938G Caterpillar Wheel Loader Operation and Maintenance Manual by quality service repair manual

Product:WHEELLOADER

Model:938GWHEELLOADER9HS

Configuration:938GWHEELLOADER9HS00001-UP(MACHINE)POWEREDBY3126Engine

OperationandMaintenanceManual PayloadControlSystem

MediaNumber-SEBU7012-08PublicationDate-01/07/2003DateUpdated-12/07/2003

Foreword

LiteratureInformation

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbe differentfromyourmachine.Guardsandcoversmighthavebeenremovedforillustrative purposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingor performinglubrication,maintenanceandrepaironthismachine.

Operation

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperienced operator.Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachment controls,transportationandtowinginformation.

s00037320

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS) liststheitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsare listedunderthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhe pagenumberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance. UsetheMaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenance procedures.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily, weekly,monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemore convenientservicingschedulesandapproximatetheindicatedservicehourmeterreading. Recommendedserviceshouldalwaysbeperformedattheintervalthatoccursfirst.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanis specifiedinthemaintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500 servicehoursor3months,alsoservicethoseitemslistedunderevery250servicehoursor monthlyandevery10servicehoursordaily.

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhands afterhandling.

CertifiedEngineMaintenance

Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformance oftherequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.

Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewiththe regulations(40CFRPart89).Certainelementsofthemachineandenginesuchastheexhaust system,fuelsystem,electricalsystem,intakeairsystemandcoolingsystemmaybeemission relatedandshouldnotbealteredunlessapprovedbyCaterpillar.

MachineCapacity

Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcan adverselyaffectperformancecharacteristics.Includedwouldbestabilityandsystemcertifications suchasbrakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerfor furtherinformation.

CatProductIdentificationNumber

EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to 17characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandother constructionequipmentmanufacturersaremovingtocomplywiththelatestversionoftheproduct identificationnumberingstandard.Non-roadmachinePINsaredefinedbyISO10261.Thenew PINformatwillapplytoallCatmachinesandgeneratorsets.ThePINplatesandframemarking willdisplaythe17characterPIN.Thenewformatwilllooklikethefollowing:

1.Caterpillar'sWorldManufacturingCode(characters1-3)

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.

MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8character PINformat.

Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8 characterSerialNumber(S/N).

FriNov1702:31:27UTC+05302023

Product:WHEELLOADER

Model:938GWHEELLOADER9HS

Configuration:938GWHEELLOADER9HS00001-UP(MACHINE)POWEREDBY3126Engine

OperationandMaintenanceManual PayloadControlSystem

MediaNumber-SEBU7012-08PublicationDate-01/07/2003DateUpdated-12/07/2003

GeneralInformation

SMCS-7494

Introduction

ThePayloadControlSystem(PCS)isanadvancedelectroniccomputersystem.Thesystemwill provideanaccurateweightofthematerialthatwasloadedbyyourwheelloader.UsingthePCS willensureproperweightsforthecustomer.ThePCSwillpreventtheriskofoverloadingatruck.

ThePCSwillinterfacewithanIBMcompatiblepersonalcomputer.Thiswillprovidethe capabilitytoanalyzeproductivity.

Thismanualisintendedasanoperator'sguidetothebasicfunctionsofthePayloadControl System.

ReadthismanualcompletelybeforeusingthePayloadControlSystem.

i01899694

GettingStarted

ThePayloadControlSystemshouldbeproperlyinstalledinthewheelloader.ThePCSshouldbe calibratedforthewheelloader.SeeServiceManual,SENR6614,"PayloadControlSystem(PCS)" forinformationoninstallationandcalibrationprocedures.

Abriefdescriptionofthecalibrationprocedureisprovidedinthismanual.SeeOperationand MaintenanceManual,"SystemCalibration"forinformationonthecalibrationprocedure.

FriNov1702:32:00UTC+05302023

This is the sample of the manual Click on the download link for complete Manual

Product:WHEELLOADER

Model:938GWHEELLOADER9HS

Configuration:938GWHEELLOADER9HS00001-UP(MACHINE)POWEREDBY3126Engine

OperationandMaintenanceManual PayloadControlSystem

MediaNumber-SEBU7012-08PublicationDate-01/07/2003DateUpdated-12/07/2003

WeighingMaterial

SMCS-7494

i01899846

Note:Inordertoobtainanaccurateweight,makesurethatthepinsarelubricatedontheliftarm linkage.Thehydraulicoiliswarmeduptothenormaloperatingtemperature.

Inordertoweighabucketofmaterial,liftaloadedbucket.Thebucketshouldberackedback fully.Movetheliftleversmoothlyintothefulldetentposition.Theloadedbucketwillbeweighed asthebuckettravelsthroughtheupperliftingrange.Asthebucketisbeingweighed,thetopline ofthedisplaywillshow"WEIGH".Thebottomlinewillshowdashes.

