938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Pilot Operated Hydraulic Control - Disassemble Caterpillar

Disassembly Procedure

Start By:

1. Remove the pilot operated hydraulic control. Refer to Disassembly and Assembly, "Pilot Operated Hydraulic Control - Remove" for the machine that is being serviced.

Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

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Illustration 1	g00987504

1. Remove screw (1) and knob assembly (2) from the rod.
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   Illustration 2	g00987505

2. Loosen nuts (3). Remove rod (4) and boots (5).
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   Illustration 3	g00987508

3. Remove clips (6) and pins (7). Remove lever assemblies (8).
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   Illustration 4	g00987510

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   Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

4. Remove nut (13), pin (12), spring (14), and washer (15). Repeat for the opposite side of plate (9). Remove spacer (11) and swivel (15).
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   Illustration 5	g00987527

5. Remove bolts (16), bolts (17), and bracket (18).
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   Illustration 6	g00987530

6. Remove adapter (19).
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   Illustration 7	g00987531

7. Remove bolts (20) and separate the valve assembly.
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   Illustration 8	g00987532

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   Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

8. Remove O-ring seal (21). Remove the spring and screen assembly (22).
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   Illustration 9	g00987534

9. Remove adapters (23).
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   Illustration 10	g00987541

10. Remove cartridge assemblies (24).
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    Illustration 11	g00987572

    Note: Slide out coil assemblies (28) in order to remove plates (25).

11. Remove adapter (26) and plates (25).

12. Remove the three valve bodies from plate (27).
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    Illustration 12	g00987574

13. Remove O-ring seals (29) from adapters (30) and (31).
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    Illustration 13	g00987576

14. Remove hex bolts (32) and the nuts. Separate the valve bodies.
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    Illustration 14	g00987579

15. Remove adapters (33) and the O-ring seals.
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    Illustration 15	g00987580

16. Remove cartridge assembly (34).

17. Remove seal connector (36) and the cap assembly.

    Note: There are 45 O-ring seals on plugs (35) in the three valve bodies.

18. Remove plugs (35). Repeat for the remaining 44 O-ring plugs.
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    Illustration 16	g00987582

19. Remove O-ring seal (37) from plug (35). Repeat for the remaining 44 plugs.
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    Illustration 17	g00987584

20. Remove O-ring seal (38) from seal connector (36). Remove screen assembly (39).
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    Illustration 18	g00987586

    Note: A ball is released when adapter (40) and cage (41) are separated.

21. Separate adapter (40) from cage (41).
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    Illustration 19	g00987587

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

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    Illustration 20	g00987589

22. Remove snap ring (42) and retainer (44).

23. Remove plunger (43) and spring (45) from adapter (40).

24. Remove O-ring seals (46) and (47).
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    Illustration 21	g00987590

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

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    Illustration 22	g00987592

25. Compress spring (50) and remove retainers (49). Remove spring (50) from spool (48).
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    Illustration 23	g00987594

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

    Note: Use the flats of cage (41) to remove stop (55).

26. Remove stop (55) and spring (53).

27. Remove O-ring seal (54).
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    Illustration 24	g00987596

28. Remove O-ring seals (56).

29. Remove spool (48).
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    Illustration 25	g00987601

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    Illustration 26	g00987603

30. Use a suitable allen wrench and the flats of spool (48) in order to remove orifice (57).

31. Repeat this procedure for the remaining cartridge assemblies.