938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Lift Cylinder - Remove and Install Caterpillar

Removal Procedure

Start By:

1. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

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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.

Note: Put identification on all lines and on all tubes for installation purposes. Plug all lines and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

1. Apply the parking brake.
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   Illustration 1	g00275553

2. Use the machine's hydraulics to put the lift arms in position on Tooling (A), as shown. Position wood blocks under the bucket, as shown.

3. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".

4. Drain the oil from the hydraulic tank into a suitable container. The tank capacity is 55 L (14.5 US gal).
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   Illustration 2	g00275554

5. Fasten a suitable lifting device onto lift cylinder (1), as shown.

6. Remove grease fitting (2) from pin assembly (4).

7. Remove bolt (3), the washer, and the spacer from pin assembly (4).
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   Illustration 3	g00275555

8. Install Tooling (B) on pin (4). Fasten a suitable lifting device onto Tooling (B). Tooling (B) will not fall when the pin assembly is removed.

9. Use Tooling (B) to remove pin assembly (4) which connects the lift cylinder to the lift arm.
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   Illustration 4	g00985387

10. Lower cylinder (1) onto the cribbing.
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    Illustration 5	g00985388

11. Remove bolts (5). Disconnect clip (7) from elbow (6).

12. Disconnect elbow (6) from the lift cylinder.
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    Illustration 6	g00985389

13. Disconnect tube assembly (8) from the lift cylinder.
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    Illustration 7	g00275557

14. Remove grease fitting (10) from pin assembly (11).

15. Remove bolt (9), the washer and the spacer from pin assembly (11).
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    Illustration 8	g00985391

16. Fasten two suitable lifting devices to each end of the lift cylinder.
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    Illustration 9	g00275558

17. Use Tooling (C) to remove pin assembly (11) which connects the lift cylinder to the loader frame.

18. Remove the lift cylinder from the machine. The weight of the lift cylinder is approximately 109 kg (240 lb).
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    Illustration 10	g00275559

19. Remove lip seal (12) from the bore in the lift arm.
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    Illustration 11	g00275560

20. Use Tooling (D) to remove the sleeve bearing from the pin bore of the lift arm.

Disassembly and Assembly Information

Illustration 12	g00985620

(1) Lubricate the threads of the bolt with clean grease. Use Tooling (E) in order to tighten the bolt to the following torque. ... 3100 ± 350 N·m (2280 ± 260 lb ft)

(2) Lubricate the threads of the head with clean grease prior to assembly. Tighten the head to the following torque. ... 600 ± 130 N·m (440 ± 95 lb ft)

(3) Lubricate the sealing lips with a minimal amount of the lubricant that is being sealed.

(4) ApplyTooling (F) to the seal groove prior to assembly.

Pin to pin length with a retracted cylinder ... 1187 mm (46.7 inch)

Cylinder stroke ... 693 mm (27.3 inch)

Installation Procedure

1. Lower the temperature of the bearings before installation. Use insulated gloves to handle the bearings.
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   Illustration 13	g00275560

2. Use Tooling (D) and install the sleeve bearing into the pin bore of the lift arm.
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   Illustration 14	g00275559

3. Use Tooling (G) to install lip seal (12) in the bore of the lift arm. Make sure that the lip of the seal is facing toward the outside of the bore. Lubricate the seal lip lightly with Tooling (H).
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   Illustration 15	g00985391

4. Fasten two suitable lifting devices to lift cylinder (1). Use the hoist to position the lift cylinder on the machine.
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   Illustration 16	g00275557

5. Put Tooling (H) in the bore of the cylinder and on the pin. Install pin assembly (11) in the loader frame and in the lift cylinder.

6. Install the spacer, the washer, and bolt (9) which holds the pin assembly in place.

7. Install grease fitting (10) in pin assembly (11).
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   Illustration 17	g00985389

8. Connect tube assembly (8) onto the lift cylinder.
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   Illustration 18	g00985388

9. Install elbow (6) in position on the lift cylinder.

10. Install bolts (5) that connect clip (7) to elbow (6).
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    Illustration 19	g00275554

11. Install pin assembly (4) which holds the lift cylinder rod end to the lift arm.

12. Install the spacers, the washer, and bolt (3) which holds pin assembly (4).

13. Install grease fitting (2) in pin assembly (4).

14. Fill the pin bores of the lift cylinder with Tooling (H).

15. Fill the hydraulic tank with oil. Refer to Operation and Maintenance Manual, "Lubricant Viscosities" and Operation and Maintenance Manual, "Capacities (Refill)".
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    Illustration 20	g00275553

16. Raise the lift arm. Remove Tooling (A).

End By:

1. Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".