Usage:
1. Activate the parking brake.
2. Connect the steering frame lock link. See "Separate & Connect Steering Frame Lock Link" in this module.
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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 the hydraulic system before and hydraulic lines or components are disconnected or removed. |
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3. Release the pressure in the hydraulic system as follows:
a. Shut off the engine.
b. Move the control levers through their full travel strokes. This will relieve any pressure that may be present in the pilot system.
c. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.
d. Tighten the air breather cap on the hydraulic oil tank.
e. The pressure in the hydraulic system has now been released. Lines and components can now be removed.
NOTE: Put identification on all tubes, lines, wires and hoses for installation purposes. Cap all lines to prevent loss of hydraulic oil.
4. Remove five bolts and washers (1) and remove left side shroud (2) from the machine.
5. Disconnect both ends of the six tube assemblies (3) attached to the hydraulic control valve.
6. Disconnect six hose assemblies (5) (three on top and three on the bottom of the hydraulic control valve).
7. Remove three bolts and washers (4) and remove the hydraulic control valve using two people. The weight of the hydraulic control valve is 41 kg (90 lb).
NOTE: Install in the reverse order.
8. Fill the hydraulic system to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.
9. Separate the steering frame lock link. See "Separate & Connect Steering Frame Lock Link" in this module.
Disassemble & Assemble Hydraulic Control Valve
Start By:
a. remove hydraulic control valve
1. Thoroughly clean the outside of the control valve before disassembly.
2. Mark for identification all components for assembly purposes.
3. Remove three nuts (1) from the hydraulic control valve.
4. Remove housing (2) from the hydraulic control valve.
5. Remove spring (3), poppet (4) and O-ring seal (6) from valve (5). Remove valve (5) from the hydraulic control valve.
6. Remove valve (7) from valve (5).
7. Remove four socket head bolts (8) and remove two caps (9) from valve (5).
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Socket head bolt holds springs that are under compression. Hold pressure against the socket head bolt while removing the bolt to prevent spring ejection and personal injury. |
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8. Remove socket head bolt (10) and remove spool assembly (11) out of valve (5).
9. Remove spring (12), poppet (13), O-ring seal (14) from valve (15) and remove valve (15) from the hydraulic control valve.
10. Remove two valves (16) from valve (15).
11. Remove four bolts (17) and remove two caps (18) from valve (15).
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Socket head bolt holds springs that are under compression. Hold pressure against the socket head bolt while removing the bolt to prevent spring ejection and personal injury. |
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12. Remove socket head bolt (19) and remove spool assembly (20) out of valve (15).
13. Remove spring (21), poppet (22), O-ring seal (23) from valve (24). Remove valve (24) from the hydraulic control valve.
14. Remove two valves (25) from valve (24).
15. Remove four socket head bolts (26) and remove caps (27) and (28) from valve (25).
16. Remove cap (28) from spool assembly (29).
17. Remove three rod assemblies (30) with nuts (1) and the washers. Remove O-ring seal (31) from housing assembly (32).
18. Remove valve (33) from housing assembly (32).
19. Remove two plugs (34) and (35) with the O-ring seals from housing (32).
NOTE: The following steps are for the assembly of the hydraulic control valve.
NOTE: Check all O-ring seals for wear or damage and replace if necessary.
20. Install two plugs (34) and (35) with the O-ring seals into housing (32).
21. Install valve (33) into housing (32). Torque valve (33) to 95 ± 13 N·m (70 ± 10 lb ft).
22. Install three nuts and washers (1) on three rod assemblies (3). Insert rod assemblies (30) into housing assembly (32). Install O-ring seal (31) into housing assembly (32).
23. Install cap (28) to spool assembly (29).
24. Install spool assembly (29) into valve (25). Install cap (27) and secure caps (27) and (28) with four socket head bolts (26). Tighten socket head bolts (26) to the torque of 7 N·m (5 lb ft).
25. Install two valves (25) to valve (24). Torque valves (25) to 95 ± 13 N·m (70 ± 10 lb ft).
26. Install O-ring seal (23), poppet (22), spring (21) into valve (24) and install valve (24) to the hydraulic control valve.
27. Install spool assembly (20) into valve (15) and secure with socket head bolt (19). Torque socket head bolt (19) to 10 N·m (7 lb ft).
28. Install two caps (18) to valve (15) and secure caps (18) with four socket head bolts (17). Torque socket head bolts (17) to 7 N·m (5 lb ft).
29. Install two valves (16) to valve (15). Torque valves (16) to 54 ± 13 N·m (40 ± 10 lb ft).
30. Install O-ring seal (14), poppet (13), spring (12) into valve (15). Install valve (15) to the hydraulic control valve.
31. Install spool assembly (11) into valve (5) and secure with socket head bolt (10). Torque socket head bolt (10) to 10 N·m (7 lb ft).
32. Install two caps (9) to valve (5) and secure caps (9) with four socket head bolts (8). Torque socket head bolts (8) to 7 N·m (5 lb ft).
33. Install valve (7) to valve (5). Torque valve (7) to 54 ± 13 N·m (40 ± 10 lb ft).
34. Install O-ring seal (6), popper (4) and spring (3) into valve (5). Install valve (5) into the hydraulic control valve.
35. Install housing (2) to the hydraulic control valve.
36. Install three nuts (1) that holds the hydraulic control valve together. Tighten the larger nut to the torque of 100 ± 10 N·m (75 ± 7 lb ft). Tighten the two small nuts to the torque of 65 ± 7 N·m (48 ± 5 lb ft).
End By:
a. install control valve