320D2 GC Excavator Machine Systems Pilot Valve (Travel) - Remove and Install Caterpillar


Pilot Valve (Travel) - Remove and Install
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1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Start By:

  1. Release the hydraulic system pressure.


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

Note: Before you begin the following procedure, swing the upper structure in order to gain access to the cover that is located under the cab.



    Illustration 1g00704086

  1. Loosen bolts (3).

  2. Remove bolts (1) in order to remove cover (2).


    Illustration 2g00704095

  3. Disconnect hose assemblies (4) from the pilot valve.


    Illustration 3g00704100

  4. Disconnect hose assemblies (5) from the pilot valve.


    Illustration 4g00704108

  5. Disconnect harness assembly (6). Remove the harness assembly from the clip.

  6. Remove left travel pressure switch (7).


    Illustration 5g00704110

  7. Disconnect harness assembly (8). Remove the harness assembly from the clip.

  8. Remove right travel pressure switch (9).


    Illustration 6g00704117

    Note: Mark the location of hydraulic connector (11) that has a filter for installation purposes.

  9. Remove hydraulic connector (11) from the pilot valve.

  10. Remove hydraulic connector (10) from the pilot valve.


    Illustration 7g01208315

  11. Remove rubber floor mat (12) from the travel pedals.


    Illustration 8g00704120

  12. Remove rubber pedal (13).

  13. Remove rubber pedal (14).


    Illustration 9g00704123

  14. Remove bolts (17) in order to remove left travel pedal (15).

  15. Remove bolts (18) in order to remove right travel pedal (16).


    Illustration 10g00704128

  16. Remove bellows (19) from the pilot valve.


    Illustration 11g00704131

  17. Remove bolts (20).

  18. Remove pilot valves (21).

Installation Procedure



    Illustration 12g00704131

    Note: Make sure that the ports of the valve are in the correct position.

  1. Install pilot valves (21).

  2. Install bolts (20).


    Illustration 13g00704128

  3. Install bellows (19) on the pilot valve.


    Illustration 14g00704123

  4. Position right travel pedal (16) on the pilot valve. Install bolts (18). Tighten the bolts to a torque of 33 ± 3 N·m (25 ± 3 lb ft).

  5. Position left travel pedal (15) on the pilot valve. Install bolts (17). Tighten the bolts to a torque of 33 ± 3 N·m (25 ± 3 lb ft).


    Illustration 15g00704120

  6. Install rubber pedal (14).

  7. Install rubber pedal (13).


    Illustration 16g01208315

  8. Install rubber floor mat (12) around the travel pedals.


    Illustration 17g00704117

  9. Install hydraulic fitting (10) in the pilot valve.

    Note: The bottom hydraulic fitting is the hydraulic fitting with the filter.

  10. Install hydraulic fitting (11) in the pilot valve.


    Illustration 18g00704110

  11. Install right travel pressure switch (9).

  12. Install the harness assembly in the clip. Connect harness assembly (8).


    Illustration 19g00704108

  13. Install left travel pressure switch (7).

  14. Install the harness assembly in the clip. Connect harness assembly (6).


    Illustration 20g00704100

  15. Connect hose assemblies (5) to the pilot valve. Tighten the hose assemblies to a torque of 37 ± 4 N·m (27 ± 3 lb ft).


    Illustration 21g00704095

    Note: Make sure that the hose assemblies are connected in the correct locations.

  16. Connect hose assemblies (4) to the pilot valve. Tighten the hose assemblies to a torque of 37 ± 4 N·m (27 ± 3 lb ft).

  17. Check the hydraulic system oil level.

  18. Start the engine, and check the operation of the pilot valve. Also, check for leaks. Stop the engine.

  19. Obtain a hydraulic oil sample from the main S·O·S port. Refer to Operation and Maintenance Manual, "Sampling Interval and Location of Sampling Valve".

  20. If the S·O·S sample exceeds ISO 18/15, flush the hydraulic system. Refer to Contamination Control Guidelines, SEBF8436, "Hydraulic System Flushing Procedure for 320C Hydraulic Excavators".


    Illustration 22g00704086

  21. Position cover (2) on the machine. Install the washers and bolts (1). Tighten bolts (3).

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