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HYDRAULICS
CHAPTER 13
HYDRAULICS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
N
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
O
LIFT CYLINDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
LIFT CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
TILT CYLINDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
SI
TILT CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
HYDRAULIC CYLINDER EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
HYDRAULIC CYLINDER REBUILDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
R
CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
MAIN RELIEF VALVE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
VE
PORT RELIEF VALVE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
HYDRAULIC CONTROL VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13
HYDRAULIC CONTROL VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
JOYSTICK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
JOYSTICK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.23
Y
AUXILIARY CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.31
AR
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.32
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.33
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.37
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.42
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.42
IN
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.42
FRONT AUXILIARY HYDRAULIC COUPLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
POWER STEERING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
13
IM
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
MANIFOLD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
TWO SPEED PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
EL
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.45
TWO SPEED MANIFOLD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.46
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.47
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.49
HYDRAULIC FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.51
PR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.51
HOUSING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.51
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.52
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.52
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.52
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.52
GEAR PUMP EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.54
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.55
13.1
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
SPECIFICATIONS Lubrication
Torque Specifications
ITEM TORQUE VALUE =
Hydraulic Cylinder Hose Recommended Hydraulic Lubricant:
22 ft-lbs (30 Nm)
Coupler Polaris Hydraulic Fluid (PN 2879746) (Gallon)
Gear Pump Mounting Bolts 26 ft-lbs (35 Nm)
N
Reservoir Capacity:
Hydraulic Cylinder Piston All Models: 2.75 qts (2.6 L)
140 ft-lb (190 Nm)
Nut
O
Housing Plug 17 ft-lbs (23 Nm) Full System Capacity:
BRUTUS: 7.2 qts. (6.8 L)
Hydraulic Filter Housing
SI
26 ft-lbs (34 Nm)
Mounting Bolts BRUTUS HD / HDPTO: 8.4 qts (7.9 L)
Hydraulic Control Mounting
22 ft-lbs (30 Nm)
Bolts
R
37° Hydraulic Control Valve
40 ft-lbs (54 Nm)
Hose Fitting
VE
Straight Hydraulic Control
22 ft-lbs (30 Nm)
Valve Hose Fitting
Special Tools
Y
PART NUMBER TOOL DESCRIPTION
AR
PU-51022 Quadrigage
PU-51107 O-ring Seal Hook
Adjustable Gland Nut Wrench
PU-51108 (PU-51108-1) and
IN
Standard Pins (PU-51108-2)
PU-51199 Quick Coupler Kit
PU-51219 Hydraulic Adapter Kit
IM
PU-51225 Port Relief Pressure Tool
PU-51292 Rod Seal Install Tool
EL
Seal Expander / Compression
PU-51293
Tool
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
PR
13.2
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
HYDRAULIC CYLINDER 6. Start the engine and actuate the lift cylinder. If there
is any leakage from the base end fitting remove the
Testing cylinder for repair or replacement.
7. Remove and cap the hose (Item 4) from the base end
WARNING of the tilt cylinder.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person's body by
N
penetrating the skin. This may cause serious injury
or death if proper medical treatment by a physician
O
familiar with this injury is not received immediately.
4
1. Lower the work equipment to the ground.
SI
2. Remove the retaining pin (Item 1) and pin (Item 2)
from the rod end of the lift cylinder.
R
VE
8. Start the engine and retract the tilt cylinder. If there is
any leakage from the base end fitting, remove the
2 cylinder for repair or replacement.
1 9. Reinstall hydraulic lines to the cylinders. Torque
Y
fasteners to specification.
AR
=T
Hydraulic Cylinder Hose Coupler:
3. Unlock the attachment arm tilt and lift switches to 22 ft-lbs (30 Nm)
IN
enable the joystick.
4. Start the engine and fully retract the cylinder rod. Turn
10. Lower the work equipment to the ground.
13
the key switch OFF.
IM
5. Remove and cap the hose (Item 3) from the base end
of the lift cylinder.
EL
3
PR
13.3
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
Lift Cylinder Removal Lift Cylinder Installation
1. Lower the work equipment to the ground. 1. Mount the case end of the lift cylinder to the
attachment mount and install the retaining pin and
2. Remove the hoses (Item 1) from the lift cylinder. clip.
2. Mount the rod end of the lift cylinder to the attachment
adapter assembly. Install the retaining pin and clip.
3. Install the hydraulic hose with the green strap to the
N
base end of the lift cylinder. Install the hydraulic hose
1 with the blue strap to the rod end of the lift cylinder.
O
Torque hydraulic couplers to specification.
SI
=T
Hydraulic Cylinder Hose Coupler:
22 ft-lbs (30 Nm)
R
3. Remove the retaining clip (Item 2) and pin (Item 3)
VE
from the rod end of the cylinder.
