Assembly Procedure
Show/hide table
Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
4C-9507 |
Retaining Compound |
1 |
Note: Cleanliness is an important factor. Before assembly, clean all parts 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. Dirt and other contaminants can damage the precision made components of the valve. 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.
Show/hide table
|
 |
|
| Illustration 1 | g01135191 |
Show/hide table
 |
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. |
 |
- Install stop (68) on spool (69) . Install O-ring seal (67) on stop (68) . Install spring (66) , retainer (65) , and retaining ring (64) on spool (69) .
Show/hide table
|
 |
|
| Illustration 2 | g01135190 |
- Install plug (62) and the O-ring seal in manifold (49) . Tighten plug (62) to a torque of 50 ± 5 N·m (37 ± 4 lb ft). Install spool (63) in manifold (49) .
Show/hide table
|
 |
|
| Illustration 3 | g00992896 |
- Install dowel (61) in manifold (49) .
Show/hide table
|
 |
|
| Illustration 4 | g00992897 |
- Install pin (60) , O-ring seal (59) , and adapter (58) on cartridge valve (53) . Apply Tooling (A) to the threads of cartridge valve (53) . Tighten adapter (58) to a torque of 16 ± 1 N·m (12 ± 1 lb ft). Install ball (57) and seat (56) . Tighten seat (56) to a torque of 17 ± 2 N·m (13 ± 1 lb ft).
Show/hide table
|
 |
|
| Illustration 5 | g00992898 |
- Install O-ring seals (54) and (55) on cartridge valve (53) .
Show/hide table
|
 |
|
| Illustration 6 | g00992899 |
- Install cartridge valve (53) in manifold (49) . Tighten cartridge valve (53) to a torque of 50 ± 5 N·m (37 ± 4 lb ft). Install coil assembly (52) , washer (51) , and nut (50) . Tighten nut (50) to a torque of 13 ± 2 N·m (115 ± 18 lb in).
Show/hide table
|
 |
|
| Illustration 7 | g00993633 |
- Install O-ring seal (48) on manifold (49) .
Show/hide table
|
 |
|
| Illustration 8 | g00993632 |
View from the bottom of separator plate (46) . |
Show/hide table
|
 |
|
| Illustration 9 | g02405997 |
Note: Note the location of plug (47) . The brakes will not modulate if plug (47) is installed in the incorrect location.
- Install the O-ring seal and plug (47) in separator plate (46) . Tighten plug (47) to a torque of 5.5 ± 0.5 N·m (49.0 ± 4.0 lb in).
- Install separator plate (46) .
Show/hide table
|
 |
|
| Illustration 10 | g00992900 |
Show/hide table
|
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. |
|
- Install spool (43) and spring (44) in valve body (26) . Install O-ring seal (45) on plug (39) .
Show/hide table
|
 |
|
| Illustration 11 | g00992902 |
Show/hide table
|
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. |
|
- Install plug (39) in valve body (26) . Tighten plug (39) to a torque of 50 ± 7 N·m (37 ± 5 lb ft). Install spool (40) and spring (41) in valve body (26) . Install O-ring seal (42) on plug (38) .
Show/hide table
|
 |
|
| Illustration 12 | g00993566 |
Show/hide table
|
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. |
|
- Install plug (38) in valve body (26) . Tighten plug (38) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Show/hide table
|
 |
|
| Illustration 13 | g01135185 |
- Install pistons (34) , retainers (36) , springs (35) , and O-ring seals (37) in valve body (26) .
Show/hide table
|
 |
|
| Illustration 14 | g00992904 |
Show/hide table
|
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. |
|
- Install plate (32) and bolts (33) on valve body (26) . Install bracket (31) and bolts (30) .
Show/hide table
|
 |
|
| Illustration 15 | g00728292 |
- Install O-ring seal (29) on valve body (26) .
Show/hide table
|
 |
|
| Illustration 16 | g00992905 |
- Install valve body (26) . Install bolts (28) and (27) on the valve body (26) . Install O-ring seal (25) .
Show/hide table
|
 |
|
| Illustration 17 | g00728255 |
- Install plate (24) on brake control valve (1) .
Show/hide table
|
 |
|
| Illustration 18 | g00992906 |
- Install O-ring seal (23) , screen (22) , O-ring seal (21) , and rectangular seal (20) on cartridge valve (16) .
Show/hide table
|
 |
|
| Illustration 19 | g00992908 |
- Install cartridge valve (16) in manifold (6) . Tighten cartridge valve (16) to a torque of 30 ± 3 N·m (22 ± 2 lb ft). Install coil assembly (17) , washer (18) , and nut (19) on cartridge valve (16) . Tighten nut (19) to a torque of 9.5 ± 2 N·m (84 ± 13 lb in).
Show/hide table
|
 |
|
| Illustration 20 | g00992909 |
- Install rectangular seal (15) , O-ring seal (13) , screen (14) , and O-ring seal (12) , on cartridge valve (8) .
Show/hide table
|
 |
|
| Illustration 21 | g00992910 |
- Install cartridge valve (8) in manifold (6) . Tighten cartridge valve (8) to a torque of 30 ± 3 N·m (22 ± 2 lb ft). Install coil assembly (9) , washer (10) , and nut (11) on cartridge valve (8) . Tighten nut (11) to a torque of 9.5 ± 2 N·m (84 ± 13 lb in).
Show/hide table
|
 |
|
| Illustration 22 | g00728175 |
- Install O-ring seal (7) in manifold (6) .
Show/hide table
|
 |
|
| Illustration 23 | g00728168 |
- Install manifold (6) on brake control valve (1) . Install washers (5) on manifold (6) .
Show/hide table
|
 |
|
| Illustration 24 | g00728087 |
- Install plate (4) on brake control valve (1) . Install bolts (3) . Tighten bolts (3) to a torque of 30 ± 4 N·m (22 ± 3 lb ft). Install cable straps (2) .
End By:
Install the brake control valve. Refer to Disassembly and Assembly, "Brake Control Valve - Install".
