938M WHEEL LOADER

Printed by Heavy Equipment Manuals Printed in U.S.A

v2.20

Heavy Equipment Manuals

This is the sample of the sample click on
the download link for complete manual

DOWNLOAD LINK

For some reason if link does not work

download this pdf and then click
 
 
 
 

 
 
 
 
 
 
 
 
 
 
 



Product: WHEEL LOADER

Model: 938M WHEEL LOADER J3R
Configuration: 938M Small Wheel Loader J3R00001-UP (MACHINE) POWERED BY C7.1 Engine

Disassembly and Assembly

Air Conditioning and Heating R134a for All Cat Machines
Media Number -UENR4125-06 Publication Date -01/02/2018 Date Updated -22/01/2018

i05907621

Air Conditioner Lines - Remove and Install

SMCS - 1808-010

Personal injury can result from contact with refrigerant.

This system is under pressure at all times, even if the engine is not
running. Heat should never be applied to a charged system.

Contact with refrigerant can cause frost bite. Keep face and hands away
to help prevent injury.

Protective goggles must always be worn when refrigerant lines are

opened, even if the gauges indicate the system is empty of refrigerant.

Always use caution when a fitting is removed. Slowly loosen the fitting.
If the system is still under pressure, evacuate the system recovering the
refrigerant before removing the fitting.

Personal injury or death can result from inhaling refrigerant through a

lit cigarette.

Inhaling air conditioner refrigerant gas through a lit cigarette or other

smoking method or inhaling fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm or death.

Do not smoke when servicing air conditioners or wherever refrigerant

gas may be present.
 Before any checks of the air conditioning and heating system are made,
move the machine to a smooth horizontal surface. Lower all implements
to the ground. Make sure the transmission is in neutral or park and that
the parking brake is engaged. Keep all other personnel away from the
machine or where they can be seen.

Personal injury can result from hot coolant. Any contact with hot
coolant or with steam can cause severe burns. Allow cooling system
components to cool before the cooling system is drained.

NOTICE

Never weld or solder any charged components.

Care must be taken during removal of air conditioner lines. Before disconnecting any tube fittings, refer to
Testing and Adjusting, "Refrigerant Recovery" in order to recover all refrigerant from the system.

Place dust caps on all hoses and fittings upon disconnecting.

Do not fold or twist hoses when you are routing the new hoses onto the machine. Damage can occur to the
inner layers of the hoses and damage can cause premature failure.

Reassemble fittings by using the correct torque values for assembly of the air conditioning unit. Refer to
Specifications, SENR3130, "Torque Specifications" in order to find the correct torque value.

Use the following procedure to reassemble the connections.

Proper Technique for Assembly

 Illustration 1 g01519272

1. Drip clean mineral oil onto the clean O-ring.

Illustration 2 g01519286

2. Place the O-ring on fitting.

 Illustration 3 g01519288

3. Oil the O-ring again.

Illustration 4 g01519290

4. Align fittings and ensure that the seal is seated correctly. Hand tighten the fittings together.

Note: DO NOT CROSS THREAD.

 Illustration 5 g01519291

5. Tighten the connection with proper torque. Use a wrench to avoid twisting parts.

Copyright 1993 - 2020 Caterpillar Inc. Sat Sep 5 00:52:41 UTC+0530 2020
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL LOADER

Model: 938M WHEEL LOADER J3R
Configuration: 938M Small Wheel Loader J3R00001-UP (MACHINE) POWERED BY C7.1 Engine

Disassembly and Assembly

Air Conditioning and Heating R134a for All Cat Machines
Media Number -UENR4125-06 Publication Date -01/02/2018 Date Updated -22/01/2018

i05907627

In-Line Refrigerant Dryer - Remove and Install

SMCS - 7322-010-QT

Dryer Installation

Personal injury can result from contact with refrigerant.

This system is under pressure at all times, even if the engine is not
running. Heat should never be applied to a charged system.

Contact with refrigerant can cause frost bite. Keep face and hands away
to help prevent injury.