Y
3
AR
2
IN
IM
4. Remove the retaining clip (Item 4) and pin (Item 5)
from the base end of the lift cylinder.
EL
4
5
PR
5. Remove the cylinder.
13.4
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
Tilt Cylinder Removal Tilt Cylinder Installation
1. Lower the work equipment to the ground. 1. Mount the case end of the tilt cylinder to the
attachment mount and install the retaining pin and
2. Remove the hoses (Item 1) from the tilt cylinder. clip.
2. Mount the rod end of the tilt cylinder to the attachment
adapter assembly. Install the retaining pin and clip.
3. Install the hydraulic hose with the pink strap to the
N
base end of the tilt cylinder and the hose without
markings to the rod end of the tilt cylinder. Torque
O
1 hydraulic couplers to specification.
SI
=T
Hydraulic Cylinder Hose Coupler:
22 ft-lbs (30 Nm)
R
VE
3. Remove the retaining clip (Item 2) and pin (Item 3)
from the rod end of the cylinder.
Y
3
AR
2
2
3
IN
13
IM
4. Remove the retaining clip (Item 4) and pin (Item 5)
from the base end of the tilt cylinder and remove the
cylinder.
EL
5
4
PR
13.5
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
Hydraulic Cylinder Exploded Views
1 11
Lift Cylinder
8
11
12
8
N
O
8 10
7 6
SI
8
1. Grease Fitting
2. Rod 6 9
R
3. Wiper
5
4. Seal
5. Head 4
VE
6. Seal
3
7. Back-up Ring
8. O-ring 1
9. Piston
10. Nut 2
11. Plug
Y
12. Case
AR
11
Tilt Cylinder
8
IN
12 11
8
1
IM
10
6
EL
8 8
7
9
1. Grease Fitting
2. Rod
PR
3. Wiper 6
4. Seal
5. Head 5
6. Seal 4
7. Back-up Ring
3
8. O-ring
9. Piston 1
10. Nut 2
11. Plug
12. Case
13.6
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
HYDRAULIC CYLINDER REBUILDING case.
Cylinder Disassembly
Use the following tools to disassemble the cylinder.
· PU-51107 - O-ring Seal Hook
· PU-51108-1 - Adjustable Gland Nut Wrench
· PU-51108-2 - Standard Pins
N
· PU-51293 - Seal Expander and Compression Kit 1
O
· PU-51292 - Rod Seal Installation Tool
1. Clean the outside of the cylinder before disassembly.
SI
2. Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the
cylinder.
R
6. Remove the cylinder case from the vise.
3. Put the base end of the cylinder in a vise.
7. Install the rod end in the vise.
VE
4. Insert the adjustable gland nut wrench into the holes
8. Remove the nut (Item 2) from the piston end of the rod.
and loosen the head. Y
AR
IN
2
13
IM
9. Remove the piston (Item 3), cushion sleeve (Item 4)
5. Remove the rod assembly (Item 1) from the cylinder
EL
PR
13.7
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
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HYDRAULICS
(if equipped) and head (Item 5). 12. Remove the wiper seal (Item 9).
5
3
N
O
9
SI
4
R
10. Remove the seal (Item 6). 13. Remove the seal (Item 10).
6
VE 10
Y
AR
IN
11. Remove the O-ring (Item 7) and back-up ring (Item 8). 14. Remove the seal (Item 11) from the piston.
IM
EL
7
PR
8
11
13.8
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
15. Remove the O-ring (Item 12). Cylinder Assembly
Always use new O-rings and seals during assembly.
1. Clean parts in clean solvent and dry with compressed
air.
2. Install the O-ring (Item 1) on the piston.
N
12 1
O
SI
R
VE 3. Install the seal (Item 2) on the seal expander tool (PU-
51293-1). Allow the seal to stretch for 30 seconds
Y
before removing.
AR
IN
13
IM
2
EL
PR
13.9
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
4. Install the seal (Item 3) on the piston. 7. Install the seal (Item 4) in the head using the rod seal
tool (PU-51292).
3
N
O
4
SI
R
5. Use a ring compressor (PU-51293-2) to compress the
piston seal. 8. Install the wiper seal (Item 5) with the lip towards the
outside of the head.
VE
Y
AR
5
IN
6. Leave the piston in the ring compressor for at least
IM
9. Install the back-up washer (Item 6) and the o-ring
three minutes.
(Item 7) on the head.
EL
6 7
PR
13.10
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
10. Install the seal (Item 8). 13. Install the piston (Item 9) on the rod with the tapered
end towards the head. Install the nut and torque to
specification.
8
N
O
SI
9
R
NOTE: Do not roll the seal. Seal damage may result.