Whenweighingiscompleted,thetoplinewillshowtheweightofthebucket.Iftheoperatorliftsa significantlylargerloadthatexceedsthecalibrationweightby50%,themessage"MAX"will appearonthedisplay.Ifthismessageappears,dumpsomematerialfromthebucketandliftagain. Ifthe"MAX"messageappearsrepeatedly,recalibrationisrequired.

SeeOperationandMaintenanceManual,"SystemCalibration"forinformationonrecalibration. Theweightwillbedisplayedintheselectedunits.Thepossibleunitsareshownbelow.

•USTons

•MetricTons

•LbX1000

Thebottomlineofthedisplaywillshowtheaccumulatedweightofthetruck.Thisweightisfrom thelasttime"STORE"or"CLEAR"waspressed.

Therpmoftheengineshouldbekeptconstantthroughtheliftingrange.Avoiddirectionalshifting orharshturninginordertoensureaccurateweighing.

Note:Iftheliftsystemhasbeenidleformorethan4hours,theerrormessage"LIFTBUCKET10 TIMES"willappearonthedisplaywhentheoperatorliftsthebucket.

SeeOperationandMaintenanceManual,"NormalWeighingMode"forinformationontheerror message.

Product:WHEELLOADER

Model:938GWHEELLOADER9HS

Configuration:938GWHEELLOADER9HS00001-UP(MACHINE)POWEREDBY3126Engine

OperationandMaintenanceManual PayloadControlSystem

MediaNumber-SEBU7012-08PublicationDate-01/07/2003DateUpdated-12/07/2003

GeneralKeypadOperations

SMCS-7494

Youshouldunderstandthebasicusageofthekeypadbeforeoperation.Thiswillhelpyouusethe PayloadControlSystemforthefirsttime.Thenumerickeysservetwopurposes.

(1)Providetheentryofdata.

(2)Provideaccesstootherfunctions.

SeeOperationManual,"KeypadModesandFunctions"formoreinformationontheavailable functions.

ClearKey

The"CLEAR"keyisusedforthreepurposes.

•The"CLEAR"keyisusedinordertoeraseanentry.

•The"CLEAR"keyisusedinordertoexitfromafunction.

•The"CLEAR"keyisusedinordertocorrectanumericalerrorthatwasmade.

Pressthe"CLEAR"keyinordertoclearamistakethatwasmadeduringtheentryofdata.Enter thecorrectinformationorpressthe"CLEAR"keyagaininordertoexitfromthecurrentmenu.

"Store"Key

The"STORE"keyisusedinordertocompletefunctions.The"STORE"keyisusedinorderto completetheentryofnumericaldata.The"STORE"keyisusedinordertocompletethe selectionsofmenus.The"STORE"keywillalsostorethedatainpermanentmemory.

Pressthe"STORE"keyinordertocompleteanumericentrywhenthedisplayshowsyourdesired entry.Thiswillcompletethecurrentfunction.Thesystemwillthenproceedtothenextstep.

i00879134

"Scroll"Key

The"SCROLL"keyisusedwhenmultipleselectionsareavailable.Pressthe"SCROLL"keyin ordertoadvancetothenextoption.Thedisplayisresettothetopofthemenuiftheendofthe menuisreached.

NextFunctionKey

The"NEXTFUNCTION"keyisusedinthesetupandservicemodes.Thiskeyisusedinorderto advancetoadditionalfunctions.

MenuBasics

Selectafunctionfromthemenu.Thetitleofthefunctionisshownonthedisplay.Thecurrent functionisthendisplayedonthetoplineandunderlined.

Pressthe"SCROLL"key.Alloftheavailablefunctionswillbeshown.Onlythecurrentlyselected functionwillbeunderlined.

Pressthe"SCROLL"keyinordertoselectanewoption.Pressthe"SCROLL"keyuntilthe desiredoptionisshownonthetopline.Whenthedesiredoptionisshown,pressthe"STORE" key.Thefunctionwillbeshownforonesecond.Thefunctionwillbeunderlined.Thiswillbe shownbeforethesystemadvances.

Pressingthe"NEXTFNCTN"keywilladvancethesystem.Thesystemwilladvanceonlyifthe currentselectionistheactiveselection.Pressthe"CLEAR"keyifthecurrentselectionisnot active.Pressthe"CLEAR"keyinordertoreturntothecurrentlyactiveselection.

Product:WHEELLOADER

Model:938GWHEELLOADER9HS

Configuration:938GWHEELLOADER9HS00001-UP(MACHINE)POWEREDBY3126Engine

OperationandMaintenanceManual

OperatorSetupFunctions

SMCS-7494

Illustration1g00988242

Note:Theunderlinedsettingsforeachmenuitemreflectthefactorydefaultsetting.

Pressthe"SETUP"keyorpressthe"NEXTFNCTN"key.Thiswillactivatethemenuthatisused forsetup.Pressthesekeysfromthenormalweighmodeorfromthestandbymodes.Allofthe setupsthataredescribedarestoredinpermanentmemory.Thesetupswillremainactiveuntilthe setupsarechanged.