Protective goggles must always be worn when refrigerant lines are

opened, even if the gauges indicate the system is empty of refrigerant.

Always use caution when a fitting is removed. Slowly loosen the fitting.
If the system is still under pressure, evacuate the system recovering the
refrigerant before removing the fitting.

Personal injury or death can result from inhaling refrigerant through a

lit cigarette.

Inhaling air conditioner refrigerant gas through a lit cigarette or other

smoking method or inhaling fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm or death.
Do not smoke when servicing air conditioners or wherever refrigerant
gas may be present.

Before any checks of the air conditioning and heating system are made,
move the machine to a smooth horizontal surface. Lower all implements
to the ground. Make sure the transmission is in neutral or park and that
the parking brake is engaged. Keep all other personnel away from the
machine or where they can be seen.

Personal injury can result from hot coolant. Any contact with hot
coolant or with steam can cause severe burns. Allow cooling system
components to cool before the cooling system is drained.

NOTICE

Never weld of solder any charged components.

Illustration 1 g01520430

Typical In-Line Dryer with quick disconnects

(1) Inlet hose with air conditioner quick disconnect

(2) Dryer

(3) Outlet hose with air conditioner quick disconnect

Note: Replace dryer (2) annually. Dryer (2) should also be replaced whenever the system is opened.

Disassembly and Assembly

This is the sample of the sample click on
the download link for complete manual

DOWNLOAD LINK

For some reason if link does not work

download this pdf and then click
Illustration 2 g01520434

In-line dryer without quick disconnects

(4) Inlet hose without air conditioner quick disconnect

(5) Dryer

(6) Outlet hose without air conditioner quick disconnects

Illustration 3 g03549076

320-0562 Refrigerant Dryer As

(7) Dryer

(8) Air conditioner orifice assembly

Note: Every 2 years replace dryer (5) and (7) . Dryer (5) and (7) should also be replaced whenever the
system is opened.

Before removing the dryer, perform the following steps in order to diagnose the
problem

1. Check the following components for blockages:

 Condenser

Evaporator

Fresh air filters

2. Check the condition and the tension of the compressor drive belt.

3. Connect a manifold gauge set to the compressor. Refer to Testing and Adjusting, "Manifold Gauge Set
(Refrigerant) - Install".

4. Operate the Air conditioning.

Operate the engine at 1400 rpm.

Place the air conditioning switch in the ON position.

Set the blower switch to the HIGH position.

Open all of the louvers in the cab.

Close the cab doors and close all of the cab windows.

5. Compare the pressures for the manifold gauge to the pressure ranges in Table 1 in order to ensure that
the pressures are normal for the current ambient air temperature.

Table 1
(1)
Pressure Range
Ambient Air Temperature High Pressure Test Fitting Low Pressure Test Fitting
C° (F°) kPa (psi) (2) (3) kPa (psi) (4) (5)

21°C (70°F) 820 to 1300 kPa (120 to 190 psi) 70 to 138 kPa (10 to 20 psi)

27°C (80°F) 950 to 1450 kPa (140 to 210 psi) 70 to 173 kPa (10 to 25 psi)

32°C (90°F) 1175 to 1650 kPa (170 to 240 psi) 105 to 210 kPa (15 to 30 psi)

38°C (100°F) 1300 to 1850 kPa (190 to 270 psi) 105 to 210 kPa (15 to 30 psi)

43°C (110°F) 1450 to 2075 kPa (210 to 300 psi) 105 to 210 kPa (15 to 30 psi)
( 1)
This table is only for reference.
( 2)
Pressure may be slightly higher in humid conditions and lower in dry conditions.
( 3)
With AC High-pressure Test Fitting is located near the Evaporator Inlet pressure reading will be 83 to 103 kPa (12 to
15 psi) lower.
( 4)
Pressure before clutch disengagement.
 ( 5)
With AC Low-pressure Test Fitting is located near the Evaporator Outlet pressure reading will be 14 to 21 kPa (2 to 3
psi) higher.

