Milton CAT 938H User Manual

Engine

Engine Model Cat®6.6 ACERT™
Net Power – SAE J1349 128 kW 172 hp
Net Power – ISO 9249 134 kW 180 hp

• Caterpillar®engine with ACERT™ Technology –
EPA Tier III, EU Stage III Compliant.

Buckets

Bucket Capacities 2.3 - 3.0 m

3

3.0 - 4.0 yd

3

Weights

Operating Weight 15 059 kg 33,190 lb

• For 2.8 m3(3.65 yd3) general purpose bucket with
standard 20.5-R25 tires.

Operating Specifications

Static Tipping Load, Full Turn 10 076 kg 22,207 lb

• For 2.8 m3(3.65 yd3) general purpose bucket with
standard 20.5-R25 tires.

938H

Wheel Loader

®

®

2

938H Wheel Loader

Setting the standard for wheel loader productivity, durability, versatility and comfort.

OPERATOR COMFORT

• Easy Entry and Exit

• Excellent Visibility

• Adjustable Machine Parameters to

Match Operator Preference pg. 14

✔

PRODUCTIVITY

• Improved Cycle Times with Load­Sensing Hydraulic System

• Locking Differentials Provide
Superior Tractive Effort in Poor
Underfoot Conditions

• Constant Net Horsepower Through
the Operating Range pg. 8

✔

✔

DURABILITY

• ACERT™ Technology Maintains
Performance, Efficiency and Durability
While Meeting Emissions Regulations

• Heavy Duty Components Stand Up to
All Operating Conditions

• Strong, Solid Structures Built to Last

pg. 6

✔

RELIABILITY

• Proven Components and Technology

• Diagnostic Systems Monitor Product
Health to Ensure Reliability

• Unmatched Parts Availability and
Dealer Support pg. 4

✔ New Feature

3

✔

SERVICEABILITY

• Service Centers for Convenient
Maintenance

• Exceptional Ground-Level Access
to Service Points

• Monitoring Systems and Dealer
Support Reduce Unexpected
Downtime pg. 12

✔

OWNING AND OPERATING COSTS

• Superior Maintenance

• Electronic Systems Monitor Product
Health and Performance

• Complete Dealer Support pg. 10

VERSATILITY

• Special Machine Arrangements for
Unique Applications

• Large Variety of Cat®Work Tools

pg. 9

• Validated components and
technology

• Electronic systems monitor vital
machine components

• Excellent uptime from the best
dealer support network in the
industry

• Unmatched genuine Cat parts
availability

PROVEN RELIABILITY. The 938H features
many of the components designed and
proven in various Caterpillar products
– all contribute to the reliability of
the 938H:

• Frames

• Axles

• Countershaft powershift
transmission

• Individual component cooling
system

• Cab

ACERT™ TECHNOLOGY. Since March
2003, ACERT Technology has been
proving itself in on-highway trucks. More
recently it has proven itself again in field
tests of off-highway equipment.

This technology allows Cat engines
to meet durability and reliability
expectations without sacrificing
performance.

CATERPILLAR DESIGNED COMPONENTS.

Components used to build Cat Wheel
Loaders are designed and manufactured
to Caterpillar quality standards to
ensure maximum performance even
in extreme operating conditions.

Engine electronic control modules and
sensors are completely sealed against
moisture and dust. Deutsche connectors
and electrical wire braiding ensure that
electrical connections resist corrosion
and premature wear.

Hoses are engineered and manufactured
for high resistance to abrasion, excellent
flexibility and easy installation and
replacement.

Caterpillar

®

couplings use o-ring face
seals to provide positive sealing for
durable leak-free connections.

Heavy duty components reduce the risk
of leaks, corrosion and premature wear,
increasing uptime and helping to protect
the environment.

MONITORING PROGRAMS. Monitoring
product health is key to maintaining
reliability of any equipment. Many
programs are available on the 938H
to help you track machine health.

Caterpillar Messenger Display.

The 938H is equipped with the
Caterpillar Messenger Display that
keeps watch over the health of your
loader while providing real-time
diagnostic feedback. In the event of
a system malfunction, Messenger will
provide the operator with a description
of the occurrence, and if serious enough,
sound an audible alarm in addition to
a flashing indicator light.

4

The Cat 938H – Tested and Proven – Ready to Work

RELIABILITY

Product Link. Standard equipment on

the 938H, this state-of-the art satellite
technology enables Caterpillar dealers
and customers to keep in touch with
their machines. The system provides
a two-way information flow between
machine on-board systems and Caterpillar
dealers/customers via the Cat Dealer
Website and EquipmentManager.

EquipmentManager. EquipmentManager
is a web-based application that uses key
indicators from your equipment such
as hours, location and diagnostic codes
and combines it with powerful tools
like mapping, maintenance and repair
scheduling, and troubleshooting
instructions. This application enables
quick identification of actions required
to maximize your equipment uptime
and control owning and operating costs.