SetupfortheOperator

Asecuritypasswordisnotrequiredforchangingthesetup.

IDoftheOperator

Thisisanoptionalnumericalinput.Thisallowstheoperatortoenteranumberthatisusedfor identification.Thisinformationisrecordedwiththeinformationforthetruck.Thisinformationis alsoprintedonthe"tickets"forthetrucks.Thisfunctionexpectsanumericinputfrom0to99999. Thisfunctionisturnedonfromthesetupoftheowner.SeeOperationandMaintenanceManual, "OwnerSetupFunctions"formoreinformation.

"Units"Menu

Thismenuallowstheselectionoftheunitsthatareusedfortheweightonthedisplay.Thereare threedifferentunitsthatareavailable.

•USTons

•MetricTons

•LbX1000

USTonsisthedefaultsetting.If"tickets"areprinted,the"tickets"willbeprintedinthesame unitsthatareonthedisplay.

"Language"Menu

Thelanguageforthedisplayiscontrolledbythisfunction.Thereareeightlanguagesthatare available.

•English(Default)

•German

•French

•Portuguese

•Italian

•Spanish

•Swedish

•Norwegian

"ScrollSpeed"Menu

Themenuallowstheoperatortoselectthescrollspeedforthemessagedisplay.Thescrollspeeds arelistedbelow.

•Slowest

•Slow

•Normal(Default)

•Fast

Product:WHEELLOADER

Model:938GWHEELLOADER9HS

Configuration:938GWHEELLOADER9HS00001-UP(MACHINE)POWEREDBY3126Engine

OperationandMaintenanceManual PayloadControlSystem

OwnerSetupFunctions

SMCS-7494

Theownersetupmenuandtheownersetupfunctionsarelocatedattheendoftheoperatorsetup menu.Thesemenusareprotectedbyapassword.Theownersetupmenuhasfunctionsthatwillbeset onetimeinmostcases.Thisisusuallydoneduringthedeliveryofthemachine.Thefunctionsneed tobesetforthedateandthetime.Thesefunctionsarethefirstoptionsafterthepassword.

Password

Accesstotheownersetupfunctionsisprotectedbyapassword.

Note:Thedefaultpasswordis12345.Thisisthepasswordthatwassetatthefactory.Enterthe passwordandpressthe"STORE"keyinordertoaccesstheownersetupfunctions.Thepasswordcan bemodifiedtoaspecificpasswordfortheowner.

SettingtheTimeandtheDate

Themonthandthedaywillbedisplayedonthetopline.Thehourandtheminutewillbedisplayed onthebottomline.Thedigitsforthehourwillflash.

Pressthedigitsforthehourorpressthe"SCROLL"key.Thiswillallowyoutoadvanceonehourata time.Pressthe"STORE"keyinordertosetthehours.

Note:Thetimeisalwayssetina24hourperiod.Thetimethatisusedismilitarytime.1:00pm= 13:00hours

Thedigitsfortheminuteswillflash.Pressthedigitsfortheminuteorpressthe"SCROLL"key.This willallowyoutoadvanceoneminuteatatime.Pressthe"STORE"keyinordertosettheminutes.

Theabbreviationforthemonthwillflash.Pressthe"SCROLL"keyinordertoscrollthroughthe months.Thenpressthe"STORE"key.

Thedaywillflash.Pressthedigitsforthedayorpressthe"SCROLL"keyinordertoadvanceone dayatatime.Pressthe"STORE"keyinordertosetthedate.

Theyearwillflash.Entertheyearandpressthe"STORE"key.

Note:Theyearmustbebetween1995and2176.Usetheclocksetfunctioninordertoadvancethe yearfrom1900to2000.Thisshouldbedoneassoonaspossibleafter31December1999.Thisis requiredforsoftwarepackage2.06orearlier.

Pressthe"NEXTFNCTN"keyinordertoskipsettingthetime.Ifonlythehoursneedtobesetuse thefollowingprocedure.

1.Setthehour.

2.Pressthe"STORE"key.

3.Pressthe"NEXTFNCTN"key.

SettingtheWeighRange

Ifthecurrentrangeisacceptable,pressthe"NEXTFNCTN"keyinordertoskipthis operation.

Thisfunctionallowsyoutocustomizetheweighrangefortheparticularapplication.Itmaybe preferabletolowerthedefaultweighrangeforloadinghoppers.Thedefaultweighrangeis50%to 80%oftheheightoftheliftarm.Thisrangeworkswellinmostcases.

Themessage"SHOWWEIGHBEGIN-STORE"willbedisplayedonthetopline.Thecurrentheight oftheliftarmisdisplayedonthebottomline.Thecurrentheightoftheliftarmisdisplayedin percentofmaximumliftheightX10.Ifthearmsareabovethecurrentsetting,thebottomlinewill flash.Pressthe"STORE"keyinordertotemporarilysavethelocationofthenewbeginning.Press the"STORE"keyinordertoadvancetothesettingfortheweighendingposition.Thearmsmustbe above15%fortheweighbeginsetting.

