938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Loader Frame and Rear Frame - Separate Caterpillar


Loader Frame and Rear Frame - Separate
`
1.1. Separation Procedure

Separation Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
A(1)  9U-7536  Lift Stand 
447-0910 Electric Hydraulic Pump (115 V) 
447-0911 Electric Hydraulic Pump (230 V) 
A1  OR 
504-9826 Lift Gp (50/60 Hz)(2) 
504-9827 Lift Gp (50/60 Hz)(3) 
439-5575  Hydraulic Jack 
439-5575  Hydraulic Jack 
6V-3160  Double Acting Cylinder 
6V-2098 Press Sleeve 
5P-4776 Tool Stud 
1P-0543 Nut 
1P-1834 Bearing Puller Adapter 
6V-3160  Double Acting Cylinder 
6V-2098 Press Sleeve 
5P-4776 Tool Stud 
1P-0543 Nut 
8S-6587 Adapter 
1P-1838 Bearing Puller Adapter 
6V-3160  Double Acting Cylinder 
5P-4776 Tool Stud 
1P-0543 Nut 
8S-6587 Adapter 
6V-2097 Sleeve 
1P-1835 Bearing Puller Adapter 
6V-3160  Double Acting Cylinder 
5P-4776 Tool Stud 
1P-0543 Nut 
8S-6587 Adapter 
6V-2097 Sleeve 
1P-1841 Puller Adapter 
(1) Use Tooling (A) or (A1) based on requirements.
(2) Operating-voltage (380-500V)
(3) Operating-voltage (180-300V)

Start By:

  1. Remove the cab.

  2. Remove the center drive shaft.

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

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.


------ 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.



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.


  1. Drain the oil from the hydraulic tank. The tank capacity is 55 L (14.3 US gal).


    Illustration 1g00983877

  2. Disconnect harness assembly (3). Disconnect hose assemblies (1) and (2).


    Illustration 2g00983879

  3. Disconnect harness assemblies (3), (4), (6), and (7). Remove bolts (5) and the clamps.


    Illustration 3g00983881

  4. Cut and remove cable strap (8). Remove bolt (9) and the clamp.


    Illustration 4g00983882

  5. Disconnect harness assemblies (10) and (11). Remove bolt (12) and the clamp.


    Illustration 5g00983883

  6. Remove bolt (13) and the clamp. Cut and remove cable strap (14).


    Illustration 6g00983885

  7. Remove bolts (15) from cover (16).


    Illustration 7g00983886

  8. Disconnect harness assembly (17). Remove cover (16).


    Illustration 8g00983887

  9. Remove bolts (18) and the clamps.


    Illustration 9g00983888

  10. Remove nuts (20) and remove cover (19).


    Illustration 10g00983889

  11. Remove bolts (21) and the clamps from harness assembly (22).


    Illustration 11g00983890

  12. Disconnect harness assembly (25). Remove bolt (23) and the clamp from harness assembly (24).


    Illustration 12g00983891

  13. Disconnect hose assemblies (26) and (27).


    Illustration 13g00983892

  14. Remove bolts (28) and the clamps. Move hose assemblies (26) and (27) and harness assembly (24) out of the way.


    Illustration 14g00983893

  15. Disconnect hose assemblies (29) and (30).


    Illustration 15g00983894

  16. Disconnect hose assembly (31). Remove bolts (32) and the clamp.


    Illustration 16g00983895

  17. Disconnect hose assemblies (33) and (34).


    Illustration 17g00983896

  18. Remove bolts (35) and the clamps.


    Illustration 18g00983897

  19. Remove bolts (36) and the clamp from hose assemblies (33) and (34).


    Illustration 19g00983914

  20. Remove bolt (37) and pin (38) from the rod end of both steering cylinders.

  21. Put blocks in the front and behind the rear wheels.


    Illustration 20g00983936
    For Tooling (A)

  22. Position Tooling (A) under the rear frame, as shown.


    Illustration 21g06395855
    Typical example
    For Tooling (A1)

  23. Position Tooling (A1) under the rear frame, as shown. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (A1).


    Illustration 22g00983915

  24. Position Tooling (B) under the front of the rear frame, as shown. Support the front of the rear frame with a wood block, as shown.


