938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Hydraulic System Pilot Valve (Joystick) Caterpillar

Two Function

Illustration 1	g00921583

(1) During the connection of the pilot lines, do not torque the hose assembly more than 50 N·m (37 lb ft).

(2) Tighten the screen assembly to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

Illustration 2	g00921616
Sectional View A-A

(3) Tighten the locking nuts to the following torque. ... 8 ± 2 N·m (71 ± 18 lb in)

(4) Tighten the spacer to the following torque. ... 45 ± 5 N·m (33 ± 4 lb ft)

Note: During installation of the handles, hold the hex in order to keep the hex from turning.

(5) Apply 4C-4030 Thread Lock Compound to the threads before assembly. Tighten the swivel assembly to the following torque. ... 45 ± 5 N·m (33 ± 4 lb ft)

(6) Apply an adequate amount of 1P-0808 Multipurpose Grease to the moving surfaces.

(7) Tighten the adapter to the following torque. ... 45 ± 5 N·m (33 ± 4 lb ft)

(8) Tighten the four connectors to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(9) Tighten the connector to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(A) The tip of the pin should be 12.15 ± 0.06 mm (0.4783 ± 0.0024 inch) from the plate after assembly.

(B) The tip of the plungers should be 4.50 ± 0.06 mm (0.1772 ± 0.0024 inch) from the plate after assembly.

Three Function

Illustration 3	g00918805

Illustration 4	g00918815
Sectional View B-B

(11) 159-3781 Spring

Free length ... 17.46 mm (0.69 inch)

Outside diameter ... 14.28 mm (0.56 inch)

Assembled length ... 7.60 mm (0.300 inch)

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

(12) Tighten the locking nuts to the following torque. ... 8 ± 2 N·m (71 ± 18 lb in)

(13) Tighten the adapter to the following torque. ... 45 ± 5 N·m (33 ± 4 lb ft)

(14) Apply an adequate amount of 4C-4030 on the threads before assembly. Tighten the swivel assembly to the following torque. ... 45 ± 5 N·m (33 ± 4 lb ft)

(15) Tighten the spacer to the following torque. ... 45 ± 5 N·m (33 ± 4 lb ft)

Note: During installation of the spacer, hold the hex in order to keep the hex from turning.

(16) Apply an adequate amount of 1P-0808 Multipurpose Grease to the moving surfaces.

(17) Tighten the bolt to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(18) Tighten the connectors to the following torque. ... 28 ± 4 N·m (21 ± 3 lb ft)

(19) During the connection of the pilot lines, do not tighten the hose assembly more than 50 N·m (37 lb ft).

Illustration 5	g00918828
Sectional View C-C

(20) 159-3781 Spring

Free length ... 17.46 mm (0.69 inch)

Outside diameter ... 14.28 mm (0.56 inch)

Assembled length ... 7.60 mm (0.300 inch)

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

(21) Tighten the adapter to the following torque. ... 45 ± 5 N·m (33 ± 4 lb ft)

(22) Tighten the spacer to the following torque. ... 90 ± 10 N·m (66 ± 7 lb ft)

Note: During installation of the handle, hold the hex in order to keep the hex from turning.

(23) Tighten the locking nuts to the following torque. ... 12 ± 3 N·m (9 ± 2 lb ft)

(24) Apply an adequate amount of 1P-0808 Multipurpose Grease to the moving surfaces.

(E) The tip of the pin should be 12.15 ± 0.06 mm (0.4783 ± 0.0024 inch) from the plate after assembly.

(F) The tip of the plungers should be 6.35 ± 0.06 mm (0.2500 ± 0.0024 inch) from the plate after assembly.

Cartridge assembly

The cartridge assemblies are being used on the pilot valve (joystick) with either the two function or the three function.

145-8711 Pilot Cartridge Valve

Illustration 6	g00921749

Note: This pilot cartridge assembly is used for the tilt functions.

(25) 157-2153 Spring

Free length ... 59.49 mm (2.342 inch)

Outside diameter ... 16 mm (0.63 inch)

Length at assembly ... 25.20 mm (0.99 inch)

Load at assembly ... 24.0 ± 1.7 N (5.4 ± 0.38 lb)

(26) 145-8707 Spring

Free length ... 27.77 mm (1.093 inch)

Outside diameter ... 7.6 mm (0.30 inch)

Length at assembly ... 23.9 mm (0.94 inch)

Load at assembly ... 14.80 ± 0.74 N (3.327 ± 0.1664 lb)

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

(28) Torque for the cage ... 15 ± 2 N·m (11.1 ± 1.48 lb ft)

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

(30) 153-8926 Spring

Free length ... 10.580 mm (0.4165 inch)

Outside diameter ... 4.200 mm (0.1654 inch)

Length at assembly ... 5.00 mm (0.197 inch)

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

(31) Torque for the Stop ... 6 ± 1 N·m (53 ± 9 lb in)

137-0266 Pilot Cartridge Valve

Illustration 7	g00921753

Note: This pilot cartridge valve is used for the lift function in the two function. This pilot cartridge valve is used for the lift function and the third function valve in the three function control.

(32) 157-2152 Spring

Free length ... 40.2 mm (1.583 inch)

Outside diameter ... 16 mm (0.63 inch)

Length at assembly ... 25.2 mm (0.99 inch)

Load at assembly ... 12.0 ± 0.8 N (2.70 ± 0.180 lb)

(33) 145-8707 Spring

Free length ... 27.77 mm (1.093 inch)

Outside diameter ... 7.6 mm (0.30 inch)

Length at assembly ... 23.9 mm (0.94 inch)

Load at assembly ... 14.80 ± 0.74 N (3.327± 0.1664 lb)

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

(35) Torque for the cage ... 15 ± 2 N·m (11.1 ± 1.48 lb ft)

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

(37) 153-8926 Spring

Free length ... 10.580 mm (0.4165 inch)

Outside diameter ... 4.200 mm (0.1654 inch)

Length at assembly ... 5.00 mm (0.197 inch)

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

(38) Torque for the Stop ... 6 ± 1 N·m (53 ± 9 lb in)