Themessage"SHOWWEIGHEND-STORE"willbedisplayeduntiltheliftarmsaremovedfrom thecurrentrange.Theheightoftheliftarmwillbedisplayedonthebottomline.Thebottomlinewill notflashwhentheliftarmsareabovethecurrentrange.

Iftheselectedrangeisnotvalid,anerrormessagethatdescribestheproblemwillbedisplayed.The procedurethatisusedforsettingtheweighrangewillbestartedagain.Nopermanentchangewillbe madeuntilbothofthesettingshavebeenstored.Therearethreelimitationsontheweighrange.

(1)Thetotalrangeofatleast15%ofthetraveloftheliftarmisrecommended.

(2)Theinitialsettingofmorethan15%isrecommended.

(3a)Thesettingoflessthan95%isrecommendedfortheend.

(3b)Thesettingofatleast30%ormoreisrecommendedfortheweighrange.

Note:Thepersonthatissettingtherangeshouldunderstandthenegativeeffectsofimproperly settingtheweighrange.Theweighrangeshouldbeintheareaofthesmoothestoperation.

Settingtheweighrangetoolow

Settingtheweighrangetoolowmaycauseexcessivereweighindicationsandpoorweighing accuracy.Thisisbecauseofsituationsofmanualbreakout.Thisisalsoduetoshiftingthe transmissionfromreversetoforward.

Settingtheweighrangetoohigh

Settingtheweighrangetoohighmaycauseexcessivereweighindications.Donotsettheweighend atthemaximumliftheight.Thiswillcauseareweigh.

HeightConsiderations

Thedistanceoftheliftrangefromthebottomtothetopshouldbekeptasbigaspossible.Thiswill allowchangesintheliftingtechniqueoftheoperator.

Settinganarrowweighrange

Settinganarrowweighrangemayleadtopooraccuracy.Thisisduetothelimitednumberofdata samples.

Note:Aweighrangeofatleast30%ormoreisrecommended.

MachineIdentification

Thisoptionwillallowtheinputofanidentificationnumber.Thisnumberwillbeprintedonall tickets.Thisnumberwillbeusedinordertoidentifydatathatisloadedtoanothercomputer.

TicketsMenu

Thismenuenablestheselectionofeitherzero,one,two,orthreeticketstobeprintedautomatically whenthe"STORE"keyispressed.Evenifthezeroticketsisselected,singleticketscanstillbe printedbypressingthe"PRNT"keyafterthe"STORE"keyispressedandbeforeanyadditional weightsaretaken.

AUTOTruckID

ThismenuenablestheautomaticoperationoftheTruckIDwhenthe"STORE"keyispressed.This menualsodisablestheautomaticoperationoftheTruckIDwhenthe"STORE"keyispressed.When themenuisenabled,theoperatorwillbeautomaticallypromptedfortheidentificationofthetruck thatwasjustloaded.Whenthisoptionisdisabled,identificationofthetruckmustbeenteredbefore storingtheTruckweight.

OperatorID

Thisoptionallowsyoutoinputanidentificationnumberofanoperator.Thenumbercanbefrom0to 99999.Thisnumberwillbeprintedonallticketsifthisnumberisnotzero.

Ifthisoptionisactivated,theIdentificationoftheOperatorisautomaticallyenabledwhenthe machineisstarted.TheidentificationoftheoperatorisalsothefirstmodeintheOperatorSetup Functions.

AutomaticIdentificationoftheMaterial

ThismenuenablestheautomaticoperationoftheMaterialIdentificationfunctionwhenthe"STORE" keyispressed.ThismenualsodisablestheautomaticoperationoftheMaterialIdentificationfunction whenthe"STORE"keyispressed.WhentheMaterialIdentificationfunctionisenabled,theoperator isautomaticallypromptedfortheidentificationoftheMaterialthatwasjustloaded.Whenthe

MaterialIdentificationfunctionisdisabled,youmustentertheidentificationofthematerialbefore youstoretheweightofthematerial.

Printer

Thismenuallowstheselectionofthebrandofprinter.Currently,theonlysupportedprintersarethe ComtecandtheRadixprinters.However,anystandardASCIIprinterwithaserialinterfacewill work.SelecttheRadixprinterinordertousesymbolswhenotherlanguagesareselected.Theprinter mustbeconnectedtothePayloadControlSystem.Theprintermustbeactivatedwhentheprinter menuisused.Usethe"SCROLL"keyinordertolocatethecorrectprinterandpressthe"STORE" key.The"STORE"keymustbepressedwhentheprinterisusedforthefirsttime.Thenameofthe printerwillbeunderlinediftheprinteristheactivechoice.

