Usage:
Fluid Spillage Containment
Care must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the 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 the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates.
 |
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 hydraulic system before any of the hydraulic lines or any of the components are disconnected or removed. |
 |
1. 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, as follows:
a. Fully retract the stick cylinder rod.
b. Adjust the position of the bucket so that 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 place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.
e. 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.
f. Return the key to "OFF" position.
g. Slowly loosen the fill plug on the hydraulic tank and release the pressure.
h. Tighten the fill plug on the hydraulic tank. Tighten the fill plug to a torque of 68 ± 7 N*m (50 ± 5 lb ft).
i. The pressure in the hydraulic system has been released and the hydraulic lines and the components can be removed.
View From Under Cab
2. Remove bolts (1), the washers and the spacers that hold access cover (2) in place. Remove the access cover from under the cab.
View From Under Cab
3. Put identification marks on ten hose assemblies (3) that are connected to the hydraulic activation control valve for installation purposes.
4. Oil will drain from ten hose assemblies (3) and the hydraulic activation control valve when the hose assemblies are disconnected from the valve. Place a drain pan under the area of the hydraulic activation control valve to contain the drain oil. Disconnect nine hose assemblies (3) from the hydraulic activation control valve. Put plugs in the ends of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system.
5. Disconnect electrical connector (4).
View From Under Cab
6. Disconnect remaining hose assembly (3) from the hydraulic activation control valve. Put a plug in the end of the hose assembly to prevent oil loss and to keep contaminants out of the hydraulic system.
7. Remove two bolts (5), the washers and hydraulic activation control valve (6).
NOTE: The following steps are for the installation of the hydraulic activation control valve.
8. Check the condition of the O-ring seals used in the ends of the hose assemblies that connect to the hydraulic activation control valve. If any of the O-ring seals are damaged, use new parts for replacement.
9. Install hydraulic activation control valve (6) in the reverse order of the removal steps.
10. Tighten the ten hose assemblies 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.
11. Check the oil level in the hydraulic oil tank. Fill the hydraulic oil tank with oil to the correct level.
Disassemble & Assemble Hydraulic Activation Control Valve
Start By:
a. remove hydraulic activation control valve
1. Make sure the outside of the hydraulic activation control valve is thoroughly clean prior to disassembly.
2. Remove two bolts (1) and solenoid valve (2) from the valve body.
3. Remove four O-ring seals (3) from solenoid valve (2).
4. Remove two bolts (4) and cover (5) from the valve body.
5. Remove spring (8) and spool (7) from the valve body. Remove O-ring seal (6) from cover (5).
6. Remove two bolts (9) and cover plate (10) from the valve body.
7. Remove O-ring seal (11) from the valve body.
8. Remove plug (12) from the valve body.
9. Remove O-ring seal (13) from plug (12).
NOTE: The following steps are for the assembly of the hydraulic activation control valve.
10. Make sure all of the components of the hydraulic activation control valve are thoroughly clean. Check the condition of all the components. If any of the components are worn or damaged, use new parts for replacement.
11. Apply clean hydraulic oil on all of the internal parts of the hydraulic activation control valve.
12. Assemble the hydraulic activation control valve in the reverse order of the disassembly.
End By:
a. install hydraulic activation control valve