11. Use a ring compressor to compress the seal on the
VE
head and leave it on for at least five minutes. =T
Hydraulic Cylinder Piston Nut
140 ft-lb (190 Nm)
14. Remove the rod from the vise.
Y
AR
IN
13
IM
12. Install the head on the rod.
EL
PR
13.11
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
15. Install the cylinder case in the vise and apply oil to the 18. Apply oil to the head seals and threads.
seal surface of the cylinder case.
N
O
SI
19. Using an adjustable gland wrench, tighten the head
R
until it is flush with the case.
16. Apply oil to the piston teflon seal.
VE
Y
AR
IN
17. Install the rod assembly (Item 10) into the cylinder
IM
case.
EL
PR
10
13.12
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
HYDRAULIC CONTROL VALVE 4. Loosen the lock nut (Item 4).
Main Relief Valve Testing
1. Remove the cover (Item 1) from the factory installed
quick coupler (Item 2) on the gear pump.
5
N
4
O
2
SI
1
R
5. Turn the adjustment screw (Item 5).
NOTE: 1/4 turn is approximately 100 psi (689 kPa).
VE
When the correct pressure setting is obtained,
tighten the lock nut while holding the adjustment
screw from turning.
2. Install the Quadrigage (PU-51022) gauge onto the
coupler (Item 3). 6. Adjust the main relief valve until the correct setting is
obtained
Y
AR
Port Relief Valve Testing
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Polaris fluid.
3
IN
1. Install the hand pump (PU-51225), hose (Item 1) and
the quadrigage (PU-51022) onto a front auxiliary 13
quick coupler (Item 2).
IM
EL
3. Start the engine and run at high idle. The gauge
should read 1378 - 1522 psi (9501 - 10494 kPa).
2
PR
1
13.13
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
2. With the engine off, pressurize the section with the 4. Remove the storage tray (Item 2).
hand pump. Watch the hand pump gauge. When the
pressure stops increasing, relief pressure 1740 - 1957
psi (11,997 - 13493 kPa) has been reached. Do not
exceed the listed relief pressure.
Hydraulic Control Valve Removal
1. Lower the lift arm and stop the engine.
N
2. Relieve the pressure from the hydraulic system by 2
O
turning engine off and moving the joystick around.
WARNING
SI
AVOID INJURY OR DEATH Always clean up spilled
R
fuel or oil. Keep heat, flames, sparks or lighted 5. Disconnect the negative battery cable (Item 3).
tobacco away from fuel and oil. Failure to use care
around combustibles can cause explosion or fire
VE
IMPORTANT: When repairing hydrostatic and
hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always use
caps and plugs on hoses, tubelines and ports to keep
dirt out. Dirt can quickly damage the system
Y
3. Remove the passenger side seat base (Item 1) by
AR
tipping it forward and lifting straight up.
3
IN
6. Tip the drivers seat forward and cut the cable ties
(Item 4). Disconnect the seat sensor harness (Item 5).
IM
1 6
EL
PR
4
5
4
7. Remove the seat base (Item 6).
13.14
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
8. Remove the storage tray (Item 7). 11. Remove the three bolts (Item 9) and reposition the
Speed Control Lever off to the side.
7
N
O
9
SI
R
9. Remove the four plastic rivets (Item 8) from the center
console. 12. Remove the two screws (Item 10) from the center tray.
VE
10
Y
8
AR
IN
13
13. Mark and remove the hoses (Item 11).
IM
EL
8
11
PR
11
10. Position the center console out of the way.
13.15
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
14. Mark and remove the hoses (Item 12). 17. Remove the bolt (Item 15) and the hydraulic control
valve (Item 16).
N
12 12
12
O
16 15
SI
R
15. Disconnect the wire harness (Item 13).
Hydraulic Control Valve Installation
VE
To install the hydraulic control valve, reverse the removal
procedure. Torque fasteners to specification.
13 =T
Y
Hydraulic Control Valve Mounting Bolts:
AR
22 ft-lbs (30 Nm)
37° Hydraulic Control Valve Hose Fitting:
13 40 ft-lbs (54 Nm)
IN
Straight Hydraulic Control Valve Hose Fitting:
22 ft-lbs (30 Nm)
