320D2 GC Excavator Machine Systems Pilot Valve (Travel) - Assemble Caterpillar


Pilot Valve (Travel) - Assemble
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1.1. Assembly Procedure

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
1U-6396  O-Ring Assembly Compound   

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.

Note: O-ring seals, gaskets, and seals should always be replaced. A used O-ring seal may not have the same sealing properties as a new O-ring seal. Apply a thin coating of Tooling (A) during the assembly procedure.



Illustration 1g01218262


    Illustration 2g01218278

  1. Install plugs (34) in body assembly (33). Tighten plugs (34) to a torque of 6.9 ± 1.0 N·m (61.07 ± 8.9 lb in).

  2. Install ball (28) and seat (29) in body assembly (33).


    Illustration 3g00712165

  3. Install spring (21).


    Illustration 4g00712141


    Illustration 5g00712139

    ------ WARNING! ------

    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. Use the following procedure to assemble spool assembly (15).

    1. Install washers (13), (10), and (9) on spool (14).

    2. Install spring (7) on spool (14).

    3. Put the end of spool (14) in the slotted opening of seat (1). Install seat (1).

  5. Install spool assembly (15).


    Illustration 6g01218269

  6. Install bushing (32).


    Illustration 7g01218266

    ------ WARNING! ------

    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.


  7. Apply pressure to bushing (32) and install retaining ring (30).


    Illustration 8g01218265

  8. Install balls (31).


    Illustration 9g00712126

  9. Install spring seat (27).


    Illustration 10g00712122

  10. Install outer spring (23) and inner spring (22).


    Illustration 11g00712119

  11. Install packing (3) in plug (8).


    Illustration 12g00712118

  12. Install cap (2) and new O-ring seal (11) on plug (8).


    Illustration 13g00712111

  13. Install pushrod (16) in plug (8).

  14. Install piston (18) on pushrod (16).


    Illustration 14g00712108

    ------ WARNING! ------

    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.


  15. Install plug (8) and the pushrod in the body assembly.

  16. Repeat Steps 3 through 15 to install the other three spool assemblies.


    Illustration 15g01021623

  17. Install cover (25) and bolts (26). Tighten bolts (26) to a torque of 29 ± 3 N·m (22 ± 2 lb ft).


    Illustration 16g01021622

  18. Install bushings (20) in covers (24).


    Illustration 17g01021621

  19. Install covers (24) and bolts (4). Tighten bolts (4) to a torque of 79 ± 10 N·m (58 ± 7 lb ft).


    Illustration 18g01021620

  20. Install setscrews (5) and nuts (17).


    Illustration 19g00711976

  21. Install pedal (12) on the pilot valve.


    Illustration 20g00711974

  22. Install camshaft (19) in pedal (12). Center camshaft (19) in pedal (12).

  23. Install setscrew (6) in pedal (12). Tighten setscrew (6) to a torque of 6.9 ± 1.0 N·m (61.07 ± 8.85 lb in).


    Illustration 21g00712296


    Illustration 22g01021620

  24. Adjust setscrew (5) to set Dimension (a) for pedal (12) at 12.4° ± 0.6°.

  25. Tighten nuts (17) to a torque of 33 ± 3 N·m (25 ± 3 lb ft).

  26. Repeat Steps 20 through 23 to install the remaining pedal.

End By:

  1. Install the pilot valve.

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