Re-Zero"Re-ZeroOn/Re-ZeroOff"

Thefunctionperiodicallyremindstheoperatorto"RE-ZERO",whenthefunctionisactivated.The messageadvisestheoperatorto"RE-ZERO".Ifthemessageappearsataninconvenienttime,the messagecanbeclearedfortwominutes.Themessagewillreappearagainuntilthe"RE-ZERO" buttonispressedbytheoperator.

Whenthemachinefirststartsupthemessage"RE-ZERO"willbefrequentlydisplayed.Asthe machinewarmsupthemessagewillappearlessfrequently.

"RE-ZEROING"thebucketregularly,improvestheaccuracybycompensatingforchanges associatedwithpinlubrication,hydraulicoiltemperatureandmaterialcarryback.

VelocityCheck(0-10-65536)

Themenumonitorstheliftspeedintheweighrange.Thenumberissetintermsofpercentper secondtimes10.Whentheliftspeedexceedsthevalueinthemenu,anerrorwilloccur.

SettingthethresholdtoahighnumberwillmakethePCSmoretoleranttochangesintheliftspeed. SettingthethresholdtoalownumberwillmakethePCSlesstoleranttochangesintheliftspeed. ChangingtheliftspeedintheweighrangewilladverselyaffecttheabilityofthePCStocalculatean accuratepayload.

Thedefaultnumberusedprovidesagoodbalancebetweenattaininggoodaccuracyandallowingthe operatortoachievehighproductivity.Thethresholdshouldbeincreasedbysmallincrementsifthe operatorismaintainingaconstantliftspeedandisstillreceivinganexcessivenumberofreweighs associatedwithliftspeed.

Note:Ifthethresholdissettoohigh,theaccuracycanbedecreasedbyallowingforoperator interventionduringtheweighrange.(Movingtheliftleveroutofthedetentpositionorchangingthe enginespeed.)

StartOfLift(None/5%/10%/15%)

Themenusetstheamountofpayloaddatathatisgatheredbeforethebucketenterstheweighrange. Thevalueissetasapercentofthefulllifttravel.Thevalueisrelativetothebottomoftheweigh range.

SampleLiftRange

Example-Theliftrangeissetfrom50%to80%andthe"StartofLift"issetto10%.ThePCS wouldbegingatheringdataatthe40%point.

Thedefaultsettingof10%providessufficientleaddatasothatPCScanobtainanaccuratereadingof thepayload.Increasingthisnumberto15%willprovideslightlybetteraccuracy.Thiswillrequirethe operatortomaintainaconstantliftspeedforalargerpartoftheliftrange.Decreasingthisnumberto 5%or"None"willreducetheliftrange.Thiswilladverselyaffecttheaccuracy.

DisplayResolution(Auto,1,2)

ThemenuallowsaconvenientmethodforsettingtheprecisionlevelinthePayloadControlSystem. Thedefaultsettingforthisfunctionis"AUTO".

Settingthismenutoavalueof1willchangeonedigitonthedisplay(30.2).Settingthismenutoa valueof2willchangetwodigitsonthedisplay(30.23).

SkewResolution(Low,Middle,High,None)

Themenumonitorstheliftpressureduringtheweighrange.Ifthepressurechangesexcessivelyan errorwilloccur.

Thisfeaturewillhelptheoperatordevelopgoodliftingtechniquesthatwillmaintainloading efficiency.ThiswillallowthePCStocalculateanaccuratepayload.Settingthemenuvalueto "Middle","High",or"None"willincreasethetolerantofthePCS.Thiswillcompensateforthe machineandtheoperatorinducednoise.

Theoperatorcanhaveexcessivereweighnoticesfromthe"SKEW"menuduetoissueswiththe machine.Theliftcapabilityofsomemachinesissoerraticthatthe"Low"thresholdcannotbeused. Whentheseconditionsoccurthe"SkewResolution"canbesettothe"Middle"setting.IfthePCSis settothe"Middle"andthesystemcontinuestoflagexcessivereweighnoticesforthe"Skew Resolution",thenchangethevalueto"High"butcheckthefollowing.

•Thevalidityofthecalibration

•Pinorpinlubrication(problems)

•Operatortechnique

•Valveandpumpproblems

Note:The"Skew"shouldonlybesetto"High"or"None"ifhighaccuracyisnotanissue.

TemperatureCompensation(0-65536)

Theoptionallowsyoutocompensateforchangesinthetemperatureofthehydraulicoil.Thedefault settingforthisfunctionis0orOFF.TheTemperatureCompensationrequiressomeadjustingbythe servicepersonnel.

SettingtheTemperatureCompensation

Note:Temperaturecompensationmustbeturnedonbeforethemachineiscalibrated.Startwiththe number12formediumwheelloaders.

Thereareseveralmethodsthatareusedtodeterminetheoptimumtemperaturecompensation coefficient.

MethodA

Monitorthemachinedaily.Lowerthenumberunderthefollowingconditions.

