- Install O-ring seal (201) to the left main valve body.
Show/hide table
Illustration 2 g00639061 - Install two large O-ring seals (200), two medium O-ring seals (199), and six small O-ring seals (198) to the right main valve body.
Show/hide table
Illustration 3 g00639060 - The weight of each main valve body is
227 kg (500 lb) . Assemble the main valve bodies. Install the washers and four bolts (196) that hold left main valve body (197) and right main valve body (195) together.Show/hide tableIllustration 4 g00639055 - Install O-ring seal (194) onto plug (192).
Show/hide table
Illustration 5 g00639054 - Install O-ring seal (193) onto sensors (191).
Show/hide table
Illustration 6 g00639051 - Install two sensors (191) and plug (192) into the main valve body.
Show/hide table
Illustration 7 g00639046 - Install seat (190) for the straight travel spool assembly into the main valve body.
Show/hide table
Illustration 8 g00639044 - Install spring (189) in the seat.
Show/hide table
Illustration 9 g00639041 - Install O-ring seal (188) in each of the nine housings (187).
Show/hide table
Illustration 10 g00639039 - Install nine housings (187). Install bolts (186) that hold the housings in position.
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
![]() | |
Illustration 1 | g00639066 |
Regeneration Valve for the Stick
- Assemble the regeneration valve (176) for the stick, as follows:
- Install O-ring seals (178), and (184) onto valve body (177).
- Install pin (185), valve (183), spring (182), rod (181), spool valve (180), and spring (179) into valve body (177).
Show/hide tableIllustration 11 g00639038 Show/hide tableIllustration 12 g00639036 - Place regeneration valve (176) into position and install four bolts (175).
Stroke Limiter for Tamping Mode
- Assemble stroke limiter (167), as follows:
- Install O-ring seal (171) into valve body (170).
- Install O-ring seal (169) onto plug (168).
- Install piston (174), spring (173), and spacer (172) into valve body (170).
- Install plug (168) into valve body (170).
Show/hide tableIllustration 13 g00639012 Show/hide tableIllustration 14 g00638988 - Put stroke limiter (167) into position on the main valve body. Compress the spring inside the stroke limiter by hand, and install two bolts (166).
Stem Assemblies for the Main Control Valve
- Assemble the stem for the boom I (137), as follows:
- Install O-ring seal (165) onto rod (159).
- Install valve (164) and spring (163) onto the end of the spool.
- Install rod (159).
- Install retainer (162), spring (161), and retainer (160) onto the end of rod (159).
- Install the washer (158) and bolt (157) to the other end of spool (148).
Show/hide table
Illustration 16 g00638986 - Install O-ring seal (155) onto plug (156).
- Install spring (149), valve (150), spring (151), valve (152), valve (153), spring (154), and plug (156) into spool (148).
Show/hide tableIllustration 15 g00638987 Note: The assembly procedure for the stem for right travel (134) and the stem for the left travel (133) is identical as the previous stems except the stems for travel have an adapter.
Show/hide tableIllustration 17 g00638985 - Install O-ring seals (144), (146) and (147) onto adapter (145).
- Assemble the stems for boom II (130), swing (132), right travel (134), bucket (136), and stick II (138), as follows:
- Install retainer (142), spring (141), and retainer (140) into spool (143).
- Install bolt (139) into the end of spool (143).
Show/hide tableIllustration 18 g00638984 Show/hide tableIllustration 19 g00638983 - Install the stems for stick I (131), left travel (133), attachment (135), and boom I (137) into the main valve bodies.
- Install the stems for the boom II (130), swing (132), right travel (134), bucket (136), and stick II (138) into the main valve bodies.
Show/hide table
Illustration 20 g00638982 - Install O-ring seal (129) into each housing (128).
Show/hide table
Illustration 21 g00638980 - Install the nine housings (128) in the original position.
- Install bolts (127) that hold the housings in position.
- Assemble the stem (100) for straight travel, as follows:
- Install O-ring seal (102) onto plug (101).
- Install valve (105), spring (104), dowel (103), and plug (101) into spool (106).
- Install piston (107) into spool (106).
Show/hide tableIllustration 22 g00638974 Show/hide tableIllustration 23 g00638973 - Install the stem (100) for straight travel into the main valve body.
Show/hide table
Illustration 24 g00638972 - Install O-ring seal (99) onto plug (98).
Show/hide table
Illustration 25 g00638971 - Install plug (98) into the main valve body.
Relief Valve for Negative Flow Control
- Assemble the two relief valves for negative flow control, as follows:
- Install O-ring seal (93) and O-ring seal (94) onto valve body (95).
- Install O-ring seal (96) onto plug (97).
- Install valve (91), spring (92), and plug (97) into valve body (95).
Show/hide tableIllustration 26 g00638969 Show/hide tableIllustration 27 g00638957 - Install two relief valves (90) for the negative flow control to the main valve bodies.
- Assemble main relief valve (73), as follows:
- Install the filter, collar (88), and ring (89) into valve (83).
Show/hide table
Illustration 29 g00638949 - Install O-ring seals (85), (86) and (87) onto valve body (84).
- Assemble valve body (84).
- Install valve (83), spring (82), and seat (81) into valve body (84).
