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    Group 7 RCV Lever: 1. Removal and Install

    Uploaded by

    Rafał Dworak
    1. The document provides instructions for removing, installing, disassembling and assembling a Group 7 RCV lever. It details the specific components and steps to take the lever apart and put it back together. 2. The disassembly process involves removing 21 separate parts in a specific sequence. Cleaning instructions are also provided to ensure parts are thoroughly cleaned before reassembly. 3. Reassembly follows the reverse of the disassembly process, noting proper orientation and torque specifications for each component. Grease and rust preventatives should be applied during assembly.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Group 7 RCV Lever: 1. Removal and Install

    Uploaded by

    Rafał Dworak
    63 views15 pages
    1. The document provides instructions for removing, installing, disassembling and assembling a Group 7 RCV lever. It details the specific components and steps to take the lever apart and put it back together. 2. The disassembly process involves removing 21 separate parts in a specific sequence. Cleaning instructions are also provided to ensure parts are thoroughly cleaned before reassembly. 3. Reassembly follows the reverse of the disassembly process, noting proper orientation and torque specifications for each component. Grease and rust preventatives should be applied during assembly.

    Original Title

    8-7

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    © © All Rights Reserved

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    1. The document provides instructions for removing, installing, disassembling and assembling a Group 7 RCV lever. It details the specific components and steps to take the lever apart and put it back together. 2. The disassembly process involves removing 21 separate parts in a specific sequence. Cleaning instructions are also provided to ensure parts are thoroughly cleaned before reassembly. 3. Reassembly follows the reverse of the disassembly process, noting proper orientation and torque specifications for each component. Grease and rust preventatives should be applied during assembly.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    63 views15 pages

    Group 7 RCV Lever: 1. Removal and Install

    Uploaded by

    Rafał Dworak
    1. The document provides instructions for removing, installing, disassembling and assembling a Group 7 RCV lever. It details the specific components and steps to take the lever apart and put it back together. 2. The disassembly process involves removing 21 separate parts in a specific sequence. Cleaning instructions are also provided to ensure parts are thoroughly cleaned before reassembly. 3. Reassembly follows the reverse of the disassembly process, noting proper orientation and torque specifications for each component. Grease and rust preventatives should be applied during assembly.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 15

    GROUP 7 RCV LEVER

    1. REMOVAL AND INSTALL


    1) REMOVAL

    (1) Lower the work equipment to the ground


    and stop the engine.
    (2) Operate the control levers and pedals
    several times to release the remaining
    pressure in the hydraulic piping.
    (3) Loosen the breather slowly to release the
    pressure inside the hydraulic tank.
    Escaping fluid under pressure can
    penetrate the skin causing serious injury. 1

    (4) Loosen the socket bolt(2).


    2
    (5) Remove the cover of the console box.
    (6) Disconnect pilot line hoses(3).
    3
    (7) Remove the pilot valve assembly(1).
    ※ When removing the pilot valve assembly,
    check that all the hoses have been
    disconnected.

    2) INSTALL
    (1) Carry out installation in the reverse order
    to removal.
    (2) Confirm the hydraulic oil level and check
    the hydraulic oil leak or not.

    8-111
    2. DISASSEMBLY AND ASSEMBLY
    1) STRUCTURE

    8-112
    1 Case 11 Plug 21 O-ring
    2 Plug 12 Rod seal 22 Handle connector
    3 Plug 13 O-ring 23 Nut
    4 O-ring 14 Push rod 24 Insert
    5 Spool 15 Plate 25 Boot
    6 Shim 16 Bushing 26 Handle
    7 Spring 17 Joint assembly 27 Switch assembly
    8 Spring seat 18 Swash plate 28 Screw
    9 Stopper 19 Adjusting nut 29 Switch assembly
    10 Spring 20 Lock nut 30 Switch cover
    40 Boot

    8-113
    2) TOOLS AND TIGHTENING TORQUE
    (1) Tools

    Tool name Remark

    Allen wrench 6 B
    22
    Spanner
    27
    (+) Driver Length 150
    (-) Driver Width 4~5
    Torque wrench Capable of tightening with the specified torques

    (2) Tightening torque

    Torque
    Part name Item Size
    kgf・m lbf・ft
    Plug 2 PT 1/8 3.0 21.7
    Joint 18 M14 3.5 25.3
    Swash plate 19 M14 5.0±0.35 36.2±2.5
    Adjusting nut 20 M14 5.0±0.35 36.2±2.5
    Lock nut 21 M14 5.0±0.35 36.2±2.5
    Screw 29 M 3 0.05 0.36

    8-114
    3) DISASSEMBLY
    (1) Clean pilot valve with kerosene.
    ※ Put blind plugs into all ports
    (2) Fix pilot valve in a vise with copper(or
    lead) sheets.
    (3) Remove end of boot(26) from case(1)
    and take it out upwards.

    ※ For valve with switch, remove cord also


    through hole of casing.

    (4) Loosen lock nut(21) and adjusting nut(20)


    with spanners on them respectively, and
    take out handle section as one body.

    (5) Remove the boot(40)

    8-115
    (6) Loosen adjusting nut(20) and plate(19)
    with spanners on them respectively, and
    remove them.

