938H Wheel Loader and IT38H Integrated Toolcarrier Hydraulic System Pilot Valve Caterpillar

Pilot Valve (No Joystick)

261-8654 Pilot Valve

Illustration 1	g01391807
Pilot Valve (Two Function)

(1) Tilt valve

(2) Lift valve

Illustration 2	g01391835
Sectional view A-A

(1) 159-3781 Spring

Free length ... 17.46 mm (0.690 inch)

Outside diameter ... 14.28 mm (0.560 inch)

Assembled length ... 7.60 mm (0.300 inch)

Load at assembly ... 24.0 ± 2.0 N (5.4 ± 0.45 lb)

(2) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(3) When you install the handle, hold the hex with a wrench in order to keep the hex from turning.

(4) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(5) Apply an adequate amount of 161-9203 Grease to the moving surfaces.

(6) Torque for the two connectors ... 28 ± 4 N·m (21 ± 3 lb ft)

(7) Torque for the three adapters ... 12 ± 3 N·m (9 ± 2 lb ft)

(8) Torque for the two fittings ... 28 ± 4 N·m (21 ± 3 lb ft)

Illustration 3	g01391822
Sectional view B-B

(1) 159-3781 Spring

Free length ... 17.46 mm (0.690 inch)

Outside diameter ... 14.28 mm (0.560 inch)

Assembled length ... 7.60 mm (0.300 inch)

Load at assembly ... 24.0 ± 2.0 N (5.4 ± 0.45 lb)

(2) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(3) When you install the handle, hold the hex with a wrench in order to keep the hex from turning.

(4) 153-8946 Spring

Free length ... 5.20 mm (0.205 inch)

Outside diameter ... 10.00 mm (0.394 inch)

Assembled length ... 4.00 mm (0.158 inch)

Load at assembly ... 24.00 ± 2.40 N (5.4 ± 0.54 lb)

(5) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(6) Apply an adequate amount of 161-9203 Grease to the moving surfaces.

(7) Torque for the two connectors ... 28 ± 4 N·m (21 ± 3 lb ft)

(8) Torque for the three adapters ... 12 ± 3 N·m (9 ± 2 lb ft)

(9) Torque for the two fittings ... 28 ± 4 N·m (21 ± 3 lb ft)

(10) Torque for the two plugs ... 28 ± 4 N·m (21 ± 3 lb ft)

261-8656 Pilot Valve

Illustration 4	g01391841
Pilot Valve (Three Function)

(1) Tilt valve

(2) Lift valve

(3) Auxiliary valve (if equipped)

Illustration 5	g01392011

(4) 159-3781 Spring

Free length ... 17.46 mm (0.690 inch)

Outside diameter ... 14.28 mm (0.560 inch)

Assembled length ... 7.60 mm (0.300 inch)

Load at assembly ... 24.0 ± 2.0 N (5.4 ± 0.45 lb)

(5) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(6) When you install the handle, hold the hex with a wrench in order to keep the hex from turning.

(7) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(8) Apply an adequate amount of 161-9203 Grease to the moving surfaces.

(9) Torque for the two plugs ... 28 ± 4 N·m (21 ± 3 lb ft)

(10) Torque for the six connectors ... 28 ± 4 N·m (21 ± 3 lb ft)

(11) Torque for the eight adapters ... 12 ± 3 N·m (9 ± 2 lb ft)

Illustration 6	g01392100

(4) 159-3781 Spring

Free length ... 17.46 mm (0.690 inch)

Outside diameter ... 14.28 mm (0.560 inch)

Assembled length ... 7.60 mm (0.300 inch)

Load at assembly ... 24.0 ± 2.0 N (5.4 ± 0.45 lb)

(5) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(6) When you install the handle, hold the hex with a wrench in order to keep the hex from turning.

(7) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(8) Apply an adequate amount of 161-9203 Grease to the moving surfaces.

