794 AC Off-Highway Truck Machine Systems Caterpillar


Control Valve (Hoist) - Assemble

Usage:

794 AC HRT

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
138-7575  Link Bracket 
1P-0510  Driver Gp 


    Illustration 1g01286132

  1. Install plug (109), plug (108), and plug (107).


    Illustration 2g06275317

  2. Install spool (106).

    Note: Spool (106) must be installed with the slot upward.



    Illustration 3g01286138

  3. Install O-ring seal (105) and O-ring seal (104).


    Illustration 4g01286088

  4. Install spring (97), spring (98), and retainer (99).


    Illustration 5g01286081

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  5. Use Tooling (B) and a suitable press to compress the springs and install retaining ring (96).


    Illustration 6g01286076

  6. Install plug (95).


    Illustration 7g01286075

  7. Install nipple assembly (94) and adapter (93).


    Illustration 8g01286074

  8. Install spring (91) and spool (92).


    Illustration 9g01286069

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  9. Install plate (89).


    Illustration 10g01286067

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  10. Install spring (86), coil assembly (87), and cartridge (88). Tighten cartridge (88) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).


    Illustration 11g01286063

  11. Install O-ring seal (85), O-ring seal (84), and O-ring seal (83).


    Illustration 12g01286097

  12. Install adapter (102). Install actuator (103).


    Illustration 13g01286096

  13. Install piston (101).


    Illustration 14g01286093

  14. Install plug (100).

  15. Repeat Step 4 through Step 11.


    Illustration 15g01286017

  16. Install actuator (82).


    Illustration 16g01286014

  17. Install valve (81), spring (80), valve (79), and spring (78).


    Illustration 17g01286011

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  18. Install plug (77), plug (76), and plug (75).


    Illustration 18g01286006

  19. Install O-ring seal (74), O-ring seal (73), O-ring seal (72), and O-ring seal (71).


    Illustration 19g01285998

  20. Apply the lubricant that is being sealed onto O-ring seal (70) and O-ring seal (69). Install O-ring seal (70) and O-ring seal (69).


    Illustration 20g01285995

  21. Install body (68). Tighten body (68) to a torque of 185 ± 15 N·m (136 ± 11 lb ft).


    Illustration 21g01285993

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  22. Install valve (67), shims (66), spring (65), shims (64), and plug (63). Tighten plug (63) to a torque of 125 ± 15 N·m (92 ± 11 lb ft).


    Illustration 22g01285988

  23. Apply the lubricant that is being sealed onto O-ring seal (62), ring (61), ring (60), O-ring seal (59), ring (58), O-ring seal (57), and ring (56).

  24. Install O-ring seal (62), ring (61), ring (60), O-ring seal (59), ring (58), O-ring seal (57), and ring (56).


    Illustration 23g01285916

  25. Install valve (55).


    Illustration 24g01285912

  26. Install plug (54) and plug (53).


    Illustration 25g01285908

  27. Install plug (52).


    Illustration 26g01285903

  28. Install plug (51) and plug (50).


    Illustration 27g01285794

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  29. Install screen (48). Tighten screen (48) to a torque of 13 ± 3 N·m (115 ± 27 lb in). Install plug (49), valve (44), spring (46), plug (47), plug (45), and plug (43).


    Illustration 28g01285792

  30. Use Tooling (A) and a suitable lifting device to install body (42) onto control valve (41).


    Illustration 29g01285780

  31. Lower the temperature of seat (40) and seat (39). Install seat (40) and seat (39). Install O-ring seal (38), O-ring seal (37), and O-ring seal (36).


    Illustration 30g01285770

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  32. Install plug (35), plug (34), plug (33), plug (32), plug (31), spool (28), spring (27), plug (30), plug (29), and plug (26).


    Illustration 31g01285765

  33. Install plugs (25).


    Illustration 32g01285758

  34. Install O-ring seals (24), O-ring seals (23), and O-ring seal (21). Install spring (21).


    Illustration 33g01285754

  35. Install valve (20).


    Illustration 34g01285749

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  36. Install body (19).


    Illustration 35g01285734

  37. Install plug (18), plug (17), stem (16), shims (15), spring (14), stop (13), valve (12), plug (11), plug (10), plug (9), stem (8), shims (7), spring (6), stop (5), and valve (4).


    Illustration 36g01285732

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  38. Install body (3).


    Illustration 37g03890149

  39. Install tube assembly (2). Install tube assembly (1).

End By:

  1. Install the hoist control valve

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