Pilot control / Joysitck / Caterpillar 242 Skid Steer

[2003cat242]

Hello all, I am in the process of doing research on my 2003 Cat 242. I have two leaking pilot control valves. I am looking for information on how to rebuild these valves. I would specifically like to know part numbers for the spool valves and how many are needed. According to my research thus far there are 4 valves per joystick meaning I would need 8 rebuild kits.

I am also curious if the two pilot valves are exactly the same part #'s of if they are two different part #'s. So far searching the web the one part # I have found for the whole pilot control valve is 204-1399 which is currently $2,181.44 each before tax at my local dealer.

Thanks in advance for information / help with this project.

 

[Nige]

Try this thread, and if you need any additional info I would suggest send a PM to the guy who created it. He seems to be pretty well on top ofthe subject.

https://www.heavyequipmentforums.com/threads/2006-cat-242b-pilot-valve-leak-repair.80611/

 

[ThreeCW]

I am also curious if the two pilot valves are exactly the same part #'s of if they are two different part #'s. So far searching the web the one part # I have found for the whole pilot control valve is 204-1399 which is currently $2,181.44 each before tax at my local dealer.

I used the Cat Parts Website to locate your parts diagrams.
The two pilots valves are different part numbers.
I plugged in the serial number from your other post and came up with the following:
Pilot Valve - Work Tool (right hand valve) - Part Number 204-1399
https://parts.cat.com/AjaxCATPartLookupResultsView?catalogId=10051&serialNumber=CMB01551&requestType=3&link=WOMNLogez9j8EvB7FTlwxX5D0Bo7yF1osO+mvp6Ref/RC5a2oduBEVcLyl24vQPb/mQjgrfEbdA=&langId=-1&storeId=20184

Pilot Valve - Speed and Direction (left hand valve) - Part Number 204-1400
https://parts.cat.com/AjaxCATPartLookupResultsView?catalogId=10051&serialNumber=CMB01551&requestType=3&link=WOMNLogez9j8EvB7FTlwxX5D0Bo7yF1osO+mvp6Ref/RC5a2oduBEYWOLL5PKlbenF34ktABq6QIk3254kZ6PXpsGkBIU+Vm&langId=-1&storeId=20184

I am not sure if you can open the above links, but best for you to create an account at Parts.Cat.com, plug in your serial number and you can search for your required parts.

Use the upper tab in Parts.Cat.com called "Parts Manual" to search for your parts.

As per the link that Nige posted, I have repaired my leaking Left Pilot Valve (speed and direction) and found that it gets pretty expensive at throwing parts at these valves. I recommend your first step is to identify where your leak(s) are occurring and then decide on your parts requirement. Have a detailed look at the link that Nige posted and let me know if you have any questions. I am a hobby mechanic only, but have a reasonable understanding of my Left Pilot Valve, which I believe looks similar to what you have.

 

[2003cat242]

ThreeCW I can't thank you enough, the links opened and took me right to the information. I have been trying to learn how to navigate the different CAT web sites for a little while now but the links took me right to the parts with exploded view and pricing information. Thanks again! I am slowly getting the information together and then I hope to dive into the rebuild of the right pilot valve for the work tool since that one seems to be leaking the worst. Hopefully that one will go well and the other side will be much easier with some experience under my belt.

 

[ThreeCW]

I suggest your first step will be to determine where the leak is coming from. If it coming from the top assembly, it will likely involve replacement of some fairly expensive seals, plungers or valve kits. If the leak is coming from the bottom assembly, then it may be a much cheaper repair ... in my case it was literally a $2 O-ring (yes, CAT does have some parts for only $2). In my case, the leak was coming from between the upper and lower body.

Refer to the thread I started for this repair as I tried to capture as many photos and learnings as possible. Same link as Nige suggested:

https://www.heavyequipmentforums.com/threads/2006-cat-242b-pilot-valve-leak-repair.80611/