938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Hydraulic Tank - Remove Caterpillar


Hydraulic Tank - Remove
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1.1. Removal Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
138-7575  Link Bracket 
ZZ  6V-9512  Face Seal Plug 
6V-9833 Cap As 
6V-9511 Face Seal Plug 
6V-9832 Cap As 
6V-9509 Face Seal Plug 
6V-9830 Cap As 
6V-9508 Face Seal Plug 
6V-9829 Cap As 
9U-7091 Tapered Cap/Plug 
9U-7082 Tapered Cap/Plug 
9U-7080 Tapered Cap/Plug 

Start By:

  1. Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install".

  2. Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.

Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

Personal injury can result from contact with refrigerant.

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 precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.

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.

Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.


------ WARNING! ------

At operating temperature, the hydraulic tank is hot and under pressure.

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.


  1. Recover the air conditioner refrigerant from the air conditioner system. The correct charge is 1.5 kg (3.3 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the tools.

  2. Drain the hydraulic oil. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change". Refer to Operation and Maintenance Manual, "Capacities (Refill)".


    Illustration 1g00980885

  3. Install Tooling (A) and a suitable lifting device. The weight of hood support (3) is approximately 50 kg (110 lb). Remove bolts (1) and cap (2) from hood support (3).


    Illustration 2g00980888

  4. Remove bolts (4) on each side of the machine. Remove hood support (3). The weight of hood support (3) is approximately 50 kg (110 lb).


    Illustration 3g00980924

  5. Disconnect harness assembly (5).


    Illustration 4g00980925

  6. Remove clamps (6) and (7).


    Illustration 5g00980926

  7. Remove bolts (8). Remove clamps (9) and (11). Remove bolts (12) and muffler support (10).


    Illustration 6g00980928

  8. Disconnect harness assembly (13).


    Illustration 7g00980939

  9. Remove nut (14).


    Illustration 8g00980996

  10. Remove clamps (17) and (18). Move harness assembly (16) out of the way.


    Illustration 9g00981001

  11. Disconnect hose assembly (19). Remove bolts (20). Remove clamp (21).


    Illustration 10g00981007

  12. Rotate elbow (22) out of the way.


    Illustration 11g00981029

  13. Disconnect hose assembly (23). Remove bolts (24). Move the bracket and accumulator (25) out of the way.


    Illustration 12g00981031

  14. Disconnect harness assembly (26) and move harness assembly (26) out of the way.


    Illustration 13g00981036

  15. Rotate plate assembly (27) and remove plate assembly (27).


    Illustration 14g00981038

  16. Disconnect tube assemblies (28) and (29). Disconnect hose assemblies (30) and (31).


    Illustration 15g00981078

  17. Disconnect tube assembly (32) and hose assembly (33).


    Illustration 16g00981083

  18. Disconnect tube assembly (39). Disconnect fitting (38). Disconnect hose assemblies (34), (35), (36), and (37).


    Illustration 17g00981087

  19. Attach Tooling (A) and a suitable lifting device onto hydraulic tank (40). Remove bolts (41) and remove hydraulic tank (40). The weight of hydraulic tank (40) is approximately 113 kg (250 lb).

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