•Whenthemachineiscoldtheweightistooheavy.

•Whenthemachineishottheweightistoolight. Raisethenumberunderthefollowingconditions.

•Whenthemachineishottheweightistooheavy.

•Whenthemachineiscoldtheweightistoolight.

Theoptimumnumberwillbefoundifthecoefficientisslowlyadjustedoveraperiodofafewweeks.

MethodB

UseaclickerboxinordertochangetheElectronicMonitoringSystemto"Mode2".Displaythe hydraulicoiltemperatureonthescreenongauge3.Startthemachine.Movetheliftlinkagebutdo notwarmupthehydraulicoil.Loadseveraltrucks.ComparetheweightofthePCStotheweightof thescale.Recordthehydraulicoiltemperature.Themachineshouldbeatthenormaloperating temperature.Loadseveraltrucks.Recordthehydraulicoiltemperature,weightofthescaleand weightofthePCS.CalculatetheerrorofthePCSbysubtractingtheweightofthePCSfromthe

weightofthescale.Calculatetheaverageerrorbyaddingtheerrorsanddividingbythenumberof truckloads.Calculatetheaveragetemperaturebyaddingthehydraulicoiltemperatureforeachlift anddividingbythenumberoftruckloads.Theoptimumcoefficientcanthenbecalculatedwiththe followingformula.

Illustration2g00988693

Password

Thisallowsyoutochangethepassword.Thiswillreplacethedefaultpassword.Thispasswordis alsousedinordertolimitaccesstothecalibrationmode.

Note:Makesurethatyourecordyournewpassword.Thispasswordwillbeneededforfuture calibrationsandfuturechanges.Ifthenewpasswordislost,contactyourCaterpillardealer.

FriNov1702:33:17UTC+05302023

Product:WHEELLOADER

Model:938GWHEELLOADER9HS

Configuration:938GWHEELLOADER9HS00001-UP(MACHINE)POWEREDBY3126Engine

OperationandMaintenanceManual PayloadControlSystem

MediaNumber-SEBU7012-08PublicationDate-01/07/2003DateUpdated-12/07/2003

SystemCalibration

SMCS-7494

Thismodeallowsthecalibrationofthesensorfortheliftarm.Thismodeallowsthecalibrationof theweighsystem.Thismodeisprotectedbythepasswordoftheowner.Pressingthe"CAL"key willdisplaythenumberofcalibrationsthathavebeenperformed.Thedateofthelastcalibration willthenbedisplayed.Thesystemwillthenrequestthepasswordoftheowner.Toenterthe calibrationmode,enterthepasswordoftheowner.Thedefaultpasswordis12345.Thiswassetat thefactory.Press"STORE".Pressingthe"SCROLL"keywilldisplaythepreviouscalibrations. Continuetopressthe"scroll"keyinordertoviewearliercalibrations.Whentheword"End"is displayed,therearenomorepreviouscalibrations.

Note:SeeServiceManual,SENR6614,"PayloadControlSystem(PCS)"formoreinformationon thecompletecalibrationprocedure.

Ifthezerofunctionisusedtocompensateforchangesthencalibrationshouldbeperformed whenevertheaverageambientairtemperaturechanges10°C(50°F).

Note:Thefollowingserviceprocedureswillrequirerecalibrationofthesystem.

(1)ReplacementofaPressureSensor

(2)Adjustingthepositionsensororreplacingthepositionsensor

(3)Replacementofthedisplayunit

(4)Replacingthecomponentsofthebucketorreplacingthecomponentsofthebucketcontrol linkage

(5)RecalibrationshouldalsobeperformedifthePCSismovedfromonemachinetoanother machine.

(6)ThesoftwareforthePayloadControlSystemisupdated.

CalibrationSteps

i01901180

PreliminaryProcedures

Thefollowingstepsbrieflydescribethecalibrationprocedure.Amoredetaileddescriptionis includedintheservicemanual.SeeServiceManual,SENR6614,"PayloadControlSystem(PCS)" formoreinformation.Thestepsthatareusedforcalibrationwillbeshownonthedisplayofthe payloadcontrolsystem.Forallcalibration,thebucketmustbeinthefullytiltedbackposition. Warmupthemachine.Ensurethatthekickoutsaresetforthemaximumheight.

Note:Setthedisplayfortheweightsbeforeyoustartthecalibration.Thedisplayfortheweights canbeENGLISHormetric.

Note:Thekickoutshouldbeadjustedinordertoensurethatweighingiscompletedpriortothe startofkickout.

Note:The988Ghasanautomatictiltfeature.Thistiltsthebucketforwardslightlyatthetopof theliftrange.Thisfeaturecaninterferewiththecalibration.Usethefollowingprocedureinorder toplacethebucketintheproperpositionforcalibrationonthe988Gonly.Thisprocedurecanbe usedforafullbucketorforanemptybucket.Theseinstructionsarenotforsettingthezerooffset. Forallothermachines,proceeddirectlytothecalibrationprocedure.