6. Check for frost at the dryer outlet.

Note: Moisture on the drier outlet tube after the orifice is normal and this moisture does not indicate a
failure with the dryer. Frost on the drier outlet tube after the orifice is an indicator of a low refrigerant
charge.

7. If frost is indicated at the dryer outlet or if pressures are low, proceed to Step 8. Otherwise, proceed to
Step 15.

8. Recover the refrigerant charge from the machine. Refer to Disassembly and Assembly, "Refrigerant
System Recovery".

9. Record the amount of refrigerant and oil that is recovered from the Air Conditioner system.

These values will be needed in order to calculate the amount of oil that is needed. Refer to Testing and
Adjusting, "Refrigerant Compressor Oil - Test" Section.

10. If the charge was low, check the system for leaks.

a. Use an Ultraviolet light and use an electronic leak detector. Ensure that the following items are
checked:

Quick disconnects which are on the dryer

Check the drier swivel nut and tighten the nut to 27 ± 4 N·m (20 ± 3 lb ft).

All the connections in the circuit that are O-ring

Hoses for rubbing, bulging, and wet spots (oil leaks)

Note: In order to help reveal leaks, simulate the vibrations which are made by the machine by
moving the connections.

11. Recharge the refrigerant. Refer to Testing and Adjusting, "Refrigerant System - Charge" Section.

12. Retest the system with the engine at 1400 rpm and check for frost at the dryer outlet.

13. Ensure that the pressures are normal for the current ambient temperature.

14. Refer to Table 1 for the pressures which are normal for the current ambient air temperature.

15. If a component is leaking, bill the claim against the leaking component and provide details in the
description.

Dryer Removal
If the dryer does not have air conditioner quick Disconnects, the refrigerant that is in the system must be
recovered. Refer to the Testing and Adjusting, "Refrigerant System Recovery" section before you remove the
dryer.

If the dryer has air conditioner quick disconnects, use the procedure that follows.

Refer to Disassembly and Assembly, "Machine Preparation for Disassembly and Assembly" before service is
performed on the air conditioning system.

1. Stop the engine for 5 minutes to allow the air conditioning system to equalize the pressure.

2. Disconnect the inlet hose from the old dryer.

3. Connect the hose that was disconnected in Step 2 to the inlet on the new dryer.

Note: For a dryer that has air conditioner quick disconnects, do not add additional oil or refrigerant to
the system.

4. Start the engine. Operate the air conditioning system for 1 minute.

5. With the air conditioning system in operation, disconnect the outlet hose from the old dryer.
Disconnect the old dryer.

6. Stop the engine for 5 minutes to allow the air conditioning system to equalize pressure.

7. Connect the outlet hose that was disconnected in Step 6 to the new dryer.

8. Mark the new dryer in permanent marker Installed mm/dd/yy to assist in future maintenance of the in-
line dryer.

Copyright 1993 - 2020 Caterpillar Inc. Sat Sep 5 00:53:39 UTC+0530 2020
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL LOADER

Model: 938M WHEEL LOADER J3R
Configuration: 938M Small Wheel Loader J3R00001-UP (MACHINE) POWERED BY C7.1 Engine

Disassembly and Assembly

Air Conditioning and Heating R134a for All Cat Machines
Media Number -UENR4125-06 Publication Date -01/02/2018 Date Updated -22/01/2018

i05907618

Machine Preparation for Disassembly and Assembly

SMCS - 7320-017

Personal injury can result from contact with refrigerant.

This system is under pressure at all times, even if the engine is not
running. Heat should never be applied to a charged system.

Contact with refrigerant can cause frost bite. Keep face and hands away
to help prevent injury.

Protective goggles must always be worn when refrigerant lines are

opened, even if the gauges indicate the system is empty of refrigerant.

Always use caution when a fitting is removed. Slowly loosen the fitting.
If the system is still under pressure, evacuate the system recovering the
refrigerant before removing the fitting.

Personal injury or death can result from inhaling refrigerant through a

lit cigarette.