S•O•SSMServices. Keep minor repairs
from becoming major ones and avoid
complete failures. By regularly taking
samples from the ports provided, your
Cat dealer tracks wear of components
and parts, oil performance, and oil
condition and uses that data to predict
wear-related problems before they
happen. Often a simple adjustment or
replacement of a part, based on S•O•S
reports, can keep a small problem from
turning into a major repair – allowing
your machine to be running when
you need it, not waiting in the shop
for service.

DEALER SUPPORT. The Caterpillar global
network of independently-owned dealers
is the best in the world at providing
support to keep your loader up and
running. Known for parts availability
and technical expertise, Cat dealers
are partners in your business.

Service Capabilities. Cat field service
technicians have the experience and
tools necessary to service your loader
on site. Field service trucks are fully
loaded with state-of-the-art tools
and diagnostic equipment as well as
specifications and schematics for every
Cat machine. Technical experts at the
dealership and Caterpillar are available
to provide assistance to field service
technicians when needed.

When on-site repair isn’t enough,
Cat dealerships are fully-equipped
to service your loader quickly.

Parts Availability. Caterpillar provides
an unsurpassed level of personalized
service for your wheel loader. With parts
distribution centers throughout the world,
most parts can be delivered in 24 hours.

Remanufactured Parts. Cat engines
and major components are designed to
be remanufactured and provide multiple
life cycles. The Cat Reman program
is more extensive than most rebuild
programs. Components are actually
remanufactured in the factory to
original specifications with necessary
product updates.

Strict reuse guidelines and unparalleled
quality control ensure that reman products
provide the reliability and durability
that you expect from Caterpillar. Reman
products are stocked in distribution
centers around the world and are ready
to install to minimize downtime,
maintain productivity and profitability.

5

• ACERT™ Technology maintains
engine performance, efficiency and
durability while reducing emissions

• Heavy duty components withstand
all operating conditions

• Strong, solid structures are built
to last

Cat C6.6 ACERT. The Cat C6.6 is a

6.6 liter (403 in3) displacement, in-line

six cylinder engine. The C6.6 utilizes
ACERT Technology, a series of
Caterpillar engineered innovations that
provides advanced electronic control,
precise fuel delivery and refined air
management, resulting in outstanding
performance and lower emissions.

The C6.6 with ACERT Technology
offers a compact design with big, heavy
duty engine features for outstanding
durability, reliability and performance.
The C6.6 incorporates a new cross flow
cylinder head design, 4 valve head and
an ADEM A4 electronic controller.
The C6.6 also features a proven cylinder
block, pistons and crankshaft.

Electronic Control ADEM A4.

The Advanced Diesel Engine
Management – Electronic Control
Module consistently monitors important
engine conditions and functions. It uses
sensors throughout the engine to regulate
fuel delivery and all other engine systems
that require input to manage load and
performance. The ADEM A4 controller
is the brain behind engine responsiveness,
self-diagnosis, controlling emissions
and fuel economy.

Air Management. Air management
is a key concept in optimizing engine
performance and controlling emissions.
Engines must breathe clean cool air in
order to perform. To aid this, the C6.6
uses a turbocharger fitted with a smart
waste gate to give precise and reliable
control of the boost pressure. A new
cross-flow design in the cylinder head
facilitates air movement, while tighter
tolerances between the piston and
cylinder wall reduce blow by gases.

Fuel System. Through multiple injection
fuel delivery, fuel is introduced in
the combustion chamber in a number
of precisely controlled microbursts.
Injecting fuel in this way allows for
precise shaping of the combustion cycle
while reducing engine sound levels

Fuel Pump. The C6.6 uses an oil­lubricated high-pressure fuel pump
to feed a common fuel rail. By using
an oil-lubricated fuel pump, the C6.6
has been designed to be more tolerant
of alternative fuels.

Fuel Priming Pump. An electrical fuel
priming pump is located between the
fuel tank and the combined water
separator/primary fuel filter. The electric
priming pump eliminates the need to
pre-fill or manually prime filters after
a change, thus reducing contamination
and improving injector life.

Engine Idle Management. The Engine
Idle Management System (EIMS)
maximizes fuel efficiency and provides
flexibility in managing idle speeds
for specific application requirements.
Four idle control speeds are available.

POWERSHIFT TRANSMISSION.

The 938H continues to use powershift
transmission technology proven on
previous series. The countershaft
powershift transmission features heavy­duty components to handle the toughest
applications. Built-in electronic controls
enhance productivity and durability.

Control Throttle Shifting. Control Throttle
Shifting regulates engine speed during
high-energy directional and gear changes
for smoother shifting and longer
component life.

Electronic Clutch Pressure Control.

Electronic Clutch Pressure Control
(ECPC) system modulates clutches
individually to improve shift quality,
component life and operator comfort.
Adjustment is simplified with all
solenoid valves externally mounted
on top of the transmission housing.

AXLES. The 938H axles are designed by
Caterpillar for durability in all operating
conditions. The front axle is rigidly
mounted to the frame to support the
weight of the wheel loader and withstand
internal torque loads as well as external
forces encountered throughout operation.

The rear axle is designed to allow ± 12°
oscillation. All four wheels remain on
the ground over uneven terrain providing
excellent stability and traction.