(9) Torque for the two plugs ... 28 ± 4 N·m (21 ± 3 lb ft)

(12) 153-8946 Spring

Free length ... 5.20 mm (0.205 inch)

Outside diameter ... 10.00 mm (0.394 inch)

Assembled length ... 4.00 mm (0.158 inch)

Load at assembly ... 24.00 ± 2.40 N (5.4 ± 0.54 lb)

(13) Torque for the two fittings ... 28 ± 4 N·m (21 ± 3 lb ft)

Illustration 7	g01392073

(4) 159-3781 Spring

Free length ... 17.46 mm (0.690 inch)

Outside diameter ... 14.28 mm (0.560 inch)

Assembled length ... 7.60 mm (0.300 inch)

Load at assembly ... 24.0 ± 2.0 N (5.4 ± 0.45 lb)

(5) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(6) When you install the handle, hold the hex with a wrench in order to keep the hex from turning.

(7) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(8) Apply an adequate amount of 161-9203 Grease to the moving surfaces.

261-8658 Pilot Valve

Illustration 8	g01392117
Pilot Valve (Four Function)

(1) Tilt valve

(2) Lift valve

(3) Auxiliary valve (if equipped)

(4) Auxiliary valve (if equipped)

Illustration 9	g01392127

(5) 159-3781 Spring

Free length ... 17.46 mm (0.690 inch)

Outside diameter ... 14.28 mm (0.560 inch)

Assembled length ... 7.60 mm (0.300 inch)

Load at assembly ... 24.0 ± 2.0 N (5.4 ± 0.45 lb)

(6) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(7) When you install the handle, hold the hex with a wrench in order to keep the hex from turning.

(8) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(9) Apply an adequate amount of 161-9203 Grease to the moving surfaces.

(10) Torque for the two plugs ... 28 ± 4 N·m (21 ± 3 lb ft)

(11) Torque for the eight connectors ... 28 ± 4 N·m (21 ± 3 lb ft)

(12) Torque for the ten adapters ... 12 ± 3 N·m (9 ± 2 lb ft)

Illustration 10	g01392128

(5) 159-3781 Spring

Free length ... 17.46 mm (0.690 inch)

Outside diameter ... 14.28 mm (0.560 inch)

Assembled length ... 7.60 mm (0.300 inch)

Load at assembly ... 24.0 ± 2.0 N (5.4 ± 0.45 lb)

(6) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(7) When you install the handle, hold the hex with a wrench in order to keep the hex from turning.

(8) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(9) Apply an adequate amount of 161-9203 Grease to the moving surfaces.

(10) Torque for the two plugs ... 28 ± 4 N·m (21 ± 3 lb ft)

(13) 153-8946 Spring

Free length ... 5.20 mm (0.205 inch)

Outside diameter ... 10.00 mm (0.394 inch)

Assembled length ... 4.00 mm (0.158 inch)

Load at assembly ... 24.00 ± 2.40 N (5.4 ± 0.54 lb)

(14) Torque for the two fittings ... 28 ± 4 N·m (21 ± 3 lb ft)

Illustration 11	g01392136

(5) 159-3781 Spring

Free length ... 17.46 mm (0.690 inch)

Outside diameter ... 14.28 mm (0.560 inch)

Assembled length ... 7.60 mm (0.300 inch)

Load at assembly ... 24.0 ± 2.0 N (5.4 ± 0.45 lb)

(6) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(7) When you install the handle, hold the hex with a wrench in order to keep the hex from turning.

(8) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(9) Apply an adequate amount of 161-9203 Grease to the moving surfaces.

262-7181 Pilot Cartridge Valve Group

The cartridge assemblies are being used on the pilot valve.

Illustration 12	g01391524

(1) Torque for the stop ... 6 ± 1.0 N·m (53 ± 9.0 lb in)

(2) Torque for the plug orifice ... 2.5 ± 0.5 N·m (22 ± 4.4 lb in)

(3) Lubricate the O-ring seals with the lubricant that is being sealed.

(4) 157-2152 Spring

Free length ... 40.20 mm (1.583 inch)

Outside diameter ... 16.00 mm (0.630 inch)

Length at assembly ... 25.20 mm (0.990 inch)

Load at assembly ... 12.0 ± 0.8 N (2.700 ± 0.180 lb)

(5) 212-4961 Spring

Free length ... 27.24 mm (1.072 inch)

Outside diameter ... 7.50 mm (0.295 inch)

Length at assembly ... 23.90 mm (0.941 inch)

Load at assembly ... 14.25 ± .72 N (3.204 ± 0.162 lb)

(6) Torque for the cage ... 15 ± 2.0 N·m (11 ± 1.5 lb ft)

(7) 153-8926 Spring

Free length ... 10.58 mm (0.417 inch)

Outside diameter ... 4.20 mm (0.165 inch)

Length at assembly ... 8.00 mm (0.315 inch)

Load at assembly ... 3.7 ± 0.2 N (0.832 ± 0.045 lb)

262-7182 Pilot Cartridge Valve Group

The cartridge assemblies are being used on the pilot valve.

