5230B Excavator Machine Systems Control Valve (Rear) - Disassemble Caterpillar

Disassembly Procedure

Start By:

1. Remove the rear control valve. Refer to Disassembly and Assembly, "Control Valve (Rear) - Remove".

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Illustration 1	g00825920

1. Remove eight bolts (2) from each adapter and remove four adapters (1) .

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Illustration 2	g00835871

2. Remove two seals (3) from the bottom of adapter (1). Remove plug (4) and the O-ring seal from adapter (1). Repeat the procedure for the other three adapters (1) .

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Illustration 3	g00825998

3. Remove 16 bolts (5) and remove cover (6) and cover (7) from the implement and travel control valve.

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Illustration 4	g00835888

4. Remove two small O-ring seals (8) and three large O-ring seals (9) from cover (6). Repeat the procedure for the other cover (7) .

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Illustration 5	g00826008

5. Remove four springs (10) and four valves (11). Remove two springs (12) and two valves (13) .

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Illustration 6	g00835902

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Illustration 7	g00835907

6. Remove four springs (14) and four valves (15). The springs and the valves are located under valves (11) .

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Illustration 8	g00826009

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Illustration 9	g00830426

7. Remove two locknuts (16) from coil assemblies (17). Remove two coil assemblies (17) .

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Illustration 10	g00830498

8. Remove two cartridges (18) from the control valve.

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Illustration 11	g00830499

9. Remove three O-ring seals (19) and two backup rings (20) from cartridge (18). Repeat the procedure for the remaining cartridge.

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Illustration 12	g00826018

10. Remove two relief valves (21) from the control valve.

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Illustration 13	g00830551
Relief Valve (21)

Note: Only the O-ring seals and backup rings in relief valves (21) are serviceable. However, the valve can be disassembled for cleaning.

11. Disassemble relief valve (21). Remove back up rings (22) and (26). Remove O-ring seal (23), two O-ring seals (24), O-ring seal (25), and O-ring seal (27). Repeat the procedure for the remaining five relief valves.

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Illustration 14	g00826022

12. Remove four plugs (28), and four seals (29) from makeup valves (30). Remove four makeup valves (30) .

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Illustration 15	g00830659
Makeup Valve (30)

13. Disassemble makeup valve (30). Remove valve (35) and spring (34) from makeup valve (30). Remove O-ring seal (31) and backup ring (32) from valve (35). Remove O-ring seal (33) from makeup valve (30). Repeat the procedure for the remaining three makeup valves (30) .

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Illustration 16	g00827843

14. Remove ten plugs (36) and the O-ring seals from manifold housings. Remove six spacers (37), and four dowels (38) from manifold housings. Remove ten resolvers (39) from manifold housings.

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Illustration 17	g00830681
Resolver Valve (39)

15. In order to disassemble resolver valves (39), use the procedure that follows:

    Note: Only the O-ring seals and backup rings in the relief valves (39) are serviceable. However, the resolver valve can be disassembled for cleaning and inspection.

    1. Remove backup rings (42) and (43) from resolver valve (39). Remove O-ring seals (40) and (41) from resolver valve (39) .

    2. Remove seat (44) from resolver valve (39) .

    3. Remove ball (45) from resolver valve (39) .

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Illustration 18	g00827862

16. Remove three resolver valves (46) from the control valve.

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Illustration 19	g00830682
Resolver Valve (46)

17. In order to disassemble resolver valves (46), use the procedure that follows:

    Note: Only the O-ring seals and backup rings in the relief valves (46) are serviceable. However, the resolver valve can be disassembled for cleaning and inspection.

    1. Remove two backup rings (50) and two backup rings (51) from resolver valve (46). Remove O-ring seals (47), (48), and (49) from resolver valve (46) .

    2. Remove seat (52) from resolver valve (46) .

    3. Remove ball (53) from resolver valve (46) .

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Illustration 20	g00827869

18. Remove two resolver valves (54) from the control valve.

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Illustration 21	g00830797
Resolver valve (54)

19. In order to disassemble resolver valves (54), use the procedure that follows:

    Note: Only the O-ring seals and backup rings in the resolver valves (54) are serviceable. However, the resolver valve can be disassembled for cleaning and inspection.

    1. Remove two backup rings (58) and two backup rings (59) from resolver valve (54). Remove O-ring seals (55), (56), and (57) from resolver valve (54) .

    2. Remove seat (60) from resolver valve (54) .

    3. Remove ball (61) from resolver valve (54) .

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Illustration 22	g00827882

20. Remove sixteen bolts (62). Remove two manifolds (63) and two spacers (64) from the control valve body. The combined weight of the manifold and a spacer is 34 kg (75 lb).

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Illustration 23	g00830800

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Illustration 24	g00827888

21. Separate the spacer from manifold housing (63). In order to disassemble manifold housing (63), use the procedure that follows:

    1. Remove three O-ring seals (68) from manifold housing (63) .

    2. Remove three retainers (67), three springs (66), and three retainers (65) from manifold housing (63) .

    3. Remove three purging screws (70). Remove three nuts (69) and remove plunger assembly (71) and the O-ring seals.

22. Repeat step 21 for the remaining manifold housing (63) .

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Illustration 25	g00830806

23. In order to disassemble spacer (64), use the procedure that follows.

    1. Remove three O-ring seals (72) from spacer (64) .

    2. Remove three plugs (74) and the O-ring seal. Remove three pistons (73) from spacer (64) .

24. Repeat step 23 for the remaining spacer (64) .

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Illustration 26	g00827891

25. Remove sixteen bolts (76). Remove two manifolds (75) from the control valve body. The weight of the manifold is 25 kg (54 lb).

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Illustration 27	g00830819

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Illustration 28	g00827894

26. In order to disassemble manifold housing (75), use the procedure that follows:

    1. Remove three O-ring seals (80) from manifold housing (75) .

    2. Remove three retainers (79), three springs (78), and three retainers (77) from manifold housing (75) .

    3. Remove three purging screws (82). Remove three nuts (81) and remove plunger assembly (83) and the O-ring seals.

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Illustration 29	g00828069

27. Put identification on spools (84). Spools (84) must be installed in the same position. Remove six spools (84) from the control valve.

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Illustration 30	g00830826

28. Attach Tooling (A) to the control valve. Secure Tooling (A) to a suitable lifting device. Position wood blocks under manifold (86). Illustration 30 shows the position of the wood blocks. Remove five bolts (87) (two bolts on top and three bolts on bottom) that hold valve (88) to manifold (86). Remove control valve (88) from manifold (86). The weight of control valve (88) is 204 kg (450 lb).

29. Repeat step 28 on control valve (85) .

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Illustration 31	g00830827

30. If necessary, remove all remaining plugs and O-ring seals from control valve (88). If necessary, remove all remaining fittings from the control valve.

31. Repeat step 30 for control valve (85) .

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Illustration 32	g00830829

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Illustration 33	g00830830

32. Remove five small O-ring seals (89), four large O-rings (90) and four large O-rings (91) from manifold (86). If necessary, remove all remaining plugs and fittings from manifold (86) .