Usage:
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide, NENG2500" for tools and the supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
1. Start the machine, and fully extend the stick and the bucket. Lower the stick and the bucket to the ground.
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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 all of the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed. |
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2. Release the pressure in all of the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed. Release the pressure as follows:
a. Shut off the engine and place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.
b. Move the control levers for the boom, the stick and the swing to all full stroke positions. This will release any pressure that might be present in the pilot system.
c. Return the key to "OFF" position.
d. Slowly loosen the fill plug on the hydraulic tank and release the pressure.
e. Tighten the fill plug on the hydraulic tank. Tighten the fill plug to a torque of 68 ± 7 N*m (50 ± 5 lb ft).
f. The pressure in the hydraulic system has been released and the hydraulic lines and components can be removed.
3. Remove five bolts (1), the washers and cover plate (2) from under the cab.
View From Under Cab
4. Put identification marks on four hose assemblies (3) for installation purposes.
5. Oil will drain from four hose assemblies (3) and the auxiliary pilot control valve when the hose assemblies are disconnected from the valve. Place a drain pan under the area of the pilot control valve to contain the drain oil. Disconnect four hose assemblies (3) from the auxiliary pilot control valve. Put plugs in the ends of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system.
View From Under Cab
6. Remove two fittings (4) from the auxiliary pilot control valve. This will provide the necessary clearance to remove the valve from the machine.
7. Remove pedal cover (5) from the auxiliary pilot control valve.
8. Remove two bolts (6), the washers and pedal plate (7).
9. Remove rubber bellow (8).
10. Remove two bolts (9), the washers and auxiliary pilot control valve (10) from the machine.
NOTE: The following steps are for the installation of the auxiliary pilot control valve.
11. Check the condition of the O-ring seals used in the ends of the hose assemblies that connect to the auxiliary pilot control valve. If any of the O-ring seals are damaged, use new parts for replacement.
12. Install auxiliary pilot control valve (10) in the reverse order of removal.
13. Tighten four hose assemblies (3) to a torque of 40 ± 5 N*m (30 ± 4 lb ft).
NOTE: Refer to the topic "Lubricant Viscosities and Refill Capacities" in the "Operation & Maintenance Manual" for the proper filling procedure and the proper levels for the hydraulic oil system.
14. Check the oil level in the hydraulic oil tank. Fill the hydraulic oil tank with oil to the correct level.
Disassemble & Assemble Auxiliary Pilot Control Valve (Straight Travel)
Start By:
a. remove auxiliary pilot control valve (straight travel)
1. Make sure the outside of the auxiliary pilot control valve is thoroughly clean prior to disassembly.
2. During disassembly of the auxiliary pilot control valve, put identification marks on each of the components for assembly purposes.
3. Remove the setscrew from the pedal.
4. Remove camshaft (2) and pedal (1).
5. Remove two socket head bolts (3) and cover (4).
6. Remove two plugs (7) from housing (5). Remove O-ring seal (6) from each plug (7).
7. Remove two spool assemblies (9) and two springs (8) from housing (5).
8. Disassembly valve spool assemblies (9) as follows:
a. Hold valve spool assembly (9) in one hand. Compress seat (10) to remove two locking collars (15).
b. Remove seat (10), spring (14), washer (13) and seat (12) from spool (11).
9. Note the orientation of two fittings (16) in housing (5). Remove two fittings (16) from housing (5).
10. Remove O-ring seal (17) from each fitting (16).
NOTE: The following steps are for the assembly of the auxiliary pilot control valve (straight travel).
11. Check the condition of all of the components of the auxiliary pilot control valve for wear of damage. If any of the components are worn or damaged, use new parts for replacement.
12. Assemble the auxiliary pilot control valve in the reverse order of disassembly.
13. During assembly, apply 9S-3263 Thread Lock on the setscrew that holds camshaft (2) in position. Install the setscrew in the pedal. Tighten the setscrew to a torque of 7 ± 1.0 N·m (5 ± 1 lb ft).Also, tighten socket head bolts (3) that hold cover (4) to housing (5) to a torque of 79 ± 10 N·m (58 ± 7 lb ft).
End By:
a. install auxiliary pilot control valve (straight travel)