Usage:
 |
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed. |
 |
- a. Fully retract the rod in the stick cylinder.
- b. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.
- c. Lower the boom until the bucket is flat on the ground.
- d. Shut off the engine, and put the hydraulic activation control lever in the "Lock" position.
- e. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.
- f. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.
- g. Tighten the air breather cap on the hydraulic oil tank.
- h. The pressure in the hydraulic system has now been released. Lines and components can now be removed.
- b. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.
1. Release the pressure in the hydraulic system as follows:
2. Remove the access cover from under the hydraulic oil tank.
3. Drain the oil from the hydraulic oil tank into a suitable container. The capacity of the hydraulic oil tank is 310 liters (82 U.S. gal).
View From Under Machine
4. Remove four bolts (1) and the washers. Remove access cover (2).
View From Under Machine
5. Put identification marks on all hose assemblies (3) that are connected to the bottom of the main control valve for installation purposes.
6. Disconnect all hose assemblies (3) that are connected to the bottom of the main control valve. Put plugs in the hose assemblies to keep dirt and debris out of the hydraulic system.
7. Remove four bolts (4), the washers and nuts.
8. Remove two socket head bolts (5).
9. Remove plate assembly (6) from the machine.
10. Open the right rear access door on the machine.
11. Remove four bolts (7), an disconnect hose assembly (8) from the right side of the control valve. Move mounting bracket (9) away from the control valve.
12. Disconnect three electrical connectors (10).
13. Put identification marks on all hose assemblies and tube assemblies that are connected to the top of the main control valve. Disconnect all hose assemblies and tube assemblies that are connected to the top of the main control valve. Put plugs in hose assemblies and tube assemblies to keep dirt and debris out of the hydraulic system.
14. Fasten a lifting strap and a hoist to main control valve (11) as shown.
| NOTICE |
|---|
Be sure all hose assemblies and tube assemblies have been disconnected from the main control valve prior to removal. |
15. Remove four bolts (12) and the washers that hold the main control valve in position. Remove main control valve (11). The weight of the main control valve is approximately 190 kg (420 lb).
NOTE: The following steps are for the installation of the main control valve.
16. Check the condition of all O-ring seals used in the tube assemblies and hose assemblies that are connected to the main control valve. If any of the seals are worn or damaged, use new parts for replacement.
17. Fasten a lifting strap and a hoist to main control valve (11). Put the main control valve in position in the machine. Install four bolts (12) and the washers that hold it.
| NOTICE |
|---|
Be sure all hose assemblies and tube assemblies for the main control valve are connected at their original locations on the valve. |
18. Connect all hose assemblies and tube assemblies to the top of the main control valve in their original locations.
19. Connect three electrical connectors (10).
20. Put mounting bracket (9) in position next to the main control valve. Connect hose assembly (8) to the right side of the main control valve with bolts (7).
21. Reinstall plate assembly (6) at the top rear of the main control valve.
22. Connect all hose assemblies (3) to the bottom of the main control valve in their original locations.
23. Fill the hydraulic oil tank with oil to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.
24. Start the machine and check the operation of all hydraulic controls. Check all hose assembly and tube assemblies connections on the main control valve for leaks.
25. Reinstall access cover (2) under the main control valve.
26. Reinstall the access cover under the hydraulic oil tank.
Disassemble Main Control Valve
Start By:
a. remove main coupling valve
NOTE: The weight of the main control valve is 190 kg (420 lb).
1. Thoroughly clean the outside of the main control valve prior to disassembling it.
| NOTICE |
|---|
Put identification marks on all components of the main control valve as they are being removed. All parts must be reinstalled in their original locations. Do not damage any of the internal parts during removal. A damaged valve component will result in oil leakage and affect valve performance, keep all internal parts of the valve clean and lubricated. |
2. Remove and disassemble pressure control valve (2) as follows:
|
There is spring force against pressure control valve (2). When four bolts (1) that hold the pressure control valve is in place are removed, the spring force will be released. To prevent possible personal injury, hold pressure control valve (2) in place by hand as bolts (1) are being removed. |
|
a. While holding pressure control valve (2) in place by hand, slowly remove four bolts (1). Remove pressure control valve (2) from the main valve body.
b. Remove spring (3) from the main valve body.
c. Remove valve assembly (4) from the main valve body.
d. Remove O-ring seals (5) and (6) from the pressure control valve body.
Exploded View Of Pressure Control Valve
e. Remove plug (7) from each end of the valve body. Remove spring (8), valve (9) and spool (10) from the valve body. If necessary, remove two plugs (11) and five plugs (12) from the valve body. Remove the O-ring seal from each plug.
