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Parts Manual SEBP4156-30 October 2008 VOLUME I Pages 1-462 See “General Information” for New Parts

Parts

Manual

SEBP4156-30

October 2008

VOLUME I

Pages 1-462

Parts Manual SEBP4156-30 October 2008 VOLUME I Pages 1-462 See “General Information” for New Parts Manual

See “General Information” for New Parts Manual Features.

930G Wheel Loader

TWR1-Up (Machine) CPT1-Up (Engine) TPA1-Up (Transmission)

Powered By 3056E Engine

This Parts Manual is also available in .PDF Format on Compact Disc (CD-ROM)-Caterpillar Form NO. SERP4156

Product and Dealer Information

Note: For product identication plate locations, see the section “Product Identication Information” in the Operation and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identi cation Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

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Name:
Branch:
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Sales:
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Service:

MEMORANDA

MEMORANDA

SEBP4156-30

 

TABLE OF CONTENTS

 

Name

Page

Name

Page

GENERAL INFORMATION

 

A5

COOLER GP-FLTR BASE & ENG OIL

 

63

 

FAN GP-SUCTION LINES GP-WATER

 

.

.

.

.

.

.

.

.

.

.

.

.

65

REPAIR ALTERNATIVES

 

A8

.

.

 

.

.

.

.

.

.

.

.

.

.

66

 

PUMP

GP-WATER

.

.

.

.

.

.

.

.

.

.

.

.

68

SUPPLEMENTAL COOLANT ADDITIVES

 

A9

RADIATOR

& AFTERCOOLER GP

 

70

 

RADIATOR

GP

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

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.

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.

.

89

MAINTENANCE

PARTS

 

.

.

.

.

.

.

.

.

.

.

.

A10

 

AIR INLET AND EXHAUST AIR CLEANER GP ELBOW GP-AIR INLET

 

SYSTEM

 

93

INDEX

.

.

.

.

.

.

.

.

.

.

.

.

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.

.

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.

.

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.

.

A15

 

.

 

.

 

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.

93

   

.

.

.

.

.

.

.

.

.

.

100

MACHINE ARRANGEMENT CHASSIS AR COMMON AR WASTE HANDLING AR

 

1

EXTENSION GP-EXHAUST

 

101

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

1

LINES GP-AFTERCOOLER MUFFLER GP PRECLEANER GP TURBOCHARGER GP

 

AIR

 

.

.

.

.

.

.

.

.

.

.

.

.

102

 

1

 

.

.

.

.

 

.

.

.

.

.

.

.

.

.

.

104

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

2

 

107

 

108

ENGINE ARRANGEMENT

. ENGINE AR-PRIMARY INSTALLATION AR-ENGINE

.

ENGINE

AR

.

.

.

.

.

.

.

.

.

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.

3

3

FUEL SYSTEM BASE GP-FUEL

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

110

 

4

 

FILTER

 

.

.

.

.

.

.

.

.

.

.

110

6

FILTER GP-FUEL

 

.

.

.

.

.

.

.

.

.

.

.

.

.

111

 

LINES

GP-FUEL

 

.

.

.

.

.

.

.

.

.

.

.

.

.

112

BASIC ENGINE CAMSHAFT GP

 

7

PUMP GP-FUEL INJECTION

 

.

.

.

.

.

.

.

116

 

.

.

.

.

.

.

.

.

.

.

.

.

.

7

PUMP GP-FUEL TRANSFER

 

122

COVER

GP-ENGINE

 

.

.

.

.

.

.

.

.

.

.

.

8

GP-WATER

 

.

.

.

.

.

.

.

.

.

128

COVER GP-VALVE MECHANISM

 

9

SEPARATOR TANK & MTG

GP-FUEL

 

.

.

.

.

.

.

.

.

.

.

129

CRANKSHAFT GP

 

13

CYLINDER

BLOCK GP

 

.

.

.

.

.

.

.