Inhaling air conditioner refrigerant gas through a lit cigarette or other

smoking method or inhaling fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm or death.

Do not smoke when servicing air conditioners or wherever refrigerant

gas may be present.
 Before any checks of the air conditioning and heating system are made,
move the machine to a smooth horizontal surface. Lower all implements
to the ground. Make sure the transmission is in neutral or park and that
the parking brake is engaged. Keep all other personnel away from the
machine or where they can be seen.

Personal injury can result from hot coolant. Any contact with hot
coolant or with steam can cause severe burns. Allow cooling system
components to cool before the cooling system is drained.

NOTICE

Never weld or solder any charged components.

Note: Before you conduct a performance check, refer to the Troubleshooting, "Visual Inspection
(Troubleshooting)" section.

Note: Refer to the Troubleshooting, "Machine Preparation for Troubleshooting" section before service work
is performed on the air conditioning system.

When the service work is done on the air conditioning system, the service work must keep the system clean
and free from contamination. Plugs and caps must be used in order to close the components and hoses when
the components and hoses are open. The plugs and caps protect the system from dirt and air (moisture). Only
new refrigerant oil of the correct viscosity and new refrigerant can be added to the system. For the correct oil,
refer to the Specifications section of this manual. Any other material or any other substance is considered non
-condensable and the material will contaminate the system. Keep the work area clean.

• Dust caps on the refrigerant compressor block fitting are the primary seal on the air conditioning
system.

• All machines should have an identification tag in the cab that specifies the proper refrigerant charge for
the machine.

When replacement or repair of components and hoses are required, perform the following procedure:

1. Remove the refrigerant charge. Measure the amount of oil recovered. Refer to the Testing and
Adjusting, "Refrigerant Recovery" and Testing and Adjusting, "Refrigerant Oil - Test" section, for
proper procedures.
 2. Remove the component or remove the hose that is being repaired or replaced. Install protective plugs
on components or hoses that are left exposed to the air.

3. Replace any damaged component or hose.

4. Use the following table in order to determine the amount of oil that is lost during individual
replacements of components. Follow the process provided in Testing and Adjusting, "Refrigerant Oil -
Test" to calculate the correct amount of oil needed for the system.

Table 1
Oil Capacities for Component Replacements

Accumulator 30 mL (1 fl oz)

Refer to the Testing and Adjusting, "Refrigerant Compressor

Compressor
Oil - Check" section.

Condenser
30 mL (1 fl oz)

Evaporator
90 mL (3 fl oz)

In-Line Dryer (1) before any oil is

installed 30 mL (1 fl oz)

Receiver-Dryer
30 mL (1 fl oz)
( 1)
Refer to the Disassembly and Assembly, "In Line Refrigerant Dryer - Remove and Install"

5. Refer to the Testing and Adjusting, "Refrigerant System - Evacuate" section.

6. Refer to the Testing and Adjusting, "Refrigerant System - Charge" section.

Copyright 1993 - 2020 Caterpillar Inc. Sat Sep 5 00:52:22 UTC+0530 2020
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL LOADER

Model: 938M WHEEL LOADER J3R
Configuration: 938M Small Wheel Loader J3R00001-UP (MACHINE) POWERED BY C7.1 Engine

Disassembly and Assembly

Air Conditioning and Heating R134a for All Cat Machines
Media Number -UENR4125-06 Publication Date -01/02/2018 Date Updated -22/01/2018

i05907623

Refrigerant Accumulator - Remove and Install

SMCS - 1808-010-ZJ; 7320-010-ZJ

The refrigerant must be recovered before the accumulator is removed. Refer to the Testing and Adjusting,
"Refrigerant Recovery" section.