1.Lowerthebuckettogroundlevel.Fullyrackbackthebucket.

2.Liftthebuckettothemaximumheight.Holdtheliftleverforapproximatelyfivetoten seconds.Thiswillallowtheautomatictiltfeaturetotiltthebucketforwardslightlytothe desiredposition.

3.Lowerthebuckettothegroundwithoutchangingthepositionofthebucket.Thebucketis nowinthecorrectpositionforcalibration.Donotchangethetiltpositionofthebucketfor theremainderofthecalibration.Youmaynowproceedwithcalibration.

CalibrationProcedure

1.CALIBRATETHELIFTARMPOSITIONSENSOR.Thisisthefirststepinthe calibration.Placethebucketontheground.Fullyrackbackthebucket.Pressthe"STORE" button.Thenraisethebuckettothehighestpossiblepositionoftheliftarmandthenpress "STORE".Acceptablerangesfortheliftarmsatthelowestpositionarefrom6500to22000. Acceptablevalueswiththeliftarmatthehighestpositionarefrom44500to61600.

2.CALIBRATEANEMPTYBUCKET.Duringthisstep,theoperatorwillbeinstructedtolift anemptybucket.Thebucketshouldbefullyrackedback.Theoperatorshouldliftthe bucketatnormalliftingspeed.Ifthetwoliftsmatchclosely,thenthecalibrationwill proceedtothenextstep.Ifthetwoliftsdonotmatch,theoperatorwillbeinstructedtolift anotherbucket.Thiswillberepeateduntiltwoliftsmatch.Thebucketshouldbeliftedwith theliftcontrolinthedetentposition.Theliftcontrolshouldbemovedsmoothlyintothe detentposition.

Note:Calibrationshouldbedoneatnormaloperatingspeed.

3.CALIBRATEAFULLBUCKET.Duringthisstep,theoperatorwillbeinstructedtolifta fullbucket.Useaknownweightoruseafullbucketofmaterial.Thebucketshouldbefully rackedback.Theoperatorshouldliftthebucketatnormalliftingspeed.Ifthetwolifts matchclosely,thenthecalibrationwillproceedtothenextstep.Ifthetwoliftsdonot match,theoperatorwillbeinstructedtoliftanotherbucket.Thiswillberepeateduntiltwo

liftsmatch.Thebucketshouldbeliftedwiththeliftcontrolinthedetentposition.Thelift controlshouldbemovedsmoothlyintothedetentposition.

Note:Calibrationshouldbedoneatnormaloperatingspeed.

Note:Donotloseanyloosematerialpriortodeterminingtheweight.

4.CALIBRATETHEEMPTYBUCKETSTATIONARY.Lowertheliftarmbelowthestart weighpoint.Then,raisetheliftarmslowly.Thedistancetothenextstationarypositionwill beshownonthebottomlineofthedisplay.Whenthisvaluereacheszero,thetoplineofthe displaywillinstructtheoperatortoSTOP.Theliftarmsmustbeheldstationaryuntilthe systeminstructstheoperatortoraisethebucketintothenextcalibrationpoint.Ten calibrationpointswillbetakenintheweighrange.

5.CALIBRATETHEFULLBUCKETSTATIONARY.Loadthebucket.Useaknown weightoruseafullbucketofmaterial.Thestepsareidenticaltothestepsthatareusedfor calibratinganemptybucket.

Note:Itisveryimportanttocalibratethesystemwithaloadthatisveryclosetotherated load.Donotusealoadthatistoosmall.Theoperatorwillreceivethemessage"MAX" duringtheweighingprocess,ifalargerloadisused.Ifthemessage"MAX"appearsduring theweighingprocess,dumpsomematerialfromthebucketandtryagain.Ifthemessage "MAX"repeatedlyappears,recalibrationisrequired.SeeOperationManual,"System Calibration".

Note:Donotloseanyloosematerialpriortodeterminingtheweight.

6.USEVELOCITYCOMPENSATIONINORDERTOCALIBRATEAFULLBUCKET. Thissteprequirestheoperatortoliftthebucketeighttimesatenginerpmfrom1000to 2400.Thisisforsoftwarepackage2.09and2.09R.Maintaintherequiredenginerpmas closeaspossible.Ifthemachinecannotattainthefinalenginespeedthatisrequested,runat HighIdleforthisstep.Theliftlevershouldbesmoothlymovedfromneutraltothedetent position.

Note:Ifthemessage"LIFTSLOWER"appearsafterliftingthebucketeighttimes,liftthe bucketat1000rpm.Ifthe"LIFTSLOWER"messageisstilldisplayed,liftthebucketat 900rpm,untilthemessage"GOODLIFT"comesonthescreen.

7.ENTERTHEWEIGHTOFTHEFULLBUCKET.Entertheweightofthematerialthatis inthebucket.Thesystemwillwaitatthispointwhiletheweightinthebucketis determined.Theelectricalsystemshouldnotbeshutoffpriortoenteringtheactualweight orthecalibrationinformationwillbelost.

