Section

8013
8013

DISASSEMBLY AND ASSEMBLY

OF THE CONTROL LEVERS

Copyright © 2007 CNH America LLC.

All rights reserved.
CNH Lep SM160B8013-0NA Printed in USA.
May 2007
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TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
CONTROL LEVER .......................................................................................................................................................... 3
Description .................................................................................................................................................................. 3
Structure ..................................................................................................................................................................... 4
Functions .................................................................................................................................................................... 4
Operation .................................................................................................................................................................... 5
Maintenance standards............................................................................................................................................... 7
Disassembly................................................................................................................................................................ 8
Inspection.................................................................................................................................................................. 11
Assembly .................................................................................................................................................................. 12
Troubleshooting ........................................................................................................................................................ 15

SPECIFICATIONS
Torque settings
Orifice plate retaining screws ........................................................................29.4 ± 1.5 Nm (21.68 lbf-ft) ± (1.11 lbf-ft)
Universal joint on control lever ......................................................................47.1 ± 2.9 Nm (34.74 lbf-ft) ± (2.14 lbf-ft)
Lock-nut on universal joint ............................................................................68.6 ± 4.9 Nm (50.60 lbf-ft) ± (3.61 lbf-ft)

Primary pressure Up to 6.9 MPa (1000.76 psi)

Secondary pressure 0 - 4.4 MPa (638016 psi) (Maximum control pressure)
Backpressure tolerance Up to 0.3 MPa (43.51 psi)
Rated flow 20 L/min.
Operating angle ±19° ±25° (alone)
Mass 1.9 kg
Pipes An approximately 3-meter long pipe having the 8-mm
internal diameter is appropriate for the best operation
response. To avoid the influence of backpressure, the
returned oil must be fed directly to the hydraulic tank.

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CONTROL LEVER
Description

312
501

302

301
212

213
151

218-2 246

211

214
218-1
216-1
216-2
241-1

241-2
201

221-2
221-1
217

101

101 CASING 218-2 SPOOL

151 PLATE 221-1 SPRING
201 SPOOL 221-2 SPRING
211 PLUG 241-1 SPRING
212 ROD 241-2 SPRING
213 SEAL 246 SPRING
214 O-RING 301 UNIVERSAL JOINT
216-1 SPRING SEAT 302 DISC
216-2 SPRING SEAT 312 LOCK-NUT
217 WASHER 501 PROTECTIVE BOOT
218-1 SPOOL

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Structure
The pilot valve has the structure as shown in the assembly section diagram (Page 14). There is a longi-
tudinal axial hole in the casing and the pressure reducing valve is installed in it.
The pressure reducing valve consists of the spool (201), secondary pressure setting spring (241), return
spring (221), spring seat (216), and washer 2 (217). The secondary pressure setting spring (241) is set
to have the 0.5 to 1 MPa converted secondary pressure (depending on the model). The spool (201) is
pressed against the pushrod (212) by the return spring (221).
When the operation section such as the handle is tilted, the pushrod (212) is pushed down, the spring
seat goes down at the same time, and the hydraulic pressure being set by the secondary pressure set-
ting spring (241) is changed.
The casing (101) has oil inlet P (for primary pressure oil) and oil outlet port (to hydraulic tank), and the
secondary pressure oil appears at ports 1, 2, 3 and 4.

Functions
1) Basic functions
The pilot valve controls the amount of stroke, direction and others of the control valve spool.
This control is done by the output pressure of pilot valve that is applied to the end of control
valve spool.
In order to satisfy this function, the pilot valve is made up of the following elements.
1] Inlet port (P) to which the oil is fed from the hydraulic pump
2] Multiple outlet ports (1, 2, 3, 4) through which the feed pressure from the inlet port is applied
to the end of control valve spool
3] Tank port (T) required for controlling the above output pressure
4] Spool that connects outlet ports to inlet or tank ports
5] Mechanical means (including the spring operating on the above spool) to control the output
pressure
2) Main part functions
When hydraulic oil is fed to the P port by the hydraulic pump, the spool (201) switches the oil
flow from P port to outlet ports (1, 2, 3 and 4) or from outlet ports to the T port. This spool is
operated by the secondary pressure setting spring (241) and the hydraulic oil pressure is
determined.
In order to change the deflection amount of the secondary pressure setting spring (241), push
rod (212) is inserted into the plug (211) so that it can slide.
The return spring (221) operates on the casing (101) and the spring seat (216) so that the
pushrod (212) is returned into the zero-displacement direction regardless of the output pressure.
It assures spool (201) to return to neutral position. It also has the effect of a counter-force
spring for giving an operator an appropriate operation feel.