Remove the accumulator. The accumulator has an internal oil drain hole which could become plugged. The
oil could be trapped inside the accumulator. It is necessary to check for excessive oil when the accumulator is
changed. Add the same amount of oil that was drained from the old accumulator. Add an additional 30 mL (1
fl oz) to the new accumulator before the new accumulator is installed. Do not add oil if the compressor was
changed also. Evacuate the system and recharge the system. Refer to the Testing and Adjusting, "Refrigerant
System - Evacuate" section. Refer to the Testing and Adjusting, "Refrigerant System - Charge" section.

Note: If the accumulator has frost on the outside, the air conditioning system still contains refrigerant.

Copyright 1993 - 2020 Caterpillar Inc. Sat Sep 5 00:53:05 UTC+0530 2020
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL LOADER

Model: 938M WHEEL LOADER J3R
Configuration: 938M Small Wheel Loader J3R00001-UP (MACHINE) POWERED BY C7.1 Engine

Disassembly and Assembly

Air Conditioning and Heating R134a for All Cat Machines
Media Number -UENR4125-06 Publication Date -01/02/2018 Date Updated -22/01/2018

i05907622

Refrigerant Compressor - Remove and Install

SMCS - 1802-010

Removal

Illustration 1 g00742981

(1) Bolt

(2) Drive belt

(3) Suction and discharge hoses

(4) Compressor

1. Remove the refrigerant charge. Refer to the Testing and Adjusting, "Refrigerant Recovery" section.

2. Disconnect electrical wires from the magnetic clutch.

3. Loosen all the mounting bolts and loosen the belt tightener (if equipped). Remove drive belt (2) .

4. Disconnect hoses (3) and put plugs or caps on the hoses. Put plugs or caps on the fittings of the
compressor. Put identification marks on the hoses. The marks will ensure that the hoses will be
connected correctly at a later time.

5. Remove all the mounting bolts and remove the compressor (4) . The weight of the compressor is
approximately 18 kg (40 lb).

Installation
1. Check the amount and condition of the oil in the compressor (4) . Refer to the Testing and Adjusting,
"Refrigerant Compressor Oil-Test" section.

2. Inspect the drive belt (2) . If the drive belt (2) is damaged or worn replace the belt.

3. Install the compressor (4) . Do not tighten the mounting bolts until drive belt (2) is installed and
adjusted.

4. Connect the discharge and the suction hoses (3) to the discharge and suction ports on the compressor.

5. Connect the electrical wires to the magnetic clutch.

6. Evacuate the system. Refer to the Testing and Adjusting, "Refrigerant System - Evacuate" section.

7. Charge the system. Refer to the Testing and Adjusting, "Refrigerant System - Charge" section.

8. For the correct system operation, refer to the Troubleshooting Section in this manual.

Note: Refer to the Specifications, "Refrigerant Compressor" in the Section for the correct belt tension.

9. For the oil level in the system, refer to Service Manual, "Refrigerant Compressor Oil - Check".

Copyright 1993 - 2020 Caterpillar Inc. Sat Sep 5 00:52:52 UTC+0530 2020
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL LOADER

Model: 938M WHEEL LOADER J3R
Configuration: 938M Small Wheel Loader J3R00001-UP (MACHINE) POWERED BY C7.1 Engine

Disassembly and Assembly

Air Conditioning and Heating R134a for All Cat Machines
Media Number -UENR4125-06 Publication Date -01/02/2018 Date Updated -22/01/2018

i05907624

Refrigerant Expansion Valve - Remove and Install

SMCS - 7320-010-EV

To replace the expansion valve, use the procedure that follows. Refer to Service Manual, "Troubleshooting
Heating and Air Conditioning Control System" before service work is performed on the air conditioning
system.

1. Recover the refrigerant.

Note: Cap all disconnected lines and hoses.

2. Remove the insulation and the clip. The insulation and the clip hold the sensing bulb to the evaporator
outlet pipe.

3. Disconnect the sensing line for pressure from the evaporator outlet pipe.

4. Loosen and remove the two connections at the expansion valve. Remove the expansion valve.

Note: Check the O-ring seals. The seals must be in good condition and the seals must be properly
lubricated with the correct refrigerant oil before assembly.