    (7) Turn joint anticlockwise to loosen it,


    utilizing jig(Special tool).
    ※ When return spring(10) is strong in force,
    plate(16), plug(11) and push rod(14, 15)
    will come up on loosening joint.
    Pay attention to this.

    8-116
    (8) Remove plate(16).

    (9) When return spring(10) is weak in force,


    plug(11) stays in casing because of
    sliding resistance of O-ring.
    ※ Take it out with minus screwdriver.
    Take it out, utilizing external periphery
    groove of plug and paying attention not to
    damage it by partial loading.
    ※ During taking out, plug may jump up due
    to return spring(10) force.
    Pay attention to this.

    (10) Remove reducing valve subassembly


    and return spring(10) out of casing.
    ※ Record relative position of reducing valve
    subassembly and return springs.

    (11) Loosen hexagon socket head plug(2) with


    hexagon socket screw key.

    8-117
    (12) For disassembling reducing valve section,
    stand it vertically with spool(5) bottom
    placed on flat workbench. Push down
    spring seat(8, 31) and remove two pieces
    of semicircular stopper(9) with tip of small
    minus screwdriver.
    ※ Pay attention not to damage spool
    surface.
    ※ Record original position of spring seat(8,
    31).
    ※ Do not push down spring seat more than
    6mm.

    (13) Separate spool(5), spring seat(8, 31),


    spring(7, 30) and shim(6) individually.
    ※ Until being assembled, they should be
    handled as one subassembly group.

    (14) Take push rod(14, 15) out of plug(11).

    (15) Remove O-ring(13) and seal(12) from


    plug(11).
    Use small minus screwdriver or so on to
    remove this seal.

    8-118
    (16) Remove lock nut(21) and then boot(26).

    8-119
    (17) Cleaning of parts
    ① Put all parts in rough cleaning vessel
    filled with kerosene and clean them
    (Rough cleaning).
    ※ If dirty part is cleaned with kerosene just
    after putting it in vessel, it may be
    damaged. Leave it in kerosene for a
    while to loosen dust and dirty oil.
    ※ If this kerosene is polluted, parts will be
    damaged and functions of reassembled
    valve will be degraded.
    Therefore, control cleanliness of
    kerosene fully.
    ② Put parts in final cleaning vessel filled
    with kerosene, turning it slowly to clean
    them even to their insides(Finish
    cleaning).
    ※ Do not dry parts with compressed air,
    since they will be damaged and/or rusted
    by dust and moisture in air.
    (18) Rust prevention of parts.
    Apply rust-preventives to all parts.
    ※ If left as they after being cleaned, they will
    be rusted and will not display their
    functions fully after being reassembled.

    8-120
    4) ASSEMBLY
    (1) Tighten hexagon socket head plug(2) to
    the specified torque.
    ※ Tighten two bolts alternately and slowly.

    (2) Put shim(6), springs(7, 30) and spring


    seat(8, 31) onto spool(5) in this order.

    (3) Stand spool vertically with its bottom


    placed on flat workbench, and with spring
    seat pushed down, put two pieces of
    semicircular stopper(9) on spring seat
    without piling them on.
    ※ Assemble stopper(9) so that its sharp
    edge side will be caught by head of spool.
    Do not push down spring seat more than
    6mm.

    (4) Assemble spring(10) into casing.


    Assemble reducing valve subassembly
    into casing.
    ※ Assemble them to their original positions.

    8-121
    (5) Assemble O-ring(13) onto plug(11).

    (6) Assemble seal(12) to plug(11).


    ※ Assemble seal in such lip direction as
    shown below.

    (7) Assemble push rod(14, 15) to plug(11).


    ※ Apply working oil on push-rod surface.

    (8) Assemble plug subassembly to casing.


    ※ When return spring is weak in force,
    subassembly stops due to resistance of
    O-ring.

    8-122
    (9) When return spring is strong in force,
    assemble 4 sets at the same time,
    utilizing plate(16), and tighten joint(18)
    temporarily.

    (10) Fit plate(16).

    (11) Tighten joint(18) with the specified torque


    to casing, utilizing jig.

    (12) Assemble plate(19) to joint(18).


    ※ Screw it to position that it contacts with 4
    push rods evenly.
    ※ Do not screw it over.

    (13) Assemble adjusting nut(20), apply


    spanner to width across flat of plate(19) to
    fix it, and tighten adjusting nut to the
    specified torque.
    ※ During tightening, do not change position
    of disk.

    8-123
    (14) Fit boot(40) to plate.

    (15) Fit boot(26) and lock nut(21), and handle


    subassembly is assembled completely.

    (16) Pull out cord and tube through adjusting


    nut hole provided in direction 60°to 120°
    from casing hole.

    8- 124
    (17) Assemble bushing(17) to plate and pass
    cord and tube through it.
    ※ Provide margin necessary to operation.

    (18) Determine handle direction, tighten lock


    nut(21) to specified torque to fix handle.

    (19) Apply grease to rotating section of joint


    and contacting faces of disk and push rod.

    (20) Assemble lower end of bellows to casing.


    (21) Inject volatile rust-preventives through all
    ports and then put blind plugs in ports.

    8-125

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