938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Pilot Operated Hydraulic Control (Joystick) - Assemble Caterpillar

Assembly Procedure

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

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Illustration 1	g00984789

1. Install plunger (34), ball (35), retainer (39), spring (40), orifice (41), cage (42), orifice (37), and stop (38) into adapter (33). Tighten orifice (41) to a torque of 2.5 ± .5 N·m (22.13 ± 4.43 lb in). Tighten cage (42) to a torque of 15 ± 2 N·m (132.8 ± 17.7 lb in). Tighten stop (38) to a torque of 6 ± 1 N·m (53.10 ± 8.85 lb in).
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   Illustration 2	g00984385

2. Install valve group (29).

3. Repeat Step 1 through Step 2 for the remaining valve groups.
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   Illustration 3	g00984383

4. Install coil assembly (28).
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   Illustration 4	g00984381

5. Install pin (26) and pin (27) into connector (25).

6. Repeat Step 4 through Step 5 for the coil assemblies.
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   Illustration 5	g00984380

7. Install wedge (24) into connector (25).
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   Illustration 6	g00984379

8. Install bolts (20), plate (21), retainer (22), and plate (23) from plate assembly (17).
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   Illustration 7	g00984378

9. Install adapter (18) and plate group (17) onto body (19).
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   Illustration 8	g00984377

10. Use Tooling (A) in order to install swivel assembly (15) and cup (16). Tighten swivel assembly (15) to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

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    Illustration 9	g00984321

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    Illustration 10	g00984357

11. Position spring (14) and washers (13) onto pins (12).

12. Install pins (12), nuts (8), and setscrews (9) into plate (10). Dimension (Z) is 12.15 ± .06 mm (0.4783 ± 0.0024 inch). Tighten nuts (8) to a torque of 8 ± 2 N·m (6 ± 1.5 lb ft).

13. Install plunger assemblies (11). Dimension (X) is 4.5 ± .06 mm (0.1772 ± 0.0024 inch).
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    Illustration 11	g00984304

14. Install plate group (7).
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    Illustration 12	g00984302

15. Position the control valve in a vise.

16. Install spacer (6). Tighten spacer (6) to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
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    Illustration 13	g00984301

17. Install nut (5) and rod (4).
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    Illustration 14	g00984300

18. Install boot (3).
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    Illustration 15	g00984299

19. Position handle (1).

20. Install screws (2).