5. Install the expansion valve for replacement and tighten the two connections.

6. Tighten the pressure sensing connection on the evaporator outlet pipe.

7. Use a 8P-6355 Clip to hold the sensing bulb onto the evaporator outlet pipe. The sensing bulb should
be as close to the coil as possible. The bulb should be upstream of the pressure sensing connection on
the evaporator outlet pipe. The 5P-7070 Insulation should be wrapped tightly around the clip, the
sensing bulb, and the outlet pipe. There should be no insulation between the bulb and the outlet pipe.

8. Tighten all the connections correctly.

9. Evacuate the system. Refer to the Testing and Adjusting, "Refrigerant System - Evacuate" section.
 10. Charge the system with the correct amount of refrigerant by weight. Refer to the Testing and
Adjusting, "Refrigerant System - Charge" section.

Copyright 1993 - 2020 Caterpillar Inc. Sat Sep 5 00:53:16 UTC+0530 2020
All Rights Reserved.
Private Network For SIS Licensees.
 



Product: WHEEL LOADER

Model: 938M WHEEL LOADER J3R
Configuration: 938M Small Wheel Loader J3R00001-UP (MACHINE) POWERED BY C7.1 Engine

Disassembly and Assembly

Air Conditioning and Heating R134a for All Cat Machines
Media Number -UENR4125-06 Publication Date -01/02/2018 Date Updated -22/01/2018

i05907628

Refrigerant Orifice Tube Assembly - Remove and Install

SMCS - 7320-010-QT

The orifice tube may be located in the refrigerant line near the evaporator inlet, or in the in-line dryer.

If the orifice tube is located in the refrigerant line near the evaporator inlet, use the procedure that follows. If
the orifice tube is located in the in-line dryer, refer to Dryer Replacement.

Removing the Orifice Tube

Refer to Safety Requirements before service work is performed on the air conditioning system.

The refrigerant must be recovered before removing the accumulator. Refer to the Testing and Adjusting,
"Refrigerant Recovery" section.

NOTICE

Do not attempt to remove the orifice tube with pliers. Do not twist or
rotate the orifice tube in the tube assembly.
Illustration 1 g00379603

Orifice tube

(1) O-Ring seals

(2) Lugs

(3) Body

(4) Drive screw

(5) Finger lock

1. Disconnect the high side line at the enlarged section of the evaporator inlet port. This will expose the
orifice tube for removal.

2. Align the short fingers of the 1U-9890 Orifice Removal Tool with the ribs of the orifice tube. Insert the
tool onto the tube until the tool bottoms out.

3. Turn drive screw (4) clockwise. Turn far enough to engage the lugs (2) on the orifice tube in the finger
lock (5) . The finger lock (5) is part of the removal tool.

4. Hold the drive screw (4) stationary. Thread the body (3) forward until the body makes contact with the
inlet port.

5. Continue holding the drive screw stationary, and thread the body forward until the orifice tube
becomes free.
 Illustration 2 g00381412

Removing the broken orifice tube

(3) Body

(4) Drive screw

(6) Extractor tip

6. For the removal of the orifice tube assembly, use the extractor tip (6) on 1U-9890 Orifice Removal
Tool . Insert the tool into the evaporator inlet tube and thread the tool into the brass center of the
orifice tube.

7. Repeat steps 3 and 4.

8. If only the brass center of the orifice tube is removed, thread the tool into the plastic body and repeat
step 3 and 4.

Orifice Tube Installation

1. Lubricate the O-Ring on the orifice tube with the proper clean refrigerant oil.

2. Place the orifice tube into the 1U-9890 Orifice Removal Tool . Insert the orifice tube straight into the
evaporator inlet tube without twisting until the tube is seated.

3. Disengage the removal tool from the orifice tube.

4. Use a new O-Ring that is lubricated with clean refrigerant oil. Reconnect the high side line at the
enlarged section of the evaporator inlet port.
This is the sample of the sample click on
the download link for complete manual

DOWNLOAD LINK

For some reason if link does not work

download this pdf and then click