3. Remove and disassemble pressure control valve (14) as follows:
a. Remove three bolts (13) and pressure control valve (14) from the main valve body.
b. Remove O-ring seals (15) from the valve body. Remove plug (16) from the valve body.
Exploded View Of Pressure Control Valve
c. Remove two plugs (17), spring (18) and spool (19) from the valve body. If necessary, remove four plugs (20) and six plugs (21) from the valve body. Remove the O-ring seal from each plug.
4. Remove the check valve assembly from the main valve body as follows:
a. Remove four bolts (22) and plates (23) and (24) from the main valve body. Remove O-ring seal (25) from plate (23). Remove O-ring seal (26) from plate (24).
b. Remove pilot (27), spring (29) and check valve (28) from the main valve body.
NOTE: Plate (31) is only for manufacturing purposes.
5. Remove two bolts (30) and the washers and plate (31) from the main valve body. Remove O-ring seal (32) from plate (31).
6. Remove the two check valves and five load check valves as follows:
a. Remove two plugs (33) from the main valve body. Remove four plugs (34) and one plug (34A) from the main valve bodies.
b. Remove O-ring seal (35) from each plug (34). Remove O-ring seal (37) and back-up ring (36) from each plug (33).
c. Remove spring (38) and plunger (39) for each check valve and load check valve.
7. Remove three plugs (40) from the main valve bodies. Remove the O-ring seal from each plug.
8. Remove sleeve (41) and sleeve (42) from the main valve body.
9. Remove the check valve from the main valve body. Remove plug (43). Remove sleeve bearing (44), spring (45) and valve (46). Remove the O-ring seal from plug (43).
10. Remove plug (50), spring (48) and check valve (47) from the main valve body. Remove O-ring seal (49) from the plug.
11. Remove line relief valves (51) and (52) from the main valve bodies.
12. Disassemble line relief valves (51) and (52) as follows:
NOTE: Only the O-ring seals and back-up rings are serviceable in the line relief valves (51) and (52). However the line relief valves can be disassembled for cleaning.
a. Disassemble the line relief valves as shown. Remove O-ring seal (58) from the adapter.
b. Remove back-up ring (53) and O-ring seal (54) from the valve.
c. Remove O-ring seal (55) and two back-up rings (59) from the seat.
d. Remove O-ring seal (57) from the piston.
13. Remove plug (60) from the main valve body. Remove the O-ring seal from the plug.
14. Remove main relief valve (61) from the main valve body.
15. Disassemble main relief valve (61) as follows:
a. Remove nut (62), the washers and plunger assembly (63) from the adjuster.
b. Remove piston (68), spring (67) and valve (66) from adjuster (65).
c. Loosen nut (64), and remove adjuster (65) from the valve group. Remove the O-ring seal from each end of the adjuster.
d. Remove insert (69) from the valve body. Remove the two O-ring seals from the insert.
e. Remove seat (76), spring (75) and valve (74) from body (73).
f. Remove O-ring seals (70), (71) and (72) from body (73).
16. Remove plug (77) from the main valve body.
17. Remove straight travel spool assembly (78) from the main valve body.
18. Disassemble the straight travel spool assembly. Remove piston (79) from spool (80). Remove dowel (82) and spring (81) from spool (80). Remove O-ring seal (83) from plug (77).
19. Remove bolts (84) that hold nine housings (85) to the main valve bodies. Remove nine housings (85).
20. Remove O-ring seal (86) from each housing (85).
21. Remove boom spool assembly (87), stick spool assembly (88), swing spool assembly (89) and travel spool assembly (90) from the main body.
22. Remove travel spool assembly (91), attachment spool assembly (92), bucket spool assembly (93), boom spool assembly (94) and stick spool assembly (95) from the main valve body.
NOTE: The disassembly procedure for spool assemblies (87), (88), (89), (90), (91), (92), (93) and (95) is the same. Spool assembly (94) is different in that it contains an internal selector spool.
23. Disassemble spool assemblies (87), (88), (89), (90), (91), (92), (93) and (95) as follows:
a. Slide adapter (96) of the spool assembly if so equipped. Remove O-ring seals (101) and (102) from adapter (96).
b. Remove bolt (100), retainer (99), spring (98) and retainer (97) from the end of the spool.
24. Disassemble boom spool assembly (94) as follows:
a. Remove plug (103), spring (108), spring (104), and valve group (109) from the end of the boom spool. Remove the O-ring seal from the plug.
b. Remove bolt (107), retainer (111), spring (106) and retainer (110) from the end of the boom spool.