6

Built Strong and Tough

DURABILITY

Integrated Braking System. The Cat

exclusive Integrated Braking System
reduces axle oil temperatures and
improves transmission neutralizer
smoothness. IBS has a direct impact
on durability of the axles and brakes
especially in applications involving
long distances and/or heavy braking.

RADIATOR. Brazed aluminum
construction provides a stronger joint
for maximum durability and resistance
to leaks. The 6-fins-per-inch design
decreases the chance of blockage
and plugging.

STRUCTURES. The articulated frame
design of the 938H features a durable
plate engine frame and two plate loader
tower that is robotically welded.
Robotic welding creates frame joints
with deep plate penetration welds and
excellent fusion for maximum strength
and durability.

Engine End Frame (EEF). The 938H uses
a proven solid plate engine end frame
which provides a strong, rigid structure
that resists twisting and evenly distributes
impact loads. The result is an extremely
solid mounting platform for the engine,
transmission, axle, ROPS and other
accessories.

Hitch. The distance between the upper
and lower hitch plates is an important
contributor to machine performance
and component life. The Caterpillar
hitch design provides excellent load
distribution and bearing life. Both the
upper and lower hitch pins pivot on
double tapered roller bearings –
improving durability by distributing
both vertical and horizontal loads over
a larger surface area. The wide opening
also provides excellent service access.

Non-Engine End Frame (NEEF).

The non-engine end frame provides a
solid mounting base for the front axle,
lift arms, lift cylinders and tilt cylinder.
The fabricated, two-plate loader tower
design reduces material packing under
the lift cylinders while absorbing the
forces associated with loading, twisting
and material handling.

Counterweight. The two-piece
counterweight is integrated into the
938H design and provides added
protection for the lights by incorporating
them into the top of the structure.

Linkage. The 938H linkage is a single­tilt Z-bar design. Z-bar linkage generates
excellent breakout force and good rack
back angle for better bucket loading
and load retention.

Lift arms are solid steel, providing
superior strength with an excellent front
end viewing area. The proven design
offers excellent dump clearance
and reach.

7

• Hydraulics are easy to control with
low effort

• Differential locks provide maximum
traction in varying underfoot
conditions

• Constant net horsepower across
various applications

• Standard and optional features that
maximize productivity

LOAD SENSING HYDRAULICS. The 938H
features a load sensing hydraulic system
that supplies flow and pressure for the
implements only upon demand, and only
in the amounts necessary to perform the
needed work thus providing a more
efficient loader.

With the new S3PC Priority Proportional
Pressure Compensation Valve, implement
control is improved over the previous
system – raise/lower and rack back/dump
can be operated simultaneously.

Operators will notice enhanced ease
of operation, more rimpull into the pile
and a 16% increase in lift force.

NEW! DIFFERENTIAL LOCK. Maximize
productivity with the new hydraulic
locking front differential. This standard
feature provides operators with the
confidence to maneuver through poor
underfoot conditions with ‘on the fly’
engagement.

A Caterpillar exclusive, the optional
automatic front/rear locking differential
collects input from sensors throughout
the loader and adapts tractive effort
to meet operating requirements.

CONSTANT NET HORSEPOWER.

On many competitive machines, gross
horsepower is constant, meaning that
net engine power available for actual
work will vary based on demands made
from parasitic sources, such as air
conditioning or cooling fans.

The Cat C6.6 engine is electronically
configured to provide constant net
horsepower at full parasitic load
enhancing productivity and improving
fuel efficiency.

On-Demand Fan. With electronic control
of the variable speed on-demand fan,
temperature levels of the engine coolant,
transmission oil, hydraulic oil and air
inlet manifold are constantly monitored.
This data is used to control and maintain
fan speed at the level necessary to
maintain normal system temperatures.
Controlled fan speed improves fuel
efficiency, lowers noise levels and
reduces radiator plugging.

Isolated Cooling System. The 938H
cooling system is isolated from the
engine compartment by a non-metallic
shield. The hydraulically driven, variable
speed fan draws in clean air from the
rear of the machine and exhausts it out
the sides and top of the hood. The end
results are optimal cooling efficiency,
increased fuel efficiency, less radiator
plugging and reduced operator sound
levels.

COUNTERSHAFT POWERSHIFT
TRANSMISSION. The electronic

countershaft powershift transmission
with automatic shift capability is
designed and built by Caterpillar.
The very responsive, full-power speed
and directional changes provide excellent
cycle times and productivity.

Fuel Economy Mode. Match transmission
shifting patterns to machine application
requirements. The Fuel Economy Mode
(within Messenger) provides operators
with the ability to choose between three
different shift modes in order to maximize
shift quality and fuel efficiency.

RIDE CONTROL. The optional Ride
Control System improves ride,
performance and load retention when
traveling over rough terrain. Operators
gain confidence moving at higher
speeds in load and carry operations
decreasing cycle times and increasing
productivity.

AUTOLUBE. The optional Caterpillar
Autolube System provides precise,
automatic lubrication of pins and
bushings – during loader operation.
Automatic lubrication reduces time spent
on daily maintenance and downtime for
unplanned repairs due to inadequate
greasing – improving productivity.

8

PRODUCTIVITY

Work Smart and Move More