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

Loader Frame and Rear Frame - Connect

938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems [RENR6081]

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FRAME AND BODY

FRAME GP

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

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

1.1. Connection Procedure

Connection Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A⁽¹⁾	9U-7536	Lift Stand	2
	447-0910	Electric Hydraulic Pump (115 V)	1
	447-0911	Electric Hydraulic Pump (230 V)	1
A1	OR
	504-9826	Lift Gp (50/60 Hz)⁽²⁾	2
	504-9827	Lift Gp (50/60 Hz)⁽³⁾	2
B	439-5575	Hydraulic Jack	2
C	439-5575	Hydraulic Jack	1
H	1P-0491	Drive Plate	1
	1P-0492	Drive Plate	1
	8S-4711	Bolt	1
	9S-8750	Nut	1
	5P-0537	Hard Washer	2
J	1P-0520	Driver Gp	1
K	9S-8750	Nut	1
	5P-0537	Hard Washer	2
	1P-0484	Drive Plate	1
	1P-0485	Drive Plate	1
	7X-0268	Bolt	1
L	1P-0510	Driver Group	1
M	5P-3931	Anti-Seize Compound	1

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⁽¹⁾	Use Tooling (A) or (A1) based on requirements.
⁽²⁾	Operating-voltage (380-500V)
⁽³⁾	Operating-voltage (180-300V)

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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.

Note: Apply Tooling (M) to all bores when you connect the frames. Lubricate all pin bores, all seals, and all pins with clean grease before installation.

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Illustration 1	g00984107

Position lower cap (55) on the upper frame. Hold the lower cap in place with bolts (53). Make sure that the lower cap is seated firmly against the upper frame.
Lower the temperature of lower bearing cup (61) to −75° ± 5°C (−103° ± 9°F). Install lower bearing cup (61) so that the cup contacts lower cap (55). Use insulated gloves to handle the bearing cup.
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Illustration 2 g00984024
Lubricate the lower bearing cone and upper bearing cone (60) with clean oil. Install the bearing cones in the correct bores in the frame.
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Illustration 3 g00984023
Lower the temperature of upper bearing cup (59) to −75° ± 5°C (−103° ± 9°F). Install upper bearing cup (59) so that the cup contacts upper bearing cone (60). Use insulated gloves to handle the bearing cup.
Remove bolts (53) and lower cap (55).
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Illustration 4 g00984242
Install Tooling (H) on the lower bearing cone and on upper bearing cone (60).
Install lower cap (55), the shims, and upper cap (54) in the upper frame.
Install three of bolts (53) so that each bolt is separated by 120 degrees. Tighten the bolts.
Use a torque wrench and Tooling (H) to determine the amount of torque that is needed to turn upper bearing cone (60). As required, adjust the number of shims to achieve a rolling torque between 3 N·m (2 lb ft) and 14 N·m (10 lb ft).
Remove bearing caps (54) and (55). Remove Tooling (H).
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Illustration 5 g00984014
Use Tooling (J) to install lip seal (57) in upper cap (54) so that the seal contacts the counterbore in the upper cap. Make sure that the sealing lip is facing inside the upper cap.
Use Tooling (J) to install lip seal (58) in lower cap (55) so that the seal contacts the counterbore in the lower cap. Make sure that the sealing lip is facing toward the outside of the lower cap.
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Illustration 6 g00984011
Install spacer (56) in lower cap (55).
Install the proper number of shims. Install upper cap (54), lower cap (55), and bolts (53).
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Illustration 7 g00984115
Install lower cap (48) and bolts (46). Make sure that the lower cap is seated firmly against the lower frame.
Lower the temperature of lower bearing cup (62) to −75° ± 5°C (−103° ± 9°F). Install lower bearing cup (62) so that the cup contacts lower cap (48). Use insulated gloves to handle the bearing cup.
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Illustration 8 g00983996
Lubricate the lower bearing cone and upper bearing cone (52) with clean oil. Install the bearing cones in the correct bores in the frame.
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Illustration 9 g00983982
Lower the temperature of upper bearing cup (51) to −75° ± 5°C (−103° ± 9°F). Install upper bearing cup (51) so that the cup contacts upper bearing cone (52). Use insulated gloves to handle the bearing cup.
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Illustration 10 g00984122
Install Tooling (K) on upper bearing cone (52).
Install lower cap (48), the shims, and upper cap (47) in the lower frame.
Install three of bolts (46) so that each bolt is separated by 120 degrees. Tighten the bolts.
Use a torque wrench and Tooling (K) to determine the amount of torque that is needed to turn upper bearing cone (52). As required, adjust the number of shims to achieve a rolling torque between 0.5 N·m (4.4 lb in) and 2.5 N·m (22 lb in).
Remove bearing caps (47) and (48). Remove Tooling (K).
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Illustration 11 g00983976
Use Tooling (L) to install lip seal (49) in upper cap (47) so that the seal contacts the counterbore in the upper cap. Make sure that the sealing lip is facing toward the outside of the upper cap.
Use Tooling (L) to install lip seal (50) in lower cap (48) so that the seal contacts the counterbore in the lower cap. Make sure that the sealing lip is facing inside the lower cap.
Install the proper number of shims. Install upper cap (47), lower cap (48), and bolts (46).
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Illustration 12 g00983917
Fasten a suitable lifting device to the rear of the front frame, as shown. The weight of the front frame is approximately 2043 kg (4500 lb).
Use the lifting device and a lift truck to connect the frames. Use Tooling (A), Tooling (B), and the lifting device to align the pin bores.
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Illustration 13 g00984204
Install pin (43) in the aligned bores of the upper hitch.
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Illustration 14 g00983937
Install plate (44) and two bolts (45) at the bottom of pin (43). Tighten the bolts.
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Illustration 15 g00984209
Use a thickness feeler gauge to measure the gap between pin (43) and the surface of the upper boss, as shown. Record the measurement.
Remove bolts (45) and plate (44).
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Illustration 16 g00283521