    Illustration 23g00983916

  25. Remove bolt (39) from pin (40) in the lower hitch.


    Illustration 24g00983917

  26. Fasten a suitable lifting device onto the front frame. The weight of the front frame is approximately 2043 kg (4500 lb).

    Note: Use the lifting device to relieve pressure from the lower hitch pin during removal.



    Illustration 25g00983919

  27. If necessary, use Tooling (C) to remove pin (40) from the lower hitch.


    Illustration 26g00983918

  28. Remove bolts (41) from pin (43) in the upper hitch. Remove bolt (42).


    Illustration 27g00983937

  29. Remove bolts (45) and plate (44) from the bottom of pin (43) in the upper hitch.


    Illustration 28g00983940


    Illustration 29g00283521
    Shim Pack

    Note: Use the lifting device to relieve pressure from the upper hitch pin during removal.

  30. Use Tooling (C) to remove pin (43) and the shim pack from the upper hitch.


    Illustration 30g00983946

  31. Use a lift truck and the lifting device to separate the front frame from the rear frame. The weight of the front frame is approximately 2043 kg (4500 lb).


    Illustration 31g00983947

  32. Position wood blocks under the front frame, as shown.


    Illustration 32g00983949

  33. Remove bolts (46), upper cap (47), lower cap (48), and the shims from the lower frame.


    Illustration 33g00983976

  34. Remove lip seals (49) and (50) from upper cap (47) and from lower cap (48).


    Illustration 34g00983978

  35. Install Tooling (D) against the inner race of the lower bearing. Use Tooling (D) to pull the bearings until the upper bearing cup is out of the bore in the frame.


    Illustration 35g00983982

  36. Remove bearing cup (51).


    Illustration 36g00983996

  37. Remove upper bearing (52) and the lower bearing from the bore in the frame.


    Illustration 37g00983997

  38. Use Tooling (E) to remove the lower bearing cup.


    Illustration 38g00983999

  39. Remove bolts (53), upper cap (54), lower cap (55), and the shims from the upper frame.


    Illustration 39g00984011

  40. Remove spacer (56) from lower cap (55).


    Illustration 40g00984014

  41. Remove lip seals (57) and (58) from upper cap (54) and from lower cap (55).


    Illustration 41g00984018

  42. Install Tooling (F) against the cup of the lower bearing. Use Tooling (F) to pull the bearings until the upper bearing cup is out of the bore in the frame.


    Illustration 42g00984023

  43. Remove upper bearing cup (59).


    Illustration 43g00984024

  44. Remove upper bearing (60) and the lower bearing from the bore in the frame.


    Illustration 44g00984026

  45. Use Tooling (G) to remove the lower bearing cup.

Information System:

Ejector Supplement for the AD55 Underground Articulated Truck{7000}
D6N Track-Type Tractor Machine Systems Fuel Tank - Install
D6N Track-Type Tractor Machine Systems Fuel Tank - Remove
D6N Track-Type Tractor Machine Systems Seat - Remove and Install
TH560B Telehandler Longitudinal Stability Indicator - Test
D6N Track-Type Tractor Machine Systems Hydraulic Tank - Remove and Install
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Cab - Install
953C Track-Type Loader Power Train Location of Power Train Components
Procedure for Converting the 815F Radiator Mounting Brackets to the Upgraded 815F Tier II Design{1353, 1374}
938G II Wheel Loader and IT38G II Integrated Toolcarrier Cooling System Coolant Extender (ELC) - Add
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Cab - Remove
C4.4 Industrial Engine Piston Ring Groove - Inspect
TH350B, TH360B, TH460B and TH560B Telehandlers Engine Supplement Engine - Remove
TH210 and TH215 Telehandlers Machine Systems Hitch Cylinder - Remove and Install
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Secondary Steering Pump and Electric Motor - Remove and Install
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Piston and Vane Pump (Steering and Implement) - Remove
2003/04/01 New Flash File Software Is Used for Product Link 151/201 {7620}
3034 Engine for Caterpillar Built Machines Pistons and Connecting Rods - Install - Fractured Connecting Rod
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Piston and Vane Pump (Steering and Implement) - Install
3500B and 3500C Marine Engines Camshaft
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Vane Pump (Braking) - Remove
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Loader Frame and Rear Frame - Connect
D6N Track-Type Tractor Machine Systems Bulldozer Angle Cylinder (VPAT) - Remove and Install
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Piston Pump (Hydraulic Fan) - Remove