Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
OperationandMaintenanceManual WorkTool(Custom)338-0312LogandLumberFork
MediaNumber-GEBU0001-00PublicationDate-01/02/2009DateUpdated-13/02/2009
Foreword
SMCS-6136-086
LiteratureInformation
Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.
Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.
Somephotographsorillustrationsinthispublicationshowdetailsthatcanbedifferentfromyour worktool.Guardsandcoversmighthavebeenremovedforillustrativepurposes.
Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour worktoolwhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machinethatyourworktoolisinstalledon.
Wheneveraquestionarisesregardingyourworktool,orthispublication,pleaseconsultyour Caterpillardealerforthelatestavailableinformation.
Safety
Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofsafetysignsandlabelsusedontheworktool.
Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthisworktool.
Operation
Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,worktoolcontrols, transportationandtowinginformation.
Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingtheworktool.
Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeoftheworktoolanditscapabilities.
Maintenance
Themaintenancesectionisaguidetoequipmentcare.Theillustrated,step-by-stepinstructionsare groupedbyserviceintervals.Itemswithoutspecificintervalsarelistedunderthewhenrequired interval.Itemsinthemaintenanceintervalsschedulearereferencedtodetailedinstructionsthat follow.
MaintenanceIntervals
Calendarintervalsshown(daily,weekly,monthly,etc)canbeusedinsteadofservicehourmeter intervalsiftheyprovidemoreconvenientservicingschedulesandapproximatetheindicatedservice hourmeterreading.Recommendedserviceshouldalwaysbeperformedattheintervalthatoccurs first.
Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalsschedulemightbenecessary.
Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:21:05UTC+05302021
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
HydraulicFittings-Inspect
SMCS-5057-040-X6
Checkallhydraulicfittingsfordamagedfittingsorleaks.Replacealldamagedpartsormissingparts. Wipeallfittingsbeforeyouconnectthehydrauliclines.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:27:47UTC+05302021
PreviousScreen
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
Note:Wipeallthefittingsbeforeyoulubricatethefittings.
1.Lubricatethefittings(1),(2),and(4).Therearesixfittings.
2.Coatthemountingholes(3)forthequickcouplerwithgrease.
Reference:RefertoOperationandMaintenanceManual,SEBU6250,"CaterpillarMachineLubricant Recommendations"forinformationonlubricants.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:28:02UTC+05302021
PreviousScreen
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
i03461550
MaintenanceIntervalSchedule
SMCS-6700
Ensurethatallsafetyinformation,warnings,andinstructionsarereadandunderstoodbeforeany operationoranymaintenanceproceduresareperformed.
Theuserisresponsiblefortheperformanceofmaintenance,includingalladjustments,theuseof properlubricants,fluids,filters,andthereplacementofcomponentsduetonormalwearandaging. Failuretoadheretopropermaintenanceintervalsandproceduresmayresultindiminished performanceoftheproductand/oracceleratedwearofcomponents.
Usemileage,fuelconsumption,servicehours,orcalendartime,WHICHEVEROCCURSFIRST,in ordertodeterminethemaintenanceintervals.Productsthatoperateinsevereoperatingconditions mayrequiremorefrequentmaintenance.
Note:Beforeeachconsecutiveintervalisperformed,allmaintenancefromthepreviousintervalmust beperformed.
Every10ServiceHoursorDaily
HydraulicFittings-Inspect LogFork-Lubricate
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:27:32UTC+05302021
PreviousScreen
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine OperationandMaintenanceManual
WeldingonMachinesandEngineswithElectronicControls
SMCS-6700
Properweldingproceduresarenecessaryinordertoavoiddamagetotheelectroniccontrolsandtothe bearings.Thefollowingstepsshouldbefollowedinordertoweldonamachineoranenginewith electroniccontrols.
Note:Ifyouareweldingonaworktool,removetheworktoolfromthehostmachinebeforewelding.
1.Turnofftheengine.
2.TurnthebatterydisconnectswitchtotheOFFposition.Ifthereisnobatterydisconnectswitch, removethenegativebatterycableatthebattery.
3.Clampthegroundcablefromtheweldertothecomponentthatwillbewelded.Placetheclamp ascloseaspossibletotheweld.Makesurethattheelectricalpathfromthegroundcabletothe componentdoesnotgothroughanybearing.Usethisprocedureinordertoreducethe possibilityofdamagetothefollowingcomponents:
Bearingsofthedrivetrain
Hydrauliccomponents
Electricalcomponents
Othercomponentsofthemachine
DoNOTuseelectricalcomponents(ECMorECMsensors)or electroniccomponentgroundingpointsforgroundingthewelder.
4.Protectanywiringharnessesfromthedebriswhichiscreatedfromwelding.Protectanywiring harnessesfromthesplatterwhichiscreatedfromwelding.
5.Usestandardweldingproceduresinordertoweldthematerialstogether.
PreviousScreen
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
i03452980
DailyInspection
SMCS-6700
Personalinjuryordeathcanresultfromimproperlycheckingforaleak. Alwaysuseaboardorcardboardwhencheckingforaleak.Escaping airorfluidunderpressure,evenapin-holesizeleak,canpenetratebody tissuecausingseriousinjury,andpossibledeath.
