This document provides instructions for disassembling a pilot valve used in a Caterpillar 322C excavator. It lists 28 steps to fully disassemble the valve, removing components like fittings, seals, covers, springs, spools and plugs. Cleanliness is important during disassembly to prevent dirt from entering the internal mechanism. Identification marks should be placed on components for reassembly. Personal protective equipment is recommended when releasing spring forces during disassembly.
𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
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2. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 322C EXCAVATOR FED
Configuration: 322C & 322C L Excavators FED00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
322C Excavator Machine Systems
Media Number -RENR3843-07 Publication Date -01/02/2017 Date Updated -20/02/2017
i02349029
Control Manifold (Pilot Oil) - Install - NFC Control Valve
SMCS - 5059-012-M9
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A FT-2674 Vacuum Cap 1
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.
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3. Illustration 1 g00691105
1. Install control manifold (10), the washers and bolts (11).
Illustration 2 g01175140
2. Connect harness assemblies (9).
Illustration 3 g00691101
3. Connect harness assembly (8) and hose assemblies (7).
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4. Illustration 4 g00691097
4. Remove the plugs and the caps.
5. Connect hose assemblies (6) and harness assemblies (5).
Illustration 5 g01175139
6. Connect hose assemblies (2).
Illustration 6 g00691104
7. Install access cover (4), the washers and bolts (3).
8. Remove Tooling (A) and install the cap to the hydraulic tank.
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5. 9. Install high efficiency filters in place of the pilot filter, the case drain filter, and the return
filter.
Note: High efficiency filters should not be run for more than 250 hours before you change
back to the standard filters.
Illustration 7 g00690963
10. Remove Tooling (A).
11. Check the hydraulic system level.
Illustration 8 g01175136
12. Close access door (1) on the right side of the machine.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 19 11:55:35 UTC+0800 2019
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6. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 322C EXCAVATOR FED
Configuration: 322C & 322C L Excavators FED00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
322C Excavator Machine Systems
Media Number -RENR3843-07 Publication Date -01/02/2017 Date Updated -20/02/2017
i01968161
Pilot Valve (Travel) - Remove
SMCS - 3220-011
Removal Procedure
Start By:
a. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic
System Pressure - Release".
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.
Note: A hydraulic oil sample should be obtained before any maintenance is performed in order to
establish the system contaminant level. Refer to Fluid Analysis Laboratory Guide, SEBF3116,
"Obtaining an Oil Sample for S·O·S Analysis". Refer to Operation and Maintenance Manual,
"Sampling Interval and Location of Sampling Valve" for the correct location.
Illustration 1 g00704086
1. Loosen bolts (3).
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7. 2. Remove bolts (1) in order to remove cover (2).
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.
At operating temperature, the hydraulic oil is hot and under pressure.
Hot oils can cause burns.
To prevent possible personal injury, release the pressure in the work
tool hydraulic circuit (boom, stick, bucket, and swing), travel circuits,
and the hydraulic oil tank at the filler cap before any hydraulic lines or
components are disconnected or removed.
Remove the filler cap only when the engine is stopped and the filler cap
is cool enough to touch.
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.
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8. Illustration 2 g00704095
3. Disconnect hose assemblies (4) from the pilot valve.
Illustration 3 g00704100
4. Disconnect hose assemblies (5) from the pilot valve.
Illustration 4 g00704108
5. Disconnect harness assembly (6). Remove the harness assembly from the clip.
6. Remove left travel pressure switch (7).
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9. Illustration 5 g00704110
7. Disconnect harness assembly (8). Remove the harness assembly from the clip.
8. Remove right travel pressure switch (9).
Illustration 6 g00704117
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.
11. Remove the O-ring seals from the connectors.
Illustration 7 g00704119
12. Remove rubber floormat (12) from the travel pedals.
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10. Illustration 8 g00704120
13. Remove rubber pedal (13).
14. Remove rubber pedal (14).
Illustration 9 g00704123
15. Remove bolts (17) in order to remove left travel pedal (15).
16. Remove bolts (18) in order to remove right travel pedal (16).
Illustration 10 g00704128
17. Remove bellows (19) from the pilot valve.
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11. Illustration 11 g00704131
18. Remove bolts (20).
19. Remove pilot valves (21).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 19 11:56:35 UTC+0800 2019
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12. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 322C EXCAVATOR FED
Configuration: 322C & 322C L Excavators FED00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
322C Excavator Machine Systems
Media Number -RENR3843-07 Publication Date -01/02/2017 Date Updated -20/02/2017
i02375113
Pilot Valve (Travel) - Disassemble
SMCS - 3220-015
Disassembly Procedure
Start By:
a. Remove the pilot valve. Refer to Disassembly and Assembly, "Pilot Valve (Travel) - Remove".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will prevent dirt from entering the internal
mechanism.