8.ZEROTHEEMPTYBUCKET.Emptythebucket.Tiltbackthebucket.Theoperator shouldliftthebucketatnormalliftingspeed.Pressthe"ZERO"key.Thiscompletesthe calibration.

9.DETERMINETHEWEIGHRANGE.SeeOperationManual,"OwnerSetupFunctions"for informationonsettingtheWeighRange.

Product:WHEELLOADER

Model:938GWHEELLOADER9HS

Configuration:938GWHEELLOADER9HS00001-UP(MACHINE)POWEREDBY3126Engine

OperationandMaintenanceManual PayloadControlSystem

MediaNumber-SEBU7012-08PublicationDate-01/07/2003DateUpdated-12/07/2003 i01900812

NormalWeighingMode

SMCS-7494

Thisisthedefaultmodeofthesystem.Inthismode,thetoplinedisplaysthelastbucketweightin theselectedunits.Thebottomlinedisplaystheaccumulated"TRUCK"weight.IfthePCSisin the"TARGET"mode,theweightneededtohitthedesiredtargetweightofthetruck.

Thenewbucketweightsareaddedtothetrucktotalbysimplyliftingthebucketthroughtheweigh rangeinauniformmannerwiththeliftleverinthefulldetentposition.

MachineConsiderations

DUETOTHESIGNIFICANTVARIATIONINTHEVISCOSITYOFHYDRAULICOIL,THE MACHINEHYDRAULICSSYSTEMSHOULDBEATTHENORMALOPERATING TEMPERATUREBEFORETHEBEGINNINGOFWEIGHINGOPERATIONS.

InorderforthePayloadControlSystemtoprovideaccurate,reliableweights,yourmachinemust bekeptingoodworkingorder.Lowhydrauliclevelsorpoorlylubricatedlinkagepinswill adverselyaffecttheweighingaccuracyofthesystem.

LiftingTechniquesandConsiderations

Theoperatorshouldpayattentiontothefollowingdetailsduringtheliftingsequence.Thiscan significantlyimprovetheoverallweighingaccuracy.

1.Ifthemachinehasbeenidleformorethan15minutes,youshouldexercisetheliftlinkage severaltimesinordertolubricatethepins.ThePayloadControlSystemcompensatesfor thechangesinhydraulicoiltemperature.ThePCSdoesnotcompensateforthelinkagethat becomesstiffduetothelackofmachinemovement.Theoperatorshouldperformtenempty lifts,byraisingthebuckettofullheightfromtheground.Thiswillexercisethepinsandthe liftarms.Thisactionwillcyclethehydraulicoilthroughthesystem.

2.Fullyrackbackthebucketbeforeweighing.

3.Weighingshouldbeperformedonaflatsurface.Weighingmaterialwiththemachineona slopewillaffectaccuracybychangingthecenterofgravityoftheload.

4.Maintainaconstantenginespeedthroughouttheweighrange.Changingtheliftspeedinthe weighrangewillaffectthecompensationoftheliftspeed.

5.Starttheliftatthelowestavailablestartingpoint.

6.Movetheliftleversmoothlyintothedetentposition.

7.Theliftlevershouldbeinthefulldetentpositionthroughtheweighrange.

8.Movethekickoutoftheliftheightwellbeyondtheendoftheweighrange.

9.Whenyouloadthetruckwatchforlossofmaterial.

10.Setthemachine'sridecontroltoAUTOorOFFifthemachineisequippedwithridecontrol.

11.Enablethe"Re-Zero"functionintheownersetupfunctions.

12.Complywiththerequestfora"Re-Weigh"bythePCS.

13.Useconsistentloadswhenmultipassloadingisusedtoloadtrucks.

14.Keepthevaluesofthelift(VelocityandSkewResolution)setastightaspossible.Keepthe startoftheliftat10%or15%.

15.Thehighestaccuracycanbeachievedwhenthemachineisstationary.

16.Configurethemachineforawideweighrange.A30%weighrange(50%to80%)is preferable.

17.Calibratethemachineatthesameliftspeedoftheoperator.

18.Themachineshouldbefullywarmedupbeforeyouattemptacalibration.

19.Asuddenmovementofthemachinewilladverselyaffecttheaccuracyofweighing.You performadirectionalshiftduringweighing.

20.Easingtheliftleverfromthecenterpositiontothefulldetentpositiongraduallycan decreasetheoscillationsinthehydraulicsystem.Thiswilldecreasevibration,thus improvingweighingaccuracyandrepeatability.

21.Anunevenworkingareawillaffectweighingaccuracy.

22.Theweighrangeshouldbesettothesmoothestoperatingportionoftheliftingcycle.See OperatorManual,"OwnerSetupFunctions"formoreinformation.

ErrorandWarningMessages

This is the sample of the manual Click on the download link for complete Manual