Iffluidisinjectedintoyourskin,itmustbetreatedimmediatelybya doctorfamiliarwiththistypeofinjury.
NOTICE
Accumulatedgreaseandoilonaworktoolisafirehazard.
Removedebriswithsteamcleaningorhighpressurewateratanytime asignificantquantityofoilisspilledontheworktool.
Note:Theworktoolshouldberemovedfromthequickcouplerduringthedailyinspectionof theworktool.Uncouplingtheworktooldailyhelpstopreventthecouplerwedgesfrom sticking.
Forthemaximumservicelifeoftheworktool,makeathoroughwalk-aroundinspectionbeforeyou mountthemachineandbeforeyoustarttheengine.
Positiontheworktoolonalevelsurface.Uncoupletheworktoolfromthequickcoupler.Referto OperationandMaintenanceManual,"Operation-UncouplingtheWorkTool".
Lowerthequickcouplertothegroundinfrontofthemachine.Stoptheengineonthehostmachine. Removetheenginestartswitchkeybeforeexitingthemachine.RefertotheOperationand MaintenanceManualofthehostmachineforadditionalinformation.
Cleananydebrisfromtheforks.
Cleananydebrisfromthecarriageassembly.
Inspecttheworktoolforthefollowingconditions:loosebolts,brokenparts,missingpartsandworn parts.
Checkthecarriageassemblyandtheforktinesforwearorfordamage.Inspectthewelds,thelocks, theshafts,andtheforktinesfordamage.Ifthecomponentsaredamaged,consultyourCaterpillar dealer.
Checktheforktinesdailyforanytwistingorbendingoftheforktines.Ifanytwistingorbendingis observed,theforktinesshouldbechangedpriortoanyliftingoperation.Iftheforktinesaredamaged, consultyourCaterpillardealer.
Ifthelogandlumberforksarenotoperatedforlongperiods,thelogforksmustbelubricated.Refer toOperationandMaintenanceManual,"LogFork-Lubricate"forinformationonlubricatingthe forks.
Performallrepairsbeforetheworktoolisputintoservice.
Checkthesafetymessages.Replacethesafetymessageswhenthesafetymessagesaredamaged. Replacethesafetymessageswhenyoucannotreadthesafetymessages.Replacethesafetymessages whenthesafetymessagesaremissing.
Coupletheworktooltothequickcoupler.RefertoOperationandMaintenanceManual,"OperationCouplingtheWorkTool".Aftertheworktooliscoupled,ensurethatthecouplerwedgesarefully engagedintotheworktool.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:25:21UTC+05302021
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
OperationandMaintenanceManual WorkTool(Custom)338-0312LogandLumberFork MediaNumber-GEBU0001-00PublicationDate-01/02/2009DateUpdated-13/02/2009
LiftingandTyingDown
SMCS-7500
Improperliftingortyingdowncanallowtheloadtoshiftcausinginjury ordeath.
i03453360
Note:Beforeyouliftthefork,refertotheOperationandMaintenanceManual,"Specifications"for theweightofyourfork.
LiftingtheFork
Note:Forliftingobjects,useproperlyratedcablesandproperlyratedslings.Positionthelifting deviceinordertokeeptheforklevel.
Illustration1g01798713
1.Usetwoliftingstrapsthatareequalinlength.
2.Placeoneliftingstraparoundthetubeofthecarriagenearoneend.
3.Placetheotherliftingstraparoundthetubeofthecarriageneartheotherend.
4.Installtheloopsthatareontheendsofeachoftheliftingstrapsontoahoist.Usethehoisttolift thefork.
TyingDowntheFork
Donottietheforkdownusingthepinboressincethiscandamagepinbores.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:26:08UTC+05302021
PreviousScreen
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
Donotrotatetheforksbackwithaloadwhenattachedtoamachine withaZbarlinkage.TheZbarlinkagecouldpushtheloadoffofthe tinesordamagethemachinelinkage.
Seriousinjuryordeathmayresultfrompushingtheloadoffthetines.
This is the sample of the manual Click on the download link for complete Manual
Typicalexample
1.Openthetopclamp.Positiontheforkinthecenteroftheload.
2.Movethehostmachineforwardintopositionandengagetheload.Thehostmachineshouldbe squarewiththeload.Spacetheforktinesevenlyundertheload.
3.Movethehostmachineforwarduntiltheloadtouchestheuprightsontheforks.
4.Closethetopclamp.Tilttheforksbackwardinordertoholdtheloadagainsttheuprightson theforks.Raisetheload.
5.Operatethehostmachineinreverseuntiltheloadisclearfromthepile.Lowertheload.
6.Lowertheloadintothetravelposition.Forthebestoperatorvision,carrytheloadclosetothe ground.
7.Travelwiththeloaduphillonupgrades.Travelwiththeloaduphillondowngrades.Forbetter vision,travelinreversewithbulkyloads.