Note: During the disassembly of the pilot valve, put identification marks on each component for
assembly purposes.
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13. Illustration 1 g00704366
Illustration 2 g01021619
1. Remove fittings (37) from the pilot valve.
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14. Illustration 3 g00711962
2. Remove O-ring seals (38) and (39) from fittings (37).
Illustration 4 g00711974
3. Remove setscrew (6) and camshaft (19) from the pedal.
Illustration 5 g00711976
4. Remove pedal (12) from the pilot valve.
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15. Illustration 6 g01021620
5. Remove nuts (17) and setscrews (5).
6. Repeat Steps 3 through 5 for the remaining pedal.
Illustration 7 g01021621
7. Remove bolts (4) and covers (24).
Illustration 8 g01021622
8. Remove bushings (20) from covers (24).
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16. Illustration 9 g01021623
9. Remove bolts (26) and cover (25).
Illustration 10 g00712108
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.
10. Remove plug (8) and the pushrod from the body assembly.
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17. Illustration 11 g00712111
11. Remove piston (18) from pushrod (16).
12. Remove pushrod (16) from plug (8).
Illustration 12 g00712118
13. Remove O-ring seal (11) and cap (2) from plug (8).
Illustration 13 g00712119
14. Remove packing (3) from plug (8).
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18. Illustration 14 g00712122
15. Remove outer spring (23) and inner spring (22).
Illustration 15 g00712126
16. Remove spring seat (27).
Illustration 16 g01021624
17. Remove balls (33).
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19. Illustration 17 g00712130
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.
18. Apply pressure to bushing (34).
19. Remove retaining ring (32).
20. Slowly release the pressure on bushing (34).
Illustration 18 g00712136
21. Remove bushing (34).
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20. Illustration 19 g00712139
22. Remove spool assembly (15).
23. Use the following procedure to disassemble spool assembly (15).
Illustration 20 g00712141
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.
a. Apply pressure to seat (1) by hand. Put the end of spool (14) in the slotted opening of
seat (1). Remove seat (1).
b. Remove spring (7) from spool (14).
c. Remove washers (9), (10), and (13) from spool (14).
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21. Illustration 21 g00712165
24. Remove spring (21).
25. Repeat Steps 10 through 24 in order to remove the other three spool assemblies.
Illustration 22 g01021626
26. Remove plugs (31) from body assembly (35).
Illustration 23 g00712173
27. Remove O-ring seals (30) from plugs (31).
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22. Illustration 24 g00712178
28. Remove seat (29), ball (28), and plugs (36) from body assembly (35).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 19 11:57:36 UTC+0800 2019
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23. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
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24. Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 322C EXCAVATOR FED
Configuration: 322C & 322C L Excavators FED00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
322C Excavator Machine Systems
Media Number -RENR3843-07 Publication Date -01/02/2017 Date Updated -20/02/2017
i02375115
Pilot Valve (Travel) - Assemble
SMCS - 3220-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 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-rings, gaskets, and seals should always be replaced. A used O-ring may not have the same
sealing properties as a new O-ring. Apply a thin coating of Tooling (A) during the assembly
procedure.
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25. Illustration 1 g00704366
Illustration 2 g00712178
1. Install plugs (36) in body assembly (35). Tighten plugs (36) 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 (35).
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26. Illustration 3 g00712173
3. Install new O-ring seals (30) on plugs (31).
Illustration 4 g01021626
4. Install plugs (31) in body assembly (35). Tighten plugs (31) to a torque of 27 ± 3 N·m
(20 ± 2 lb ft).
Illustration 5 g00712165
5. Install spring (21).
6. Use the following procedure to assemble spool assembly (15).
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27. Illustration 6 g00712141
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.
a. Install washers (13), (10), and (9) on spool (14).
b. Install spring (7) on spool (14).
c. Put the end of spool (14) in the slotted opening of seat (1). Install seat (1).
Illustration 7 g00712139
7. Install spool assembly (15).
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