308C CR Excavator Hydraulic System – Main Control Valve – Remove

Removal Procedure

Table 1
Required Tools    
Tool     Part Number     Description     Qty    
A     6V-9510     Plug     11    
6V-9831 Cap     11    
6V-9509 Plug     9    
6V-9830 Cap     9    
6V-9508 Plug     27    
6V-9829 Cap     27    
6V-9507 Plug     5    
6V-9828 Cap     5    
7E-8716 Cap     1    
B     138-7573     Link Bracket     2    

Start By:

  1. Release the pressure in the hydraulic system. Refer to the Disassembly and Assembly Manual, “Hydraulic System Pressure – Release” for the procedure.

Note: SERVICE DATA: TOOLING (A) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR IN THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.

Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.



NOTICE

Keep all parts clean from contaminants.

Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components.

To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly.

Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.


------ WARNING! ------

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

----------------------

Note: The hose assemblies and the tube assemblies that are connected to the main control valve contain loose O-ring seals. These seals can be lost during removal and installation of the main control valve. Use care when you disconnect the hose assemblies and the tube assemblies. Also, use care when you connect the hose assemblies and the tube assemblies to the main control valve.

  1. Obtain a hydraulic oil sample before you begin to remove the main control valve. The hydraulic oil sample will be used to establish a system contaminant level. Refer to the Operation and Maintenance Manual, SEBU7613, “Sampling Interval and Location of Sampling Valve”.
  1. Drain the oil from the hydraulic oil tank into a suitable container for storage or for disposal. Refer to the Operation and Maintenance Manual, SEBU7613, “Hydraulic System Oil – Change”. The capacity of the hydraulic oil tank is approximately 92 L (24.3 US gal).



    Illustration 1 g00910336

  1. Remove bolts (2). Remove right hand cover assembly (1) .



    Illustration 2 g00910026

  1. Remove bolts (3) and remove storage compartment (4) .
  1. Mark the location and orientation of each hose assembly on the main control valve. The marks will be used during the future installation of the main control valve.



    Illustration 3 g00910051

  1. Disconnect two hose assemblies (5) .



    Illustration 4 g00910063

  1. Disconnect two hose assemblies (6) .



    Illustration 5 g00910118

  1. Disconnect two hose assemblies (7) .



    Illustration 6 g00910122

  1. Disconnect three hose assemblies (8) from the right side of the control valve.
  1. Remove two bolts (9) and position the bracket out of the way.
  1. Remove two bolts (10) and position the water separator out of the way.
  1. Remove bolts (11) and position bracket (12) out of the way.



    Illustration 7 g00910202

  1. Disconnect hose assemblies (13) from the top of the control valve.
  1. Disconnect harness assembly (14) .



    Illustration 8 g00910211

  1. Remove bolts (15) and position block (16) out of the way.



    Illustration 9 g00910233

  1. Disconnect hose assemblies (17) on the left side of the control valve.

    Note: It may be necessary to lift the control valve in order to access the bottom hose assemblies.




    Illustration 10 g00910223

  1. Install Tooling (B). Use a suitable lifting device to remove the control valve. The approximate weight of the control valve is 91 kg (200 lb). Remove four bolts (18) .