.

.

.

17

ELECTRICAL AND STARTING SYSTEM

 

130

CYLINDER

HEAD GP

 

.

.

.

.

.

.

.

.

.

.

.

20

ALARM

GP

 

130

DRAIN GP-ENGINE OIL

 

22

.

ALTERNATOR GP-CHARGING BATTERY & WIRING GP

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

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.

.

.

.

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.

.

.

131

FASTENER

FLYWHEEL

GP-CYLINDER HEAD

GP .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

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.

.

23

24

 

139

141

 

.

.

.

 

.

.

.

.

.

.

.

.

.

.

.

. GEAR GP-FRONT GUARD GP-BELT HOUSING GP-FLYWHEEL HOUSING GP-FRONT

 

25

BATTERY GP CAMERA AR

CONTROL

CONTROL

CONTROL

. GP-COMMUNICATION GP-LIFT KICKOUT GP-POSITION

.

.

.

 

.

.

.

.

.

.

.

.

.

.

.

141

 

.

.

.

.

.

.

.

.

.

.

.

.

26

 

142

 

28

 

.

.

.

.

.

.

.

143

29

 

.

.

.

.

.

.

.

.

.

144

LIFTING GP-ENGINE MOUNTING GP-ALTERNATOR

 

33

CONTROL GP-UNPROGRAMMED CONVERTER GP-ELECTRICAL ELECTRONICS AR-MACHINE ELECTRONICS GP- COMMUNICATION ELECTRONICS GP-MACHINE

 

145

34

 

.

.

.

.

.

.

146

MOUNTING

GP-ENGINE

 

.

.

.

.

.

.

.

.

.

35

 

147

MOUNTING

GP-ENGINE &

TMSN

 

.

.

.

.

.

36

 

.

.

.

.

.

.

.

MOUNTING

GP-FAN DRIVE

 

38

 

147

PAN GP-OIL PISTON & ROD GP

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

39

147

 

.

.

.

.

.

.

.

.

.

.

.

.

45

HEATER GP-JACKET WATER INSTALLATION GP-COMMUNICATION INSTALLATION GP-SECURITY LAMP GP-FLOOD

.

.

.

.

.

.

 

148

PLUG

PLUG

GP-CYLINDER BLOCK GP-ENGINE

 

47

150

 

.

.

.

.

.

.

.

.

.

.

.

.

48

152

PULLEY GP-CRANKSHAFT

 

49

 

.

.

.

.

.

.

.

.

.

.

.

.

154

ROCKER ARM GP VALVE MECHANISM GP

 

.

.

.

.

.

.

.

.

.

.

.

.

50

LAMP GP-HEAD &

 

SIGNAL

 

.

.

.

.

.

.

.

.

155

 

.

.

.

.

.

.

.

.

.

52

LAMP

GP-STOP &

TAIL .

 

.

.

.

.

.

.

.

.

 

.

 

.

.

.

.

.

.

.

.

.

.

159

 

LAMP GP-WARNING BEACON

 

160

LUBRICATION SYSTEM FILTER GP-ENGINE OIL GAUGE GP-OIL LEVEL (DIPSTICK) PUMP GP-ENGINE OIL VALVE GP-FLUID SAMPLING

 

53

LIGHTING

AR-ROADING

 

161

.

.

.

.

.

.

.

.

.

53

LIGHTING GP-AUXILIARY

 

163

 

54

LIGHTING

GP-FLOOD

 

.

.

.

.

.

.

.

.

.

.

164

55

LIGHTING

GP-ROADING

 

168

61

LIGHTING GP-WARNING BEACON MOTOR GP-ELECTRIC MOUNTING GP-CAMERA

 

172

 

174

COOLING SYSTEM CONNECTION GP-WATER

 

62

 

.

.

.

.

.

.

.

.

.