Shim Pack
Tap pin (43) upward. Install shims under the plate of pin (43). Refer to the measurement that was obtained in Step 31.
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Illustration 17 g00983918

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Illustration 18 g00983937
Push pin (43) downward and install bolts (41).
Install plate (44) and bolts (45). Tighten bolts (41) and (45). Install bolt (42).
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Illustration 19 g00984221

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Illustration 20 g00983936

For Tooling (A)

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Illustration 21 g06395855

Typical example
For Tooling (A1)
Install pin (40) in the aligned bores of the lower hitch. Install bolt (39).
Remove Tooling (A) or (A1), Tooling (B), the wood blocks, and the hoist. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (A1).
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Illustration 22 g00983914
Install pin (38) and bolt (37) into the rod end of both steering cylinders.
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Illustration 23 g00983897
Position hose assemblies (33) and (34). Install the clamp and install bolts (36).
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Illustration 24 g00983896
Install the clamps and bolts (35).
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Illustration 25 g00983895
Connect hose assemblies (33) and (34).
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Illustration 26 g00983894
Install the clamp and bolts (32). Connect hose assembly (31).
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Illustration 27 g00983893
Connect hose assemblies (29) and (30).
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Illustration 28 g00983892
Position harness assembly (24) and hose assemblies (26) and (27). Install the clamps and bolts (28).
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Illustration 29 g00983891
Connect hose assemblies (26) and (27).
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Illustration 30 g00983890
Install the clamp and bolt (23) onto harness assembly (24). Connect harness assembly (25).
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Illustration 31 g00983889
Install the clamps and bolts (21) onto harness assembly (22).
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Illustration 32 g00983888
Position cover (19) and install nuts (20).
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Illustration 33 g00983887
Install the clamps and bolts (18).
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Illustration 34 g00983886
Install cover (16). Connect harness assembly (17).
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Illustration 35 g00983885
Install bolts (15) into cover (16).
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Illustration 36 g00983883
Install the clamp and bolt (13). Install a new cable strap (14).
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Illustration 37 g00983882
Install the clamp and bolt (12). Connect harness assemblies (10) and (11).
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Illustration 38 g00983881
Install the clamp and bolt (9). Install a new cable strap (8).
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Illustration 39 g00983879
Install the clamps and bolts (5). Connect harness assemblies (3), (4), (6), and (7).
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Illustration 40 g00983877
Connect hose assemblies (1) and (2). Connect harness assembly (3).
Fill the hydraulic tank with oil. Refer to Operation and Maintenance Manual, "Capacities (Refill)" .