Options 1.Option Line Control

9.)Assembling the brake piston (1-15)

Assemble the D-rings (1-16, 1-17) onto the brake piston (1-15).

With the side with the larger diameter of the brake piston (1-15) up, assemble it onto the flange (1-1).

Note:

a.When installing the D-rings (1-16, 1-17), generously apply grease on the rings. b.Using a positioning jig, align the knock pin holes of the base plate (1-2-1) on the flange (11) and the brake piston (1-15) so that they are arranged in line, and then assemble the brake piston (1-15). c.When assembling the brake piston (1-15), apply grease on the external surface and inside the bore of the flange (1-1). d.Assemble while evenly pressing down the brake piston (1-15) so that it may not incline.

Assembling the piston as inclined may cause operational failure or ripping of a D-ring.

10.)Assembling the spring (1-18)

Assemble the springs (1-18) into the bores (at eight locations) provided for assembling the springs (1-18) on the brake piston (1-15).

11.)Assembling the valve plate (1-21)

Place the base plate (1-2-1) on a work bench and press fit the bearing (1-9) in the center of the base plate (1-2-1), using a bearing press-fit jig.

After checking that the knock pin (1-19) is installed on the base plate (1-2-1), assemble the valve plate (1-21) onto the base plate (1-2-1).

Note:

a.Assemble the valve plate (1-21) with its copper-base alloy side up. b.In order to prevent falling of the valve plate (121), apply grease sufficiently on the alignment surface of the base plate (1-2-1) and the valve plate (1-21). c.Take care not to damage the copper-base alloy surface of the valve plate (1-21).

12.)Assembling the base plate (1-2-1)

Assemble the O-rings (1-23) and O-rings (1-22) (at four locations) onto the upper surface of the flange (1-1).

Assemble the knock pin (1-19) on the base plate (1-2-1).

With the surface of the base plate (1-21) contacting the valve plate (1-21) when assembled down, assemble the base plate onto the flange (1-1) and tighten it using the socket head bolt (1-11).

Note:

a.Apply grease on the O-ring (1-23). b.Do not apply grease on the O-ring (1-22). c.Assemble the knock pin (1-19) with its tapered section up. d.After applying hydraulic oil on the surface of the valve plate (1-21) and the surface of the cylinder block (1-4-1), assemble the base plate (1-2-1). e.When assembling the base plate (1-2-1), check that the valve plate will not fall even though the side having the valve plate (1-21) installed is oriented downward. f.Check the location where the O-ring (1-22) is assembled and the location of the notch for the oil channel on the base plate (1-2-1). g.Check for the locations of the knock pin (1-19) mounted on the base plate (1-2-1), the hole on the base plate (1-2-1) for installing the spring (1-18), and the knock pin hole on the flange (11) side as well as the location of the spring (118). h.When tightening the socket head bolt (1-11), tighten it by applying force evenly along the periphery.

13.)Assembling the valve assembly (1-2-9)

Assemble the spring (1-2-10) into the valve assembly (1-2-9), and then onto the base plate (1-2-1). After assembling the valve assembly (12-9), check that the O-ring (1-2-12) is installed onto the plug (1-2-11). Then, assemble the plug (1-2-11) onto the base plate (1-2-1) and tighten to the specified torque.

Next, check that the O-ring (1-2-12) is installed onto the plug (1-2-14), and assemble the washer (1-2-15) into the spring guide (1-2-13), assemble the plug (1-2-14) onto the base plate (1-2-1), and then tighten to the specified torque.

Note:

a.With the piping port side of the base plate (1-21) on the near side, assemble the valve assembly (1-2-9) onto the base plate (1-2-1) so that the side of the valve assembly (1-2-9) with the spring (1-2-10) installed comes on the righthand side. Reverse assembly leads to trouble such as switching failure. b.Apply hydraulic oil around the exterior of the valve assembly (1-2-9) and then proceed with the assembling procedure. c.After assembling the valve assembly (1-2-9), check that the valve assembly (1-2-9) operates smoothly.

14.)Assembling the relief valve assembly (1-27)

Check that the poppet seat (1-2-7-3) is installed on the tip of the relief valve assembly (1-2-7), assemble the relief valve assembly (1-2-7) onto the base plate (1-2-1), and then tighten to the specified torque.

Note:

a.Replace the O-ring (1-2-7-7) with a new one before assembling the valve assembly. b.Check that the O-ring (1-2-7-17) and the backup ring (1-2-7-18) are installed onto the poppet seat (1-2-7-3). c.Apply grease on the O-ring (1-2-7-17) and the backup ring (1-2-7-18), and then assemble them.