303.5D CR, 304D CR, 305D CR and 305.5D CR Mini Hydraulic Excavators Machine Systems Pilot Valve (Travel) - Disassemble Caterpillar


Pilot Valve (Travel) - Disassemble
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1.1. Disassembly Procedure

Disassembly Procedure

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-0006     Connector Pliers     1    

Start By:

  1. Remove the pilot valve. Refer to, "Pilot Valve (Travel) - Remove".

Note: Cleanliness is an important factor. Thoroughly clean the exterior of the component before the disassembly procedure in order to prevent dirt from entering the internal mechanism.

Note: During the disassembly of the pilot valve, put identification marks on each component for assembly purposes.




Illustration 1g00704366

Fittings are not displayed in this illustration.




    Illustration 2g01021619

  1. Remove fittings (37) from the pilot valve.



    Illustration 3g00711962

  1. Remove O-ring seals (38) and (39) from fittings (37) .



    Illustration 4g00711974

  1. Remove setscrew (6) and camshaft (19) from the pedal.



    Illustration 5g00711976

  1. Remove pedal (12) from the pilot valve.



    Illustration 6g01021620

  1. Remove nuts (17) and setscrews (5) .

  1. Repeat Steps 3 through 5 for the remaining pedal.



    Illustration 7g01021621

  1. Remove bolts (4) and covers (24) .



    Illustration 8g01021622

  1. Remove bushings (20) from covers (24) .



    Illustration 9g01021623

  1. Remove bolts (26) and cover (25) .



    Illustration 10g00712108

    ------ 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.

    ----------------------

  1. Use Tooling (A) in order to remove plugs (8) and the pushrods from the body assembly.



    Illustration 11g00712111

  1. Remove pistons (18) from pushrods (16) .

  1. Remove pushrods (16) from plugs (8) .



    Illustration 12g00712118

  1. Remove O-ring seals (11) and caps (2) from plugs (8) .



    Illustration 13g00712119

  1. Remove packing (3) from plugs (8) .



    Illustration 14g00712122

  1. Remove outer springs (23) and inner springs (22) .



    Illustration 15g02151071

    Note: Note the orientation of housing (38) for assembly purposes.

  1. Remove bolts (37) and housing (38) .



    Illustration 16g02151072

  1. Remove four O-ring seals (39) and two O-ring seals (40) .



    Illustration 17g00712126

  1. Remove spring seat (27) .



    Illustration 18g01021624

  1. Remove balls (33) .



    Illustration 19g00712130

    ------ 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.

    ----------------------

  1. Apply pressure to bushing (34) .

  1. Remove retaining ring (32) .

  1. Slowly release the pressure on bushing (34) .



    Illustration 20g00712136

  1. Remove bushing (34) .



    Illustration 21g00712139

  1. Remove spool assembly (15) .

  1. Use the following procedure to disassemble spool assembly (15) .



      Illustration 22g00712141

      ------ 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.

      ----------------------

    1. Apply pressure to seat (1) by hand. Put the end of spool (14) in the slotted opening of seat (1). Remove seat (1) .

    1. Remove spring (7) from spool (14) .

    1. Remove washers (9), (10), and (13) from spool (14) .



    Illustration 23g00712165

  1. Remove spring (21) .

  1. Repeat Steps 18 through 26 in order to remove the other three spool assemblies.



    Illustration 24g01021626

  1. Remove plugs (31) from body assembly (35) .



    Illustration 25g00712173

  1. Remove O-ring seals (30) from plugs (31) .



    Illustration 26g00712178

  1. Remove seat (29), ball (28), and plugs (36) from body assembly (35) .

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