Show/hide table
Illustration 30 g00638946 - Install O-ring seal (75) onto adjuster (76).
- Install O-ring seal (78) onto adapter (77).
- Install valve (80), spring (79), and adapter (77) into valve group (84).
- Install adjuster (76) and nut (74) into adapter (77).
Show/hide tableIllustration 28 g00638955 Show/hide tableIllustration 31 g00638945 - Install the filter, collar (88), and ring (89) into valve (83).
- Install main relief valve (73) into the main valve body.
Plug for the Attachment Control Valve
- Install O-ring seal (72), backup ring (71), and O-ring seal (70) onto plug (69).
Show/hide table
Illustration 33 g00638943 - Install plug (69) into the attachment control valve.
![]() | |
Illustration 32 | g00638944 |
- Assemble line relief valves (43), (44), (45), (46), (47), and (48), as follows:
- Install O-ring seals (58) and (59) into nut (68).
- Install O-ring seal (56), backup ring (65), and seal (55) onto adapter (66).
- Install backup ring (62) and O-ring seal (52) onto valve (53).
- Install O-ring seal (49) onto adapter (50).
- Install spring (64), spring (54), valve (63), valve (53), and sleeve (51) into the bottom half of the relief valve.
- Install needle valve (57) and spring (67) into adapter (66).
- Screw nut (68) onto adjusting screw (60). Make sure that you install the nut with the correct number of turns that was documented in the disassembly. The valve must be reset to the correct relief pressure if the number of turns were not documented.
- Install cap (61) onto adjusting screw (60).
- Connect adapter (50) into adapter (66).
Show/hide tableIllustration 34 g00638941 Show/hide tableIllustration 35 g00638926 Show/hide tableIllustration 36 g00638940 - Install line relief valve (43), (44) and (45) to the top of the main valve. Install line relief valve (46), (47), and (48) to the bottom of the main valve.
Check Valve for the Boom II Control Valve
- Install check valve (38) to the boom II control valve, as follows:
- Install O-ring seal (41) onto plug (42).
- Install check valve (39), spring (40), and plug (42) into the Boom II Control Valve.
Show/hide tableIllustration 38 g00638878
![]() | |
Illustration 37 | g00638863 |
Check Valves for the Left Travel Control Valve and the Right Travel Control Valve
- Install two check valves (34) to the travel control valves, as follows:
- Install two sleeves (37) into the travel control valves.
Show/hide table
Illustration 41 g00638861 - Install O-ring seal (35) onto each plug (36). Install two plugs (36).
Show/hide tableIllustration 40 g00638862 - Install two sleeves (37) into the travel control valves.
![]() | |
Illustration 39 | g00638858 |
Check Valves for the Straight Travel Control Valve
- Install two check valves (28) to the straight travel control valve, as follows:
- Install two check valves (32) and two springs (33) into the left travel control valve and the right travel control valve.
Show/hide table
Illustration 44 g00638848 - Install backup ring (30) and O-ring seal (29) onto each plug.
- Install two plugs (31) into the main valve body.
Show/hide tableIllustration 43 g00638851 - Install two check valves (32) and two springs (33) into the left travel control valve and the right travel control valve.
![]() | |
Illustration 42 | g00638844 |
- Install six load check valves (23) into the main control valve, as follows:
- Install O-ring seal (26) onto each plug (27).
- Install six check valves (24), six springs (25), and six plugs (27) into the main valve body.
Show/hide tableIllustration 46 g00638838
![]() | |
Illustration 45 | g00638841 |
- Install O-ring seal (22) onto adapter (21).
Show/hide table
Illustration 48 g00638787 - Install adapter (21) into the front of the main valve body.
![]() | |
Illustration 47 | g00638836 |
Check valve for the Stick I Control Valve
- Install the check valve to the stick I control valve, as follows.
Show/hide table
Illustration 49 g00638786 - Install two shims (20) and sleeve (19) into the stick I control valve.
Show/hide table
Illustration 50 g00638783 - Install check valve (18) into the stick I control valve.
Show/hide table
Illustration 51 g00638782 - Install spring (17) into the stick I control valve.
Show/hide table
Illustration 52 g00638780 - Install pilot valve (16) into the stick I control valve.
Show/hide table
Illustration 53 g00638768 - Install O-ring seal (15) to the plate. Install plate (14) to the stick I control valve.
Note: Use bolts in order to hold the plate in position until the main control valve is placed back into the machine and the proper tube assembly is hooked up.
- Assemble swing priority valve (2), as follows:
- Install O-ring seal (12) onto plug (13).
- Install O-ring seal (8) onto plug (7).
- Install plug (13), valve (11), spool (10) and spring (9) into the valve body.
- Install plug (7).
Show/hide table
Illustration 55 g00638763 - Install O-ring seals (5) and (6) into the valve body.
Show/hide tableIllustration 54 g00638765 Show/hide tableIllustration 56 g00638557 - Install check valve (4) into the main valve body.
Show/hide table
Illustration 57 g00638556 - Install spring (3) into the main valve body.
Show/hide table
Illustration 58 g00638555 - Install swing priority valve (2) into the main valve body.
- While you hold swing priority valve (2) in place, install four bolts (1).
End By:
- Install the main control valve. Refer to Disassembly and Assembly, "Main Control Valve - Install".