25. Remove bolts (112) and the washers that hold ten covers (113) to the main valve bodies. Remove ten covers (113).
26. Remove O-ring seal (114) from each cover (113).
27. Remove spring (115) and seat (116) for the straight travel spool assembly.
28. Remove line relief valves (117) and (118) from the main valve bodies.
29. Disassemble line relief valves (117) and (118) as follows:
NOTE: Only the O-ring seals and back-up rings are serviceable in the line relief valves (117) and (118). However, the line relief valves can be disassembled for cleaning.
a. Disassemble the line relief valves as shown. Remove O-ring seal (124) from the adapter.
b. Remove back-up ring (119) and O-ring seal (120) from the valve.
c. Remove O-ring seal (121) and two back-up rings (125) from the seat.
d. Remove O-ring seal (123) from the piston.
30. Remove two relief valves (126) from the main valve bodies.
31. Remove two plugs (127) from the main valve bodies. Remove the O-ring seals from the plugs.
32. Disassemble relief valves (126) as follows:
a. Remove O-ring seal (132) from body (128).
b. Remove plug (131) from body (128). Remove the O-ring seal from the plug. Remove spring (130) and valve (129) from body (128).
33. Remove remaining plugs (133) from bottom side of the main valve bodies. Remove the O-ring seals from the plugs.
34. Remove four bolts (136) and the washers that hold main valve bodies (134) and (135) together. Separate the valve bodies.
35. Remove four large O-ring seals (137) and seven small O-ring seals (138) from the main valve body.
36. Using an appropriate size Allen wrench, remove the two plugs from main valve body (135) at locations (X).
Assemble Main Control
| NOTICE |
|---|
Be sure all parts of the main control valve are thoroughly clean and free of dirt and debris. Remove any scratches or burrs from valve components with polishing paper or oil stone. Check the condition of all O-ring seals, back-up rings, and springs. If any of the components are worn or damaged, use new parts for replacement. Put clean hydraulic oil on the components of the valve as they are being installed. Be sure to install all parts in their original locations. |
1. Using an appropriate size Allen wrench, install the two plugs in main valve body (135) at locations (X).
2. Install four large O-ring seals (137) and seven small O-ring seals (138) in the main valve body.
3. Put main valve body (135) in position on main valve body (134). Install four bolts (136) that hold the main valve bodies together. Tighten the four bolts evenly.
4. Install the O-ring seals on plugs (133). Reinstall plugs (133) in their original locations in the main valve bodies.
5. Assemble two relief valves (126) as follows:
a. Install O-ring seal (132) on body (128). Install the O-ring seal on plug (131).
b. Install valve (129), spring (130) and plug (131) in body (128).
6. Install two relief valves (126) in the main valve bodies as shown. Tighten the relief valves to a torque of 145 ± 15 N·m (105 ± 11 lb ft).
7. Install the O-ring seal on each plug (127). Install the two plugs in the main valve bodies as shown.
8. Assemble line relief valves (117) and (118).
a. Install O-ring seal on the piston.
b. Install two back-up rings (125) and O-ring seal (121) on the seat in the positions shown.
c. Install O-ring seal (120) and back-up ring (119) on the valve in the positions shown.
d. Install O-ring seal (124) on the adapter.
e. Reassemble the line relief valves and as shown.
9. Install line relief valves (117) and (118) in the main valve body as shown.
10. Install seat (116) and spring (115) for the straight travel spool in the main valve body as shown.
11. Install an O-ring seal (114) in each cover (113).
12. Reinstall ten covers (113) on the main valve bodies as shown. Use bolts (12) and the washers to hold the covers in place.
NOTE: The assembly procedure for spool assemblies (95), (93), (92), (91), (90), (89), (88) and (87) is the same. Spool assembly (94) is different in that it contains an internal selector spool.
13. Assemble boom spool assembly (94) as follows:
a. Install retainer (110), spring (106), retainer (111) and bolt (107) on the end of the valve spool as shown.
b. Install the O-ring seal on plug (103). Install valve group (109), spring (104), spring (108) and plug (103) in the end of the valve spool as shown.
14. Assemble spool assemblies (95), (93), (92), (91), (90), (89), (88) and (97) as follows:
a. Install O-ring seals (101) and (102) in each adapter (96).
b. Install retainer (97), spring (98), retainer (99) and bolt (100) on the end of the spool assembly as shown.
c. Slide adapter (96) on the appropriate spool assemblies.
15. Install stick spool assembly (95), boom spool assembly (94), bucket spool assembly (93), attachment spool assembly (92) and travel spool assembly (91) in the main valve body as shown.
16. Install travel spool assembly (90), swing spool assembly (89), stick spool assembly (88) and boom spool assembly (87) in the main valve body as shown.
17. Install an O-ring seal (86) in each housing (85).
18. Reinstall nine housings (85) on the main valve bodies as shown. Use bolts (84) and the washers to hold the housings in place.