175

62

SENSOR GP-POSITION

 

176

SEBP4156-30

TABLE OF CONTENTS

A1

 

TABLE OF CONTENTS

 

Name

Page

Name

Page

SENSOR

GP-PRESSURE

 

177

STOP GP-AXLE OSCILLATION TIRE & RIM AR TRANSMISSION AR VALVE GP-BYPASS

VALVE

GP-MODULATING

 

323

SENSOR

GP-SPEED

.

.

.

.

.

.

.

.

.

.

.

178

.

.

.

.

.

.

.

.

.

.

.

.

.

.

323

SENSOR

GP-TEMPERATURE

 

180

 

.

.

.

.

.

.

.

.

.

.

.

333

. STARTING MOTOR GP-ELECTRIC

STARTING

GP

AID

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

182

184

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

334

335

SWITCH

GP-DISCONNECT

 

187

VALVE

GP-RELIEF

 

.

.

.

.

.

.

.

.

.

.

.

.

336

SWITCH

GP-MAGNETIC

 

188

VALVE

GP-TIRE

 

.

.

.

.

.

.

.

.

.

.

.

.

.

339

SWITCH

GP-WIPER

.

.

.

.

.

.

.

.

.

.

.

194

VALVE GP-TRANSMISSION

 

WARNING GP-BACKUP

 

196

CONTROL

.

.

.

 

.

.

.

.

.

.

.

.

.

.

.

.

.

340

WIRING

GP-ALTERNATOR

 

197

WIRING

GP-CAB

.

.

.

.

.

.

.

.

.

.

.

.

.

198

FRAME AND

BODY

 

.

.

.

.

.

.

.

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

344

WIRING GP-CAMERA

 

208

BOX GP-BATTERY

 

.

.

.

.

.

.

.

.

.

.

.

.

344

WIRING

GP-COMMUNICATION

 

.

.

.

.

.

.

210

COUNTERWEIGHT GP COVER GP-ACCESS

 

345

WIRING GP-ELECTRONIC CONTROL

 

212

 

.

.

.

.

.

.

.

.

.

.

.

348

WIRING

WIRING

WIRING

WIRING

GP-ENGINE GP-FRONT GP-REAR GP-RIDE CONTROL

 

.

.

.

.

.

.

.

.

.

.

.

214

FENDER

AR-ROADING

 

.

.

.

.

.

.

.

.

.

.

349

.

.

.

.

.

.

.

.

.

.

.

227

FENDER

GP-FRONT

 

.

.

.

.

.

.

.

.

.

.

.

350

.

.

.

.

.

.

.

.

.

.

.

.

229

FENDER

GP-REAR

 

.

.

.

.

.

.

.

.

.

.

.

.

355

 

233

FENDER

GP-ROADING

 

.

.

.

.

.

.

.

.

.

.

357

WIRING GP-SECONDARY STEERING

 

237

FRAME

FRAME

GUARD

GUARD

GUARD

GUARD

GUARD

GUARD

GP-LOADER GP-REAR GP-CRANKCASE GP-DRIVE SHAFT GP-LIGHTING GP-LINES GP-POWER TRAIN GP-RADIATOR

 

.

.

.

.

.

.

.

.

.

.

.

360

 

.

.

.

.

.

.

.

.

.

.

.

.

363

POWER

TRAIN

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

239

 

366

AXLE

AR-FIXED

.

.

.

.

.

.

.

.

.

.

.

.

.

239

 

.

.

.

.

.

.

.

.

367

AXLE AR-OSCILLATING AXLE GP-OSCILLATING BRAKE & PLANETARY GP

 

.

.

.

.

.

.

.

.

.

239

 

368

.

.

.

.

.

.

.

.

.

242

 

.

.

.

.

.

.

.

.

.

.

.

.

370

 

243

 

373

CASE & PARTS GP-TRANSMISSION

 

246

374

CLUTCH GP

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

249

HITCH

HOOD

GP-ARTICULATING & GUARD GP

 

378

COOLER GP-AXLE OIL

 

257

 

.

