303.5D CR, 304D CR, 305D CR and 305.5D CR Mini Hydraulic Excavators 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    
A     1U-6396     O-Ring Assembly Compound     1    

Note: Cleanliness is an important factor. Thoroughly clean all parts in cleaning fluid before assembly. 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 1g00704366

Fittings are not displayed in this illustration.




    Illustration 2g00712178

  1. Install plugs (36) in body assembly (35). Tighten plugs (36) to a torque of 7 ± 1.0 N·m (61 ± 9 lb in).

  1. Install ball (28) and seat (29) in body assembly (35) .



    Illustration 3g00712173

  1. Install new O-ring seals (30) on plugs (31) .



    Illustration 4g01021626

  1. Install plugs (31) in body assembly (35). Tighten plugs (31) to a torque of 27 ± 3 N·m (20 ± 2 lb ft).



    Illustration 5g00712165

  1. Install spring (21) .

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



      Illustration 6g00712141



      Illustration 7g00712139

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

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

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

  1. Install spool assembly (15) .



    Illustration 8g00712136

  1. Install bushing (34) .



    Illustration 9g00712130

    ------ 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) and install retaining ring (32) .



    Illustration 10g01021624

  1. Install balls (33) .



    Illustration 11g00712126

  1. Install spring seat (27) .



    Illustration 12g00712122

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



    Illustration 13g02151072

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



    Illustration 14g02151071

    Note: Position housing (38) in the original orientation.

  1. Position housing (38) and install bolts (37). Tighten bolts (37) to a torque of 8.8 ± 1.0 N·m (78 ± 9 lb in).



    Illustration 15g00712119

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



    Illustration 16g00712118

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



    Illustration 17g00712111

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

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



    Illustration 18g00712108

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

  1. Repeat Steps 5 through 19 in order to install the other three spool assemblies.



    Illustration 19g01021623

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



    Illustration 20g01021622

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



    Illustration 21g01021621

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



    Illustration 22g01021620

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



    Illustration 23g00711976

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



    Illustration 24g00711974

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

  1. Install setscrew (6) in pedal (12). Tighten setscrew (6) to a torque of 7 ± 1.0 N·m (61 ± 9 lb in).



    Illustration 25g00712296



    Illustration 26g01021620

  1. Adjust setscrew (5) in order to set Dimension (a), at 12.4° ± 0.6° for pedal (12) .

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

  1. Repeat Steps 24 through 27 in order to install the remaining pedal.



    Illustration 27g00711962

  1. Install new O-ring seals (38) and (39) on fittings (37) .



    Illustration 28g01021619

  1. Install fittings (37) on the pilot valve.

End By: Install the pilot valve. Refer to , "Pilot Valve (Travel) - Install".

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