Illustration 13	g01391524

(1) Torque for the stop ... 6 ± 1.0 N·m (53 ± 9.0 lb in)

(2) Torque for the plug orifice ... 2.5 ± 0.5 N·m (22 ± 4.4 lb in)

(3) Lubricate the O-ring seals with the lubricant that is being sealed.

(4) 157-2152 Spring

Free length ... 40.20 mm (1.583 inch)

Outside diameter ... 16.00 mm (0.630 inch)

Length at assembly ... 25.20 mm (0.990 inch)

Load at assembly ... 12.0 ± 0.8 N (2.700 ± 0.180 lb)

(5) 212-4961 Spring

Free length ... 27.24 mm (1.072 inch)

Outside diameter ... 7.50 mm (0.295 inch)

Length at assembly ... 23.90 mm (0.941 inch)

Load at assembly ... 14.25 ± .72 N (3.204 ± 0.162 lb)

(6) Torque for the cage ... 15 ± 2.0 N·m (11 ± 1.5 lb ft)

(7) 153-8926 Spring

Free length ... 10.58 mm (0.417 inch)

Outside diameter ... 4.20 mm (0.165 inch)

Length at assembly ... 8.00 mm (0.315 inch)

Load at assembly ... 3.7 ± 0.2 N (0.832 ± 0.045 lb)

Pilot Valve (Joystick)

261-8653 Pilot Valve

Illustration 14	g01392159

(1) Torque for the four connectors ... 28 ± 4 N·m (21 ± 3 lb ft)

(2) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(3) Torque for the swivel assembly ... 45 ± 5 N·m (33 ± 4 lb ft)

(4) Torque for the spacer ... 45 ± 5 N·m (33 ± 4 lb ft)

(5) Torque for the two fittings ... 28 ± 4 N·m (21 ± 3 lb ft)

(6) Torque for the six adapters ... 12 ± 3 N·m (9 ± 2 lb ft)

Note: Do not install the pilot lines at a torque that is greater than 50 N·m (37 lb ft). Also, hold the adapter with a wrench.

261-8655 Pilot Valve

Illustration 15	g01392162

Illustration 16	g01444869

(1) Torque for the four connectors ... 28 ± 4 N·m (21 ± 3 lb ft)

(2) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(3) Torque for the spacer ... 45 ± 5 N·m (33 ± 4 lb ft)

(4) Torque for the swivel assembly ... 45 ± 5 N·m (33 ± 4 lb ft)

(5) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(6) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(7) Torque for the two plug assemblies ... 28 ± 4 N·m (21 ± 3 lb ft)

(8) Torque for the two fittings ... 28 ± 4 N·m (21 ± 3 lb ft)

(9) Torque for the eight adapters ... 12 ± 3 N·m (9 ± 2 lb ft)

Note: Do not install the pilot lines at a torque that is greater than 50 N·m (37 lb ft). Also, hold the adapter with a wrench.

261-8657 Pilot Valve

Illustration 17	g01444876

Illustration 18	g01392164

(1) Torque for the four connectors ... 28 ± 4 N·m (21 ± 3 lb ft)

(2) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(3) Torque for the spacer ... 45 ± 5 N·m (33 ± 4 lb ft)

(4) Torque for the swivel assembly ... 45 ± 5 N·m (33 ± 4 lb ft)

(5) Apply sealant to the threads and tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(6) Torque for the adapter ... 45 ± 5 N·m (33 ± 4 lb ft)

(7) Torque for the two plug assemblies ... 28 ± 4 N·m (21 ± 3 lb ft)

(8) Torque for the eight adapters ... 12 ± 3 N·m (105 ± 25 lb in)

(9) Torque for the two fittings ... 28 ± 4 N·m (21 ± 3 lb ft)

Note: Do not install the pilot lines at a torque that is greater than 50 N·m (37 lb ft). Also, hold the adapter with a wrench.