.

.

.

.

.

.

.

.

.

.

380

COVER

GP-SHIPPING

 

258

LADDER GP LINES GP-GREASE

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

382

COVER GP-TRANSMISSION

 

259

 

384

DIFFERENTIAL

GP .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

261

LINK GP-STEERING FRAME LOCK

 

385

DIFFERENTIAL

. GP-LIMITED SLIP

 

262

PANEL

GP-ACCESS

 

.

.

.

.

.

.

.

.

.

.

.

386

DRIVE GP-FLEXIBLE COUPLING

263

PANEL

GP-TOP

 

.

.

.

.

.

.

 

.

.

.

.

.

.

.

.

.

.

.

.

.

388

DRIVE

FILLER

GP-PUMP GP-POWER TRAIN OIL

.

.

.

.

.

.

.

.

.

.

.

.

.

264

 

265

BRAKING SYSTEM

 

389

FILTER & LINES GP-TRANSMISSION

 

266

ACCUMULATOR GP-BRAKE ACCUMULATOR GP-HYDRAULIC

 

.

.

.

.

.

.

.

389

FILTER

GP-OIL

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

268

 

390

GAUGE GP-SIGHT

.

.

.

.

.

.

.

.

.

.

.

.

269

BRAKE

GP-PARKING

 

.

.

.

.

.

.

.

.

.

.

.

391

GEAR

GP-BEVEL & PINION

 

.

.

.

.

.

.

.

.

270

. CONTROL GP-PARKING BRAKE CONTROL GP-SERVICE BRAKE LINES GP-SERVICE BRAKE

BRAKE

GP

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

392

GEAR

GP-INPUT TRANSFER

 

.

.

.

.

.

.

.

274

 

.

.

.

.

.

393

GEAR

GP-OUTPUT TRANSFER

 

275

.

.

.

.

.

395

HOUSING

GP-FIXED AXLE

 

279

 

403

HOUSING GP-OSCILLATING AXLE

 

281

LINES GP-AXLE OIL COOLER LINES GP-TORQUE CONV COOLER MOUNTING GP-AXLE

 

285

STEERING SYSTEM

 

412

303

CYLINDER

CYLINDER

& MTG GP-STEERING GP-STEERING

 

.

.

.

.

.

412

305

 

413

MOUNTING

GP-RIM

.

.

.

.

.

.

.

.

.

.

.

306

LINES GP-SECONDARY STEERING LINES GP-STEERING

 

414

POWER TRAIN AR

306

439

PUMP

PUMP

RIM

RIM

RIM

& MOTOR GP-AXLE OIL CLR GP-TRANSMISSION . .

.

.

.

.

AR

.

.

.

.

.

.

.

.

.

.

.

.

.

.

AS

GP-DEMOUNTABLE

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

 

307

PUMP

& MOTOR GP

 

.

.

.

.

.

.

.

.

.

.

.

453

 

.

.

.

.

.

.

.

.

308

STEERING

AR

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

454

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

310

312

313

STEERING

STEERING COLUMN GP- ADJUSTABLE

AR-SECONDARY

.

.

.

.

.

.

.

.

.

.

.

.

.

.

454

456

SHAFT GP-DRIVE SLIP JOINT GP

 

319

VALVE

VALVE

& MTG GP-SOLENOID GP-SHUTTLE

 

.

.

.

.

.

.

.

459

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

321

 

.

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.

460

A2

TABLE OF CONTENTS

SEBP4156-30

 

TABLE OF CONTENTS

 

Name

Page

Name

Page

VALVE GP-SOLENOID

461

VALVE

VALVE

& MTG GP-SOLENOID GP-CHECK

 

721

   

.

.

.

.

.

.

.

.

.

.

.

.

723

HYDRAULIC SYSTEM

ACCUMULATOR

ACCUMULATOR GP-RIDE CONTROL