank of the lifter for wear or damage. Refer to Specifications, "Lifter
Group" for more information.
c. Inspect the face of the lifter that runs on the camshaft for visual wear or damage.
2. If the crankshaft is installed, use Tooling (A) to rotate the crankshaft to access to the
cylinder block in order to install appropriate lifters (1).
3. Lubricate lifters (1) with clean engine oil.
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4. Use Tooling (B) to install lifters (1) to the cylinder block. Ensure that used lifters are
installed in the correct location.
Note: The lifters should be free to rotate.
5. Repeat Steps 1 and 4 in order to install the remaining lifters.
End By:
a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".
b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
Thu May 7 13:03:10 UTC+0800 2020
4/4
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Shutdown SIS
Previous Screen
i02786879
Camshaft - Remove and Install
SMCS - 1210-010
Removal Procedure
Start By:
a. Remove the rockershaft and pushrods. Refer to Disassembly and Assembly, "Rocker shaft
and Pushrod - Remove".
b. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Remove".
NOTICE
1. The engine should be mounted on a suitable stand and placed in the inverted position.
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Typical example
2. Remove thrust washer (1) from the cylinder block. Do not remove dowel (2) from the
cylinder block unless the dowel is damaged.
Note: The thrust washer can have one or two slots (X).
NOTICE
Do not damage the lobes or the bearings when the camshaft is removed
or installed.
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3. Carefully remove camshaft (3) from the cylinder block.
4. If necessary, remove key (4) from camshaft (3).
NOTICE
1. Clean the camshaft and the thrust washer. Inspect the camshaft and the thrust washer for
wear and for damage. Refer to Specifications, "Camshaft" for more information. Replace
any worn components or any damaged components.
2. Clean the camshaft bearing in the cylinder block. Inspect the camshaft bearing for wear and
for damage. Refer to Specifications, "Camshaft Bearings" for more information. If
necessary, replace the camshaft bearing. Refer to Disassembly and Assembly, "Camshaft
Bearing - Remove and Install".
NOTICE
It is strongly recommended that all lifters should be replaced when a
new camshaft is installed.
3. Inspect the lifters for wear and for damage. Refer to Specifications, "Lifter Group" for more
information. Replace any worn lifters or any damaged lifters. Refer to Disassembly and
Assembly, "Lifter Group - Remove and install".
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Typical example
4. If necessary, install a new key (4) into camshaft (3).
5. Lubricate the bearing surfaces of camshaft (3) and lubricate the lobes of the camshaft with
clean engine oil.
NOTICE
Do not damage the lobes or the bearings when the camshaft is removed
or installed.
6. Carefully install camshaft (3) into the cylinder block.
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Typical example
7. Lubricate the thrust washer with clean engine oil. Align slot (X) in thrust washer (1) with
dowel (2) in the cylinder block. Install thrust washer (1) into the recess in the cylinder
block.
Note: The thrust washer can have one or two slots (X).
End By:
a. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
b. Install the rockershaft and pushrods. Refer to Disassembly and Assembly, "Rocker shaft and
Pushrod - Install".
Thu May 7 13:04:07 UTC+0800 2020
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Shutdown SIS
Previous Screen
i02786892
Camshaft Gear - Remove and Install
SMCS - 1210-010-GE
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A(1)
A(2)
9U-7336 Housing 1
B 230-6284 Timing Pin (Camshaft) 1
C
136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
(1)
(2)
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
b. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and
Install".
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NOTICE
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.
Dispose of all fluids according to local regulations and mandates.
1. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead
center on the compression stroke. Refer to System Operation, Testing and Adjusting,
"Finding Top Centre Position for No.1 Piston".
2. Install Tooling (B) through hole (X) in camshaft gear (1) into the front housing. Use
Tooling (B) in order to lock the camshaft in the correct position.
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3. Remove plug (4) from the cylinder block. Install Tooling (C) into hole (Y) in the cylinder
block. Use Tooling (C) in order to lock the crankshaft in the correct position.
Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the
crankshaft during repairs.
4. Loosen nuts (6) on all rocker arms (7). Unscrew adjusters (5) on all rocker arms (7) until all
valves are fully closed.
Note: Failure to ensure that all adjusters are fully unscrewed can result in contact between
the valves and pistons.
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Alignment of timing marks
5. Mark gears (1) and (8) in order to show alignment. Refer to Illustration 4.
Note: Identification will ensure that the gears can be installed in the original alignment.
6. Remove Tooling (B). Remove bolt (3) and washer (2) from camshaft gear (1).
7. Remove camshaft gear (1) from the camshaft.
Note: If the camshaft gear is a tight fit on the nose of the camshaft, use a prybar in order to
remove the camshaft gear.
4/8
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8. If necessary, remove the key from the nose of the camshaft.
Table 2
Required Tools
B 230-6284 Timing Pin (Camshaft) 1
C
136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
NOTICE
1. Ensure that number one piston is at top dead center on the compression stroke. Refer to
System Operation, Testing and Adjusting, "Finding Top Center for No. 1 Piston".
2. Ensure that Tooling (C) is installed in hole (Y) in the cylinder block. Use Tooling (C) in
order to lock the crankshaft in the correct position. Refer to System Operation, Testing and
Adjusting, "Finding Top Centre Position for No.1 Piston".
3. Ensure that the camshaft gear and the key are clean and free from wear or damage.
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4. If necessary, install the key into the nose of the camshaft.
Note: Ensure that the key is squarely seated.
Alignment of timing marks
5. Align the keyway in camshaft gear (1) with the key in the camshaft. Install camshaft gear
onto the camshaft. Ensure that the timing marks on gears (1) and (8) are in alignment and
that the mesh of the gears is correct. Refer to Illustration 8.
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6. Install Tooling (B) through hole (X) in the camshaft gear into the front housing. Install
washer (2) and bolt (3) to camshaft gear (1).
7. Remove Tooling (B) and (C). Install plug (4) into hole (Y) in the cylinder block. Refer to
Illustration 6.
8. Tighten bolt (3) to a torque of 95 N·m (70 lb ft).
9. Ensure that the backlash for gears (1) and (8) is within specified values. Refer to
Specifications, "Gear Group (Front)" for further information.
10. Ensure that the end play for camshaft gear (1) is within specified values. Refer to
Specifications, "Camshaft" for further information.
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Caterpillar Cat 938H Wheel Loader (Prefix JKM) Service Repair Manual (JKM00001 and up).pdf

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