Terex TR60 Maintenance Manual page 396

5. Remove plug (18) from valve body (5).
6. Remove gasket (17), spring end (15), 'O' ring (16),
springs (13 & 14), relief spool (12), backup ring (11)
and 'O' ring (10) from plug (18). Remove spool seat (9),
backup rings (7) and 'O' ring (8) from valve body (5).
Discard backup rings (7 & 11) and 'O' rings (8, 10 & 16).
INSPECTION
Numbers in parentheses refer to Fig. 1.
1. Clean all metal parts thoroughly in suitable solvent
and dry with compressed air. Inspect valve body (5)
bores, plugs (1, 6, 18 & 25), guide (21) and relief
spool (12) for grooves, deep scratches or excessive
wear.
2. Inspect poppet (24) for grooves or defects which
may cause leakage. If poppet (24) appears to be
faulty, replace with a new one.
3. Inspect all parts for ridges, nicks, burrs or scoring
which may cause leakage. Replace parts if worn or
damaged.
ASSEMBLY
Numbers in parentheses refer to Fig. 1.
1. Install new 'O' ring (8), and new backup rings (7)
on spool seat (9). Install spool seat in valve body (5).
Install new 'O' ring (10) and new backup ring (11) on
relief spool (12). Install relief spool (12) assembly in
valve body (5).
2. Install new 'O' ring (16) on spring end (15) and
install in plug (18). Install springs (13 & 14) in plug
(18) and install plug (18) in valve body (5).
3. Install nut (19) and screw (20) in plug (18).
4. Install poppet (24) in valve body (5). Install spring
(23) and new 'O' ring (22) in guide (21). Align with
poppet (24) and install guide (21) assembly in valve
body (5). If removed, install connector (25) and cap
(26) in guide (21).
5. Install plug (6) in valve body (5).
6. Install new 'O' ring (3) on pin assembly (4) and
install in valve body (5). Install new 'O' ring (2) on
plug (1) and install into valve body (5).
SM 1218 2-98
Body System - Kick-over Valve
ADJUSTMENT
Numbers in parentheses refer to Fig. 1.
1. Install kick-over valve onto a test bench.
2. Remove cap (26) from connector (25) in port 'G' of
valve body (5) and install a 0 - 207 bar (0 - 3 000 lbf/in²)
pressure gauge.
3. Install a suitable return to tank line at port 'V'.
4. Slacken nut (19) and set kick-over pressure by
supplying oil to port 'C', at 1.26 litres/s (20 GPM),
and adjusting screw (20) until pressure at port 'C' is
172 bar (2 500 lbf/in²). Lock nut (19) and
re-check pressure setting.
5. Turn off hydraulic oil supply and bleed off pressure
from hydraulic lines. Remove hydraulic oil lines from
kick-over valve.
WARNING
Make sure pressure in the testing circuit has
dissipated before removing any lines or
personal injury could occur.
6. Remove pressure gauge from gauge port and
install plug (25). Remove kick-over valve from test
bench and set aside for 'Installation'.
INSTALLATION
Numbers in parentheses refer to Fig. 1.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000,
BODY SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
1. Position spacer, if used, and kick-over valve on
mounting bracket and secure with mounting hardware.
2. Connect hydraulic lines as marked at 'Removal'.
3. Raise body and check kick-over valve and
hydraulic lines for leaks.
4. Remove cap (26) and install a pressure gauge in
port 'G'. Check kick-over pressure is 172 bar
(2 500 lbf/in²), at maximum rev/min, and with body
Section 230-0090
3