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Operation
The following explains the pilot valve operation using the hydraulic circuit diagram (Figure 1) and opera-
tion diagrams (Figures 2 - 4). Figure 1 gives the typical application example of the pilot valve

(1) Pilot valve (2) Pilot pump (3) Main pump

(4) Control valve (5) Hydraulic motor (6) Hydraulic cylinder

Figure 1. Application example of pilot valve

1] When the handle is in neutral (See Figure 2.)
The force of secondary pressure setting spring (241), that determines the output pressure of pilot
valve, is not applied to the spool (201). Therefore, the spool (201) is pushed up by the return
spring (221) (and the spring seat (216)) and outlet port (2, 4) are connected to the T port. There-
fore, the output pressure is the same as the tank pressure.

Figure 2. When the handle is in neutral

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2] When the handle is tilted (See Figure 3.)
When the handle is tiled, the pushrod (212) strokes and the spool (201) (and the spring seat
(216)) moves downward. The P port is connected to the port (2, 4), and hydraulic oil from the pilot
pump is fed to the port (2, 4) and the hydraulic pressure is generated.

Figure 3. When the handle is tilted

3] When the handle is held (See Figure 4.)
When the handle is tilted and when hydraulic pressure at the port (2, 4) increases to the same
level as the force of the spring (241), the hydraulic oil pressure and the spring force are balanced.
When the pressure at the port (2, 4) increases above the preset level, both port (2, 4) and P port
are closed but T port is opened. When the pressure at the port (2, 4) drops below the preset level,
both port (2, 4) and P port are opened but T port is closed. Therefore, the secondary hydraulic
pressure is held constant.

Figure 4. When the handle is held

(Secondary pressure is higher than the preset level)

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4] When the handle is tilted largely (depends on the model)
In some models, if the handle is largely tilted, the pushrod end may touch the spool top end and
the output pressure may be kept to the same pressure as the P port.
Also, if the spring seat and the spring have been built into the pushrod and if the handle is tilted
largely, the pushrod end may touch the spring. This spring force may change the secondary pres-
sure gradient, and the pushrod end may touch the upper end of spring seat. As the result, the
output pressure may be kept to the same level as the P port

Maintenance standards
Checkpoints Standard Remarks
When handle is in neutral: 1000 cc/min. or
more Conditions
Leakage amount When operating:2000 cc/min. or more Primary pressure: 2.94 MPa
If either of them has occurred, replace the Viscosity of oil: 23 mm2/s
entire pilot valve assembly.
If abrasion of sliding part is 10μm or more This large abrasion is almost the
Spool than non-sliding part, replace the entire same as the large oil leakage as
pilot valve assembly. described above.
If the pushrod end is worn 1 mm or more,
replace it.

Pushrod

If a 2 mm or larger looseness of the oper- If the looseness is caused by the

Looseness of oper-
ation section is found due to the worn disk unsecured fasteners, retighten and
ation section
(302) or joint (301), replace it. adjust them.
If abnormal noise, hunting, dropped pri-
mary pressure or other problem has
occurred during operation and if it cannot
Operation stability be solved by troubleshooting as
described in Chapter 8 "Causes of prob-
lems and countermeasures", replace the
entire pilot valve assembly.
NOTE: O-rings and other sealing can be reused if not damaged although it is desirable to replace them during
disassembly.

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Disassembly
NOTE: The numbers within brackets in the following STEP 4
steps refer to the schematic on page 3.
Always handle high precision parts with the greatest
care to prevent them being damaged by being knocked
or dropped. The components of the control lever may
rust due to contamination and humidity if they are left
without protection after disassembly. If work has to be
stopped, the components must be protected against
contamination or corrosion.
STEP 1

Install the control lever in a soft-jawed vice. Remove

the protective boot (501).
STEP 2

Remove the lock-nut (312) from the control lever.

Used the special tool 380001055.
STEP 3 Install two nuts on the universal joint and tighten them
fully. While holding the upper nut, turn the lower nut
anti-clockwise to unscrew the universal joint. Remove
the universal joint from the control lever.
NOTE: Carefully remove the universal joint to prevent
the plate and the push-rods, which are under pressure
from the springs, from flying out too quickly.

Remove the disc (302) from the control lever.

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STEP 5 STEP 8

Remove the plate (151).

NOTE: Mark the components removed in the following
steps to facilitate their insertion in the correct bore
during assembly.
STEP 6

Press the spring down a few millimetres so as to free

the spool (201) from the spring seat (216-1). Separate
the spool (201) from the spring (241-1) and the washer
(217). Keep these components together for the
reassembly procedure.
Depending on the condition of the return springs (221), STEP 9
the friction of the O-rings can keep the plunger
assemblies in place in the body. In this case, use a flat
screwdriver to remove the plunger assemblies. Slide
the screwdriver into the external groove of the plunger
assembly, taking care not to damage the plunger
assembly. This must be done carefully, since the
plunger assembly can be thrown out suddenly, due to
the action of the return springs.
STEP 7

Remove the spool (218-1) and the spring (246) from

the plunger assembly (211).

Remove the spool assembly from the control lever.

