324D, 325D, 326D and 329D Excavators and 329D MHPU Mobile Hydraulic Power Unit Machine Systems Pilot Valve (Joystick) - Assemble Caterpillar


Pilot Valve (Joystick) - 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 
9S-3263  Thread Lock 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-rings, 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. Use Tooling (A) during the assembly procedure.



Illustration 1g00741704
Spool assembly (17) is installed in port (1) and port (3) in the pilot valve.
Spool assembly (18) is installed in port (2) and port (4) in the pilot valve.
Spring seat (7) is installed in port (1) and port (3) in the pilot valve.
Spring seat (10) is installed in port (2) and port (4) in the pilot valve.


    Illustration 2g00914124

  1. Install bushing (16) in valve body (9).

  2. Install new O-ring seal (21) on valve body (9).

  3. Install spring pin (24) in plate (25).

    Note: Make sure that spring pin (24) is installed in the correct location in the valve body.

  4. Install plate (25) on the pilot valve.

  5. Install washers (27) and bolts (28). Tighten bolts (28) to a torque of 21 ± 2 N·m (16 ± 1 lb ft).


    Illustration 3g00914179

    Note: Three different springs are available for the pilot valve. See Table 2.

  6. Install spring (26) in the pilot valve.

    Table 2
    Spring 
    165-9461(1) 
    190-7750(2) 
    190-7751(3) 
    (1) Standard spring
    (2) This spring reduces the operating torque by seventy percent.
    (3) This spring reduces the operating torque by eighty percent.

  7. Use the following procedure to assemble spool assemblies (17) and (18).

      Note: Spool (22) is assembled in Port (1) and Port (3) in the pilot valve. Spool (23) is assembled in Port (2) and Port (4) in the pilot valve.

    1. Install washer (19) on the spool.

      Note: Spring (13) is installed on spool (22). Spring (15) is installed on spool (23).

    2. Install spring (13) or spring (15) on the spool.

    3. Put the end of the spool in the slotted opening of seat (11). Install seat (11).

    Note: Spool assembly (17) is installed in Port (1) and Port (3) in the pilot valve. Spool assembly (18) is installed in Port (2) and Port (4) in the pilot valve.

  8. Install spool assembly (18) in the pilot valve.

  9. Install new seal (1) in plug (2).

  10. Install new O-ring seal (3) on plug (2).

  11. Install rod (5) in plug (2).

    Note: Spring seat (7) is installed in Port (1) and Port (3) in the pilot valve. Spring seat (10) is installed in Port (2) and Port (4) in the pilot valve.

  12. Install spring (6) and the correct spring seat in rod (5).

    Note: Make sure that spring seat (7) or (10) and the spring do not fall out of the rod while you install the plug.

  13. Install plug (2) in the pilot valve.

  14. Repeat Steps 6 through 13 in order to install the other three spool assemblies.


    Illustration 4g00914163

  15. Install plate (20) on the pilot valve.

  16. Apply Tooling (B) on the threads on the upper half of U-joint (14).

  17. Install plate (12) on U-joint (14).

  18. Install nut (8) on U-joint (14).

  19. Tighten nut (8) against plate (12).

  20. Install plate (12), nut (8), and U-joint (14). Tighten U-joint (14) to a torque of 47 ± 3 N·m (35 ± 2 lb ft).


    Illustration 5g01021450

  21. Adjust plate (12) to dimension (A) that was recorded in the disassembly procedure.

  22. Tighten nut (8) against plate (12). Tighten nut (8) to a torque of 69 ± 5 N·m (51 ± 4 lb ft).

  23. Install rubber boot (4) on the pilot valve.

End By:

  1. Install the pilot valve. Refer to Disassembly and Assembly, "Pilot Valve (Joystick) - Install".

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