19. Reassemble straight travel spool assembly (78) as follows:
a. Install O-ring seal (83) on plug (77).
b. Install spring (81), dowel (82) and plug (77) in the end of the spool as shown.
c. Install piston (79) in the end of the spool as shown.
20. Install straight travel spool assembly (78) in the main valve body as shown.
21. Install the O-ring seal on plug (77). Install the plug over the end of the straight travel spool assembly as shown.
22. Assemble the main relief valve (61) as follows:
a. Instal O-ring seals (72), (71) and (70) on body (73).
b. Install valve (74), spring (75) and seat (76) in body (73) as shown.
c. Install the two O-ring seals on insert (69). Install the insert in the valve body.
d. Install the O-ring seal on each end of adjuster (65). Install nut (64) and adjuster (65) in the valve group as shown.
e. Install valve (66), spring (67) and piston (68) in adjuster (65) as shown.
f. Install plunger assembly (63), the washer and nut (62) in the adjuster as shown.
23. Install main relief valve (61) in the main valve body. Tighten the main relief valve to a torque of 135 ± 10 N·m (100 ± 7 lb ft).
24. Install the O-ring seal on plug (60). Install plug (60) in the main valve body. Tighten the plug to a torque of 95 ± 14 N·m (70 ± 10 lb ft).
25. Assemble line relief valves (51) and (52).
a. Install O-ring seal on the piston.
b. Install two back-up rings (59) and O-ring seal (55) on the seat in the positions shown.
c. Install O-ring seal (54) and back-up ring (53) on the valve in the positions shown.
d. Install O-ring seal (58) on the adapter.
e. Reassemble the line relief valves as shown.
26. Install line relief valves (51) and (52) in the main valve bodies as shown. Tighten the line relief valves to a torque of 95 ± 14 N·m (70 ± 10 lb ft).
27. Install O-ring seal (49) on plug (50). Install check valve (47), spring (48) and plug (50) in the main valve body. Tighten the plug to a torque of 200 ± 25 N·m (150 ± 18 lb ft).
28. Install the O-ring seal on plug (43). Install valve (46), spring (45) and sleeve bearing (44) in the main valve body as shown. Install plug (43). Tighten the plug to a torque of 200 ± 25 N·m (150 ± 18 lb ft).
29. Install sleeves (41) and (42) in the main valve body as shown.
30. Install an O-ring seal on each plug (40). Install the plugs in the main valve bodies as shown.
31. Install the two check valves and five load check valves in the main valve bodies as follows:
a. Install plunger (39) and spring (38) for each check valve and load check valve.
b. Install O-ring seal (35) on five plugs (34). Install O-ring seal (37) and back-up ring (36) on two plugs (33).
c. Install two plugs (33) in the main valve body as shown.
d. Install four plugs (34) and one plug (34A) in the valve bodies as shown. Tighten four plugs (34) to a torque of 200 ± 25 N·m (150 ± 18 lb ft). Tighten plug (34A) to the standard torque value.
NOTE: The main control valve may not be equipped with plate (31).
32. Install O-ring seal (32) in plate (31). Install plate (31) and two bolts (30) that hold it to the main valve body as shown.
33. Install the check valve assembly in the main valve body as follows:
a. Install check valve (28), spring (29) and pilot (27) in the main valve body.
b. Install O-ring seal (26) in plate (24). Install O-ring seal (25) in plate (23).
c. Install plates (24) and (23) on the main valve body as shown. Install four bolts (22) and the washers that hold the plates in place.
34. Assemble and install pressure control valve (14) as follows:
a. Install the O-ring seal on plugs (21), (20) and (17).
b. Install six plugs (21) and four plugs (20) in the valve body.
c. Install spool (19), spring (18) and two plugs (17) in the valve body.
d. Install plug (16) in the valve body. Install O-ring seals (15) in the valve body as shown.
e. Put pressure control valve (14) in position on the main valve body as shown. Install three bolts (13) that hold it.
35. Assemble and install pressure control valve (2) as follows:
a. Install the O-ring seals on plugs (7), (11) and (12).
b. Install two plugs (11) and four plugs (12) in the valve body.
c. Install spool (10), valve (9) and spring (8) in the valve body. Install plugs (7) in the valve body.
d. Install O-ring seals (5) and (6) in the valve body as shown.
e. Install valve assembly (4) in the main valve body as shown.
f. Install spring (3) in the main valve body.
g. Put pressure control valve (2) in position on the main valve body as shown. Push down on the pressure control valve body to compress spring (3). While holding the valve in position, install four bolts (1).
End By:
a. install main control valve