Typicalexample
8.Positiontheloadovertheunloadingarea.Tilttheforkdownwardandraisetheclampinorder toreleasetheload.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:25:38UTC+05302021
PreviousScreen
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
MediaNumber-GEBU0001-00PublicationDate-01/02/2009DateUpdated-13/02/2009
i03453800
Shipping
SMCS-7500
1.Placetheforktinesofthelogandlumberforkonapallet.
2.Tiethehydraulichosestothelogandlumberforkinordertokeepthehosesofftheground.If protectivecapsareavailable,installthecapsonthequickdisconnectfittings.
3.Usetie-downsinordertosecurethelogandlumberforktothepallet.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:26:24UTC+05302021
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
MediaNumber-GEBU0001-00PublicationDate-01/02/2009DateUpdated-13/02/2009
Storage
SMCS-0355
i03453820
Storethelogforksothattheforktinesarepositionedflatontheground.Tieanyhydraulichosesto thelogandlumberforkinordertokeepthehosesofftheground.Ifcapsareavailable,installcaps overthehydraulicfittingsinordertoprotectthefittings.Installcapsoverthehydraulicfittingsin ordertokeepdirtoutofthefittings.
Copyright1993-2021CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedDec811:26:40UTC+05302021
PreviousScreen
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
OperationandMaintenanceManual WorkTool(Custom)338-0312LogandLumberFork
MediaNumber-GEBU0001-00PublicationDate-01/02/2009DateUpdated-13/02/2009 i01214623
TransportPosition
SMCS-7500
Travelwiththelogandlumberforkaslowaspossibletotheground.Youshouldstillmaintain groundclearance.
Copyright1993-2021CaterpillarInc. AllRightsReserved.
PrivateNetworkForSISLicensees.
WedDec811:25:53UTC+05302021
PreviousScreen
Product:WHEELLOADER
Model:938GWHEELLOADER4YS
Configuration:938GWheelLoader4YS00001-UP(MACHINE)POWEREDBY3126Engine
OperationandMaintenanceManual
WorkToolInstallationandRemoval
SMCS-6700-010
CouplingtheWorkTool
Placetheforkinasafepositionbeforeengagingordisengagingthe quickcoupler.Ensurethattheforkisnotcarryingaload.
Seriousinjuryordeathmayresultfromengagingordisengagingthe forkwhenitisinanunstablepositionorcarryingaload.
Inspectthequickcouplerengagementbeforeoperatingthemachine.
Seriousinjuryordeathmayresultfromimproperlyengagedcoupler.
1.Positiontheforkonalevelsurface.
2.MovethequickcouplerswitchtotheUnlockorDisengageposition.
Ifthecoupleriscontrolledbythe3rdAuxiliaryHydraulicControlLever,movethecontrol backtotheUnlockorDisengageposition.RefertotheOperationandMaintenanceManualof thehostmachineforadditionalinformationoncontrols.
Illustration1g01796133
3.Tiltthecouplerforward.Ensurethatthecouplerisbelowthehooksonthefork.Referto illustration1.
4.SlowlydrivethemachineFORWARD.Centerthecouplerbetweenthehooksonthefork.
5.Raisethecoupleruntilthecouplercomesincontactwiththehooksonthefork.Continueto slowlyraisethecoupleruntiltheforkbeginstolift.Ensurethattheforkhasremainedlevel.
Illustration2g01796136
6.Tiltthecouplerbackwarduntiltheforkfullycontactsthecoupler.Refertoillustration2.
7.MovethequickcouplerswitchtotheLockorEngageposition.
Ifthecoupleriscontrolledbythe3rdAuxiliaryHydraulicControlLever,movethecontrol forwardtotheLockorEngageposition.RefertotheOperationandMaintenanceManualofthe hostmachineforadditionalinformationoncontrols.
Inspectthequickcouplerengagementbeforeoperatingthemachine.
Seriousinjuryordeathmayresultfromimproperlyengagedcoupler.
8.Visuallyinspectthequickcouplerinordertoensurethatthecouplerwedges(1)arefully extendedthroughthecorrespondingholes(2)inthefork.Refertoillustration3.
9.Alsousethefollowingproceduretoverifyengagementofthecouplerwedges.
a.Enterthemachine.
b.Fastentheseatbeltandlowerthearmrests.
c.Starttheengine.
d.Disengagetheparkingbrake.
e.Raisetheforkandfullydumpthefork.
f.Shaketheforkupanddownwiththetiltcylindersinordertoverifyengagementofthe couplerwedges.
10.Ensurethatthecouplingsforthequickdisconnectofthetopclampareclean.Connectthe couplingstothehostmachine.
Note:Thepositionofthetopclampmayaffectthepressureintheconnectinglines.Thiscan makeconnectingtheconnectinglinesdifficult.
Donotapplydownwardpressureontheforktines.Donotprywiththe forktines.Donotsideloadtheforktines.Prematurefailureofthefork
tinesmayoccurandcauseacrushhazard.Personalinjuryordeathmay occur.