16. Remove the bolt (Item 14).
IM
EL
PR
14
13.16
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
Joystick Exploded View
30
23
29 22
24
28
N
21
O
20
27 4
SI
12 19 17
25 18
R
26 4
22 4
VE
11 16
25
** 4
25 8
11 7
4 6
15
Y
22 5
4
1. Screw 10 4
11
AR
2. Cap 11
3. Spool Positioner 12
14
4. O-ring 4
5. Bolt 4
12
6. Spacer 11 13 4
IN
7. Spool
8. Coil 11
9. Nut 4 13
10. Pin 18
10
IM
11. Plug
4
12. Washer
13. Spring 4 10
14. Relief Valve 8
4 9
EL
15. Valve Body 4
16. Backup Ring 7 8
17. Relief Valve 6 4 4
18. Spool 7
19. Gasket 4
PR
20. Screw 5 4 6
21. Plate 3 5
22. Nut 4
23. Bracket 3
24. Screw 2
25.Rod End
26. Plate 1
27. Screw 2
28. Bolt
29. Boot 1
30. Tie Strap
13.17
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
HYDRAULICS
Joystick Disassembly 4. Remove the rod end (Item 5).
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from fuel
and oil. Failure to use care around combustibles can
N
cause explosion or fire
IMPORTANT: When repairing hydrostatic and
O
hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always use 5
SI
caps and plugs on hoses, tubelines and ports to keep
dirt out. Dirt can quickly damage the system
1. Clean the outside of the control valve before
R
disassembling. 5. Remove the nut (Item 6) and pin (Item 7).
2. Loosen the jam nut (Item 1) and remove the hand grip
VE
(Item 2).
7
1
Y
AR
6
2
IN
6. Remove the nut (Item 8) and rod end assembly (Item
9).
IM
3. Remove the bolts (Item 3) and boot (Item 4).
EL
9
PR
3 3
8
4
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HYDRAULICS
7. Remove the two screws (Item 10) and rod end 10. Remove the relief valve (Item 13).
assembly bracket.
N
O
13
SI
10
R
11. Remove the o-rings (Item 14) and backup ring (Item
8. Remove the other two screws (Item 11) from the 15).
bracket.
VE
Y 15
AR
14
11
IN
13
12. Remove the nuts (Item 16) from the coils.
IM
9. Remove the gasket (Item 12).
16
EL
PR
12
13.19
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HYDRAULICS
13. Remove the o-rings (Item 17) and coils (Item 18). 16. Remove the two screws (Item 22) and end cap (Item
23).
18
23
N
O
17
SI
22
R
14. Remove the o-rings (Item 19) and spools (Item 20).
17. Remove the spool (Item 24).
20
VE
Y
24
AR
19
IN
15. Remove the o-ring (Item 21) from the spool.
18. To remove the plugs from the spool, a holding fixture
IM
will have to be made from a 19 mm thick x 38 mm wide
x 50 mm long block of wood.
CUT
EL
PR
51 mm
16mm (2.0 in)
21 (0.63 in)
38mm
(1.5 in) 19mm
(0.75 in)
13.20
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HYDRAULICS
NOTE: Do not use anything other than hardwood 21. Remove the screws (Item 29) and end cap (Item 30).
blocks to grip the spool or the spool will be damage.
19. Using the wood blocks (Item 25) clamp the spool
assembly (Item 26) in a vise and remove the spool
positioner (Item 27).
29
N
30
O
25
SI
27 26
R
22. Remove the spool (Item 31).
VE
20. Remove the pin (Item 28).
31
Y
28
AR
IN
13
23. Using the wood blocks clamp the other spool in a vise.
IM
EL
PR
32
24. Loosen the screw and remove the spool positioner
(Item 32).
13.21
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HYDRAULICS
25. Remove the pin (Item 33). 28. Remove the o-rings (Item 37) and from both sides of
the spacers.
37 37
N
O
33
SI
R
26. Remove the o-rings (Item 34).
29. Remove the brass seals (Item 38).
VE
Y
AR
34 34
38
IN
27. Remove the screws (Item 35) and spacers (Item 36).
30. Remove the o-rings (Item 39) and cross port relief
IM
valves (Item 40). Remove the o-rings from the cross
36 port relief valves.
EL
39
PR
40
35
13.22
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HYDRAULICS
31. Remove the caps (Item 42). 34. Remove the o-rings (Item 46) and backup rings (Item
47).
47
N
O
42
46
SI
R
32. Remove the spring (Item 43) and pin (Item 44).
35. Remove the plugs (Item 48) and the plug o-rings.
VE
Y
AR
43
44
48
IN
13
33. Remove the plugs (Item 45).
IM
EL
PR
48
45
13.23
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HYDRAULICS
Assembly 3. Install the o-rings (Item 2) and backup ring (Item 3).
1. Clean all parts in solvent and dry with compressed
air. Replace all o-rings and seals. Inspect all parts for
wear or damage. Replace worn or damaged parts. 3
2. Install o-rings on the plugs and install the plugs (Item
1). Torque to specification.
N
O
2
SI
R
4. Install the plugs (Item 4). Torque to specification.
1
VE
Y
AR