Assembly Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
1P-1861 |
Snap Ring Pliers |
1 |
| B |
138-7574 |
Link Bracket |
2 |
| C |
1P-0510 |
Driver Group |
1 |
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| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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Note: Inspect the O-ring seals, the seals, and the gaskets. Replace the O-ring seals, the seals, and the gaskets that are worn or damaged.
Note: Lubricate the O-ring seals lightly with the lubricant that is being sealed.
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| Illustration 1 | g01620977 |
- Install plug orifice (119). Install screen (118). Tighten screen (116) to a torque of 13 ± 3 N·m (115 ± 27 lb in). Install O-ring seal (118) and plug (117) .
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| Illustration 2 | g01620974 |
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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. |
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- Install poppet (116), spring (115), O-ring seal (114), plug (113), and plugs (112) .
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| Illustration 3 | g01620972 |
- Install plug orifice (111) and plug (110) .
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| Illustration 4 | g01620957 |
- Install plug orifice (106) into manifold assembly (89) .
- Install plug (109), plug (108), and plug (107) into manifold assembly (89) .
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| Illustration 5 | g01620953 |
Note: The O-ring seals and the backup rings are the only serviceable parts of the counterbalance valve. The parts are available as a kit.
- Install O-ring seals (105) and the backup rings onto counterbalance valve (96) .
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| Illustration 6 | g01620934 |
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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. |
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- Install O-ring seal (103) onto valve body (104) .
- Install valve (102) into valve body (104) .
- Install shim (101), spring (100), and shim (99) into valve (102) .
Note: Do not adjust shims at this location. There must be seven shims at this location.
- Install plug (97) and O-ring seal (98) into valve body (104). Tighten plug (97) to a torque of 125 ± 15 N·m (92 ± 11 lb ft).
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| Illustration 7 | g01620932 |
- Install counterbalance valve (96) and install bolts (95) .
- Install relief valve (94). Tighten relief valve (65) to a torque of 185 ± 15 N·m (136 ± 11 lb ft).
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| Illustration 8 | g01620854 |
- Install O-ring seal (93), O-ring seal (92), O-ring seal (91), and O-ring seal (90) .
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| Illustration 9 | g01620419 |
- Use Tooling (C) and a suitable lifting device in order to install manifold assembly (89). The weight of manifold assembly (89) is approximately 55 kg (121 lb). Install bolts (88) and bolts (87). Tighten bolts (88) and bolts (87) evenly by one turn at a time. Use Tooling (C) in order to turn over valve assembly (86). The weight of valve assembly (86) is approximately 141 kg (310 lb).
- Remove Tooling (C) and the suitable lifting device.
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| Illustration 10 | g01620832 |
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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. |
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- Install poppet (84), bearing sleeve (83), spring (82), O-ring seal (81), and plug (80). Repeat this step for the remaining plug (85) .
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| Illustration 11 | g01620830 |
- Install plug (79), plug (78), and plug (77) .
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| Illustration 12 | g01620810 |
- Install spool (76). Install O-ring seal (75). Install plug (74) and plug (73) .
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| Illustration 13 | g01620809 |
- Install plate (72). Install bolts (71) .
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| Illustration 14 | g01620807 |
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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. |
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- Install O-ring seal (70). Install spring (69). Install coil assembly (68) and install cartridge (67). Tighten cartridge (67) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
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| Illustration 15 | g01620805 |
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| Illustration 16 | g01620790 |
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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. |
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- Install spring (66), spring (65), spring (64), and retainer (63) .
- Use Tooling (D) and a suitable press in order to compress the springs. Use Tooling (B) in order to install retaining ring (62) .
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| Illustration 17 | g01620788 |
- Install O-ring seal (61) and O-ring seals (60) .
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| Illustration 18 | g01620785 |
- Install actuator assembly (59) and install bolts (58) .
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| Illustration 19 | g01620783 |
- Install stem (57) into body (18) .
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| Illustration 20 | g01620775 |
- Install spool (56). Install O-ring seal (55). Install plug (54) and plug (53) .
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| Illustration 21 | g01620610 |
- Install plate (52). Install bolts (51) .
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| Illustration 22 | g01620605 |
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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. |
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- Install O-ring seal (50). Install spring (49). Install coil assembly (48) and install cartridge (47). Tighten cartridge (47) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
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| Illustration 23 | g01620594 |
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| Illustration 24 | g01620587 |
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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. |
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- Install spring (46), spring (45), spring (44), and retainer (43) .
- Use Tooling (D) and a suitable press in order to compress the springs. Use Tooling (B) in order to install retaining ring (42) .
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| Illustration 25 | g01620570 |
- Install O-ring seal (41) and O-ring seals (40) .
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| Illustration 26 | g01620560 |
- Install O-ring seal (39), piston (38), plug (37), and O-ring seal (36) .
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| Illustration 27 | g01620548 |
- Install adapter (35), actuator assembly (34), and bolts (33) .
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| Illustration 28 | g01620492 |
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| Illustration 29 | g01620544 |
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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. |
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- Install plugs (32), plugs (31), and plugs (30) into valve body (5) .
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| Illustration 30 | g01620481 |
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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. |
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- Install seats (29), spring (28), spool (27), plug (26), and plug (25) into valve body (5) .
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| Illustration 31 | g01620465 |
- Install spring (24), valve (23), O-ring seals (22), O-ring seal (21), O-ring seals (20), and O-ring seal (19) into valve body (5) .
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| Illustration 32 | g01620457 |
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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. |
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- Install valve body (5) onto body (18) and install bolts (17) .
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| Illustration 33 | g01620450 |
- Install plugs (16), plug (15), and plug (14) onto valve assembly (4) .
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| Illustration 34 | g01620439 |
- Install orifice (13), stems (12), shims (11), stops (10), springs (9), valves (8), O-ring seal (7), and O-ring seals (6) onto valve body (4) .
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| Illustration 35 | g01620432 |
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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. |
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- Install valve body (4) onto valve body (5). Install bolts (3) .
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| Illustration 36 | g01620428 |
- Install bracket (2) and install bolts (1) .
End By:
Install the control valve (hoist). Refer to Disassembly and Assembly, "Control Valve (Hoist) - Install".
