938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Tilt 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".

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

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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 marks on all lines and on all hoses for installation purposes. Plug all lines and all hoses. This will help to prevent fluid loss and this will help to keep contaminants from entering the system.

1. Drain the oil from the hydraulic tank. The tank capacity is 55 L (14.5 US gal).
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   Illustration 1	g00275530

2. Disconnect grease line (3) from fitting (2).

3. Remove fitting (2) from the pin assembly.

4. Remove bolts (1) and clamps.

5. Remove bolts (4). Disconnect bucket positioner (5) from the tilt cylinder.
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   Illustration 2	g00275531

6. Disconnect hose assembly (6) from the tilt cylinder.

7. Remove allen head screws (7).

8. Loosen the bolts. Unscrew magnet assembly (8).
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   Illustration 3	g00275532

9. Disconnect hose assembly (9) from the cylinder.
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   Illustration 4	g00275533

10. Remove bolt (10), the washer and the spacer that holds pin assembly (11).
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    Illustration 5	g00275534

11. Install Tooling (A) and fasten a suitable lifting device to Tooling (A), as shown. Fasten a suitable lifting device to tilt cylinder (14). Remove pin assembly (11) that connects the tilt cylinder to the tilt lever.

12. Remove bolt (13) from rear pin assembly (12).
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    Illustration 6	g00275535

13. Fasten a suitable lifting device and Tooling (B) to rear pin assembly (12), as shown. Remove rear pin assembly (12).

14. Remove tilt cylinder (14) from the machine. The weight of the tilt cylinder is approximately 136 kg (300 lb).

Disassembly and Assembly Information

Illustration 7	g00911196

(1) Lubricate the threads of the nut with clean grease prior to assembly. Torque for the nut ... 3100 ± 310 N·m (2280 ± 230 lb ft)

(2) Outside diameter of a new piston ... 139.20 ± 0.05 mm (5.4803 ± 0.0020 inch)

(3) Bore diameter of a new cylinder tube ... 139.75 ± 0.10 mm (5.502 ± .004 inch)

(4) Diameter of a new cylinder rod ... 69.80 ± 0.038 mm (2.7480 ± .0015 inch)

(5) Bore diameter of a new cylinder head ... 70.13 ± 0.03 mm (2.7610 ± 0.0012 inch)

(6) Torque for the bolts ... 900 ± 100 N·m (660 ± 75 lb ft)

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

(8) Apply Tooling (C) to the seal groove prior to assembly.

Pin to pin length with a retracted cylinder ... 1106 mm (43.5 inch)

Cylinder stroke ... 527 mm (20.75 inch)

Pin diameter for the rod eye ... 70 mm (2.756 inch)

Pin diameter for the trunnion end ... 76.2 mm (3.00 inch)

Installation Procedure

1. Lubricate the bores and the pins with Tooling (D) prior to installation.
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   Illustration 8	g00275672

2. Install tilt cylinder (14). The weight of the tilt cylinder is approximately 136 kg (300 lb).

3. Install rear pin assembly (12) and bolt (13).
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   Illustration 9	g00275533

4. Install pin assembly (11), the spacer, the washer, and bolt (10).
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   Illustration 10	g00275532

5. Connect hose assembly (9) to the cylinder.
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   Illustration 11	g00275531

6. Screw magnet assembly (8) inward. Tighten the bolts.

7. Install allen head screws (7).

8. Connect hose assembly (6) to the tilt cylinder.
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   Illustration 12	g00275530

9. Connect bucket positioner (5) to the tilt cylinder. Install bolts (4). The torque for bolts (4) is 900 ± 100 N·m (660 ± 74 lb ft).

10. Install clamps and bolts (1).

11. Install fitting (2) in the pin assembly.

12. Connect grease line (3) to fitting (2).

End By:

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