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STEP 10 STEP 12

Remove the push-rod (212) from the plunger assembly
(211).
STEP 11
Remove and scrap the plunger assembly O-ring (214).
Remove and scrap the plunger assembly seal.
STEP 13
Cleaning the components:
1. Soak them in a suitable cleaning solvent until
contamination and oil are removed. Components can
be damaged if they are washed while they are still
contaminated.
2. Final washing: Immerse the components in a clean
receptacle containing a suitable cleaning solvent.
Impart a rotary motion to the receptacle so as to wash
the inner surface of the components as well. Dry the
components with a clean cloth.
NOTE: Never dry them with compressed air. Dust and
water contained in the air will damage and corrode their
surfaces.
3. Corrosion prevention: Apply an anti-rust product to
all the components.
NOTE: Components can rust if left in the open air after
cleaning.

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Inspection
Change all the seals and O-rings which have been
removed. Also change the washers on all screws which
have been removed.
STEP 1
Inspect the spools to ensure that the finish is not
damaged, that they are not bent or damaged in any
other manner. Make sure that the spool slides freely in
the control valve body bore. If defects are found,
change the entire control valve.
STEP 2

JS00784A
Inspecting the controls. Change the components if
wear on the shaft pin and seal create play in the
controls greater than 2 mm.
STEP 3
If it is impossible after inspection of the parts to
determine the cause of an abnormal noise or a
reduction in primary pressure, change the control lever.

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Assembly
Carry out the assembly with the very greatest care. Do STEP 2
not hit or force the components, since that will damage
them and cause seizure or oil leaks which would result
in impaired performance of the machine. Before
reassembly, remove all traces of metal particles or
foreign bodies from all components. Check that there
are no burrs on the components and remove them with
an oil stone. Replace all O-rings and thrust rings with
new components. Lubricate the O-rings and thrust rings
to prevent any damage during assembly. Tighten all
cap screws to the specified torque. Plug all orifices with
plugs to prevent any contamination of the control lever
by dust after reassembly.
STEP 1
Turn the control lever the other way up in the vice.
Install the return spring and the complete spool
assembly in the body, respecting the positions noted
during steps 5 to 7 (disassembly).
STEP 3

Install the O-ring on the plunger.

Assemble the spool assembly by installing the washer

(217), the spring (241-1) and the spring seat (216-1) on
the spool (201).

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STEP 4 STEP 6

Install the spool (218-1) and the spring (246) in the

plunger (211).
STEP 7

213

212

Install the lip seals (213) with their ends as shown

above.
STEP 5 Install the plunger in the body. Depending on the
condition of the return springs, the friction of the
O-rings may keep the plungers in place in the body.
STEP 8
Repeat steps 5 to 11 for the other three bodies.
STEP 9

Coat the surfaces of the push-rod (212) with hydraulic

fluid and install it in the plunger (211).

Install the plate and retain it by means of the universal

joint.

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STEP 10 STEP 13

Used the special tool 380001055. Place a few spots of grease on the push-rods.
Tighten the universal joint to a torque of 47.1 ± 2.9 Nm
(34.74 lbf-ft) ± (2.14 lbf-ft). STEP 14

STEP 11

Install the protective boot (2) on the control lever.

Install the disc on the universal joint. Tighten until the

disc touches the four push-rods equally.
STEP 12

Install the lock-nut and tighten it to a torque of

68.6 ± 4.9 Nm (50.60 lbf-ft) ± (3.61 lbf-ft) while holding
the flats on the disc (3) with a flat wrench.

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Troubleshooting
It is not easy to locate the failure in the field. The troubleshooting table below lists the possible causes of
failure. Because the repair work is difficult, take the "corrective actions" given by referring to the "possi-
ble causes" column.
The troubleshooting table lists the typical failure, possible causes, and corrective actions taken. How-
ever, machine failure is often caused by a combination of problematic parts rather than a problem with a
single part. You should remember that you may need to carry out more corrective actions than those
given on the table.
The following troubleshooting table does not cover all possible causes or all countermeasures required.
The repair manager should locate the actual cause of the failure and take appropriate actions when
necessary.

Symptom Possible causes Solution

(1)Primary pressure is insufficient.
(1)Apply the primary pressure.
(2)The secondary pressure setting
(2)Replace the spring with the new
spring (241) is broken or deterio-
one.
Secondary pressure is rated.
(3)Replace the entire pilot valve
low. (3)Clearance between the spool
assembly with the new one.
(201) and the casing (101) is too
(4)Replace the handle by disas-
large.
sembling and reassembling it.
(4)The handle is excessively loose.
(1)Repair the sliding parts.
(1)The sliding parts do not slide
smoothly.
(2)Return the oil directly to the
Secondary pressure is (2)The pressure of tank line is unsta-
hydraulic tank.
unstable. ble.
(3)Remove the air from the hydrau-
(3)Air has entered the hydraulic pip-
lic line by carrying out deaeration
ing.
several times.
(1)The pressure of hydraulic tank
(1)Return the oil directly to the
Secondary pressure is line is high.
hydraulic tank.
too high. (2)The sliding parts do not slide
(2)Repair the sliding parts.
smoothly.

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NOTES
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