212-4962 Pilot Cartridge Valve Group

Illustration 19	g01391524

(1) Torque for the stop ... 6 ± 1.0 N·m (53 ± 9.0 lb in)

(2) Torque for the plug orifice ... 2.5 ± 0.5 N·m (22 ± 4.4 lb in)

(3) Lubricate the O-ring seals with the lubricant that is being sealed.

(4) 157-2152 Spring

Free length ... 40.20 mm (1.583 inch)

Outside diameter ... 16.00 mm (0.630 inch)

Length at assembly ... 25.20 mm (0.990 inch)

Load at assembly ... 12.0 ± 0.8 N (2.700 ± 0.180 lb)

(5) 212-4961 Spring

Free length ... 27.24 mm (1.072 inch)

Outside diameter ... 7.50 mm (0.295 inch)

Length at assembly ... 23.90 mm (0.941 inch)

Load at assembly ... 14.25 ± .72 N (3.204 ± 0.162 lb)

(6) Torque for the cage ... 15 ± 2.0 N·m (11 ± 1.5 lb ft)

(7) 153-8926 Spring

Free length ... 10.58 mm (0.417 inch)

Outside diameter ... 4.20 mm (0.165 inch)

Length at assembly ... 8.00 mm (0.315 inch)

Load at assembly ... 3.7 ± 0.2 N (0.832 ± 0.045 lb)

212-4963 Pilot Cartridge Valve Group

Illustration 20	g01391524

(1) Torque for the stop ... 6 ± 1.0 N·m (53 ± 9.0 lb in)

(2) Torque for the plug orifice ... 2.5 ± 0.5 N·m (22 ± 4.4 lb in)

(3) Lubricate the O-ring seals with the lubricant that is being sealed.

(4) 157-2153 Spring

Free length ... 59.49 mm (2.342 inch)

Outside diameter ... 16.00 mm (0.630 inch)

Length at assembly ... 25.20 mm (0.990 inch)

Load at assembly ... 24 ± 1.7 N (5.395 ± 0.382 lb)

(5) 212-4961 Spring

Free length ... 27.24 mm (1.072 inch)

Outside diameter ... 7.50 mm (0.295 inch)

Length at assembly ... 23.90 mm (0.941 inch)

Load at assembly ... 14.25 ± .72 N (3.204 ± 0.162 lb)

(6) Torque for the cage ... 15 ± 2.0 N·m (11 ± 1.5 lb ft)

(7) 153-8926 Spring

Free length ... 10.58 mm (0.417 inch)

Outside diameter ... 4.20 mm (0.165 inch)

Length at assembly ... 8 mm (0.315 inch)

Load at assembly ... 3.7 ± 0.2 N (0.832 ± 0.045 lb)

262-7181 Pilot Cartridge Valve Group

The cartridge assemblies are being used on the pilot valve.

Illustration 21	g01391524

(1) Torque for the stop ... 6 ± 1.0 N·m (53 ± 9.0 lb in)

(2) Torque for the plug orifice ... 2.5 ± 0.5 N·m (22 ± 4.4 lb in)

(3) Lubricate the O-ring seals with the lubricant that is being sealed.

(4) 157-2152 Spring

Free length ... 40.20 mm (1.583 inch)

Outside diameter ... 16.00 mm (0.630 inch)

Length at assembly ... 25.20 mm (0.990 inch)

Load at assembly ... 12.0 ± 0.8 N (2.700 ± 0.180 lb)

(5) 212-4961 Spring

Free length ... 27.24 mm (1.072 inch)

Outside diameter ... 7.50 mm (0.295 inch)

Length at assembly ... 23.90 mm (0.941 inch)

Load at assembly ... 14.25 ± .72 N (3.204 ± 0.162 lb)

(6) Torque for the cage ... 15 ± 2.0 N·m (11 ± 1.5 lb ft)

(7) 153-8926 Spring

Free length ... 10.58 mm (0.417 inch)

Outside diameter ... 4.20 mm (0.165 inch)

Length at assembly ... 8.00 mm (0.315 inch)

Load at assembly ... 3.7 ± 0.2 N (0.832 ± 0.045 lb)