HYDRAULICS - Toro TX420, TX425 Series Service Manual Rev. 000 7B-3 10. Remove 6 bolts, 3 located on...

HYDRAULICS

7B-1TX420, TX425 Series Service Manual Rev. 001

Hydraulic Tandem Pump Removal

TX420 & 425 240000299 & lower

Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material.

Upon removal, all seals, o-rings, and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings, and gaskets with clean petroleum jelly prior to assembly.

1. Raise the hood assembly.

2. Raise the loader arms and use the cylinder lock to secure the loader arm.

3. Remove the RH side panel (Fig. 0387).

Fig 0387 CLR DSC-3333

Fig 0389 DSC-3335

5. Remove the three bolts and nuts retaining the cooler mounting bracket to the grill assembly (Fig. 0389).

Fig 0388 DSC-3334

4. Remove the LH side panel (Fig. 0388).

HYDRAULICS

7B-2 Rev. 001 TX420, TX425 Series Service Manual

Fig 0393 DSC-3340

9. Remove the heat shield from the unit (Fig. 0393).


8 Loosen the 4 bolts and nuts on the front counterweight (Fig. 0392).

6. Remove left side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0390).

Fig 0390 DSC-3336

7. Remove the right side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0391).

Fig 0391 DSC-3337

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10. Remove 6 bolts, 3 located on each side, retaining the grill assembly to the frame (Fig. 0394).

Fig 0394 DSC-3341

11. Lift one side of the grill assembly up and slide the grill assembly forward and off the frame (Fig. 0395).

Fig 0395 DSC-3342


13. Remove both hydraulic suction hoses from the hydraulic fittings on the hydraulic pump (Fig. 0397).

Note: Protect the openings on the hoses by placing protective caps on the hoses.

Fig 0396 DSC-3343

12. On the right hand side of the pump, loosen the two hose clamps retaining the hydraulic suction hoses to the hydraulic fittings on the hydraulic pump (Fig. 0396).

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Fig 0401 DSC-3351

17. Remove the hydraulic pump from the pump mount (Fig. 0401).

Fig 0400 DSC-3348

16. Remove the two screws retaining the hydraulic pump to the pump mount (Fig. 0400).

14. Remove the two hydraulic lines off the hydraulic fittings located on the left side of the hydraulic pump (Fig. 0398).

Fig 0398 DSC-3345

15. Remove the two locknuts located on the pump hub (Fig. 0399). Remove one locknut and rotate the engine crankshaft 180º to gain access to the other locknut.

Note: Remove both spark plug wires prior to rