POPPET 8M2538 - Caterpillar

Assembly Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A - Loctite 271 -
Illustration 2 g02154700
Illustration 3 g02154699
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.
Use the following procedure to assemble spool assembly (13).Note: Spool (13) is assembled in Port (1) and Port (3) in the pilot valve.
Install washer (21), spring (19), and seat (17) on spool (23). Put the end of the spool in the slotted opening of seat (17).
Use the following procedure to disassemble spool assembly (12).Note: Spool (12) is assembled in Port (2) and Port (4) in the pilot valve.
Install washer (20), spring (18), and seat (16) on spool (22). Put the end of the spool in the slotted opening of seat (16).Note: Spool assembly (13) is installed in Port (1) and Port (3) in the pilot valve. Spool assembly (12) is installed in Port (2) and Port (4) in the pilot valve.
Install springs (14) and (15). Install spool assemblies (12) and (13).
Illustration 4 g02154698
Install new seal (6) in plug (7).
Install new O-ring seal (8) on plug (7).
Install rod (9) in plug (7).Note: Make sure that spring seats (11) are assembled in the correct port location.
Install spring (10) and the correct spring seat (11) in rod (9).Note: Make sure that spring seat (11) and the spring do not fall out of the rod while you install the plug.
Install plug (7).
Illustration 5 g02154696
Illustration 6 g02154697
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.
Install plate (5).
Apply Tooling (A) on the threads on the upper half of U-joint (4).
Install plate (3) on U-joint (4).
Install nut (2) on U-joint (4).
Tighten nut (2) against plate (3).
Install plate (3), nut (2), and U-joint (4). Tighten U-joint (4) to a torque of 47.1 2.9 N m (34.7 2.1 lb ft).
Adjust plate (2) to Dimension (X) that was recorded in the disassembly procedure.
Tighten nut (2) against plate (3). Tighten nut (2) to a torque of 68.6 4.9 N m (50.6 3.6 lb ft).
Install rubber boot (1).End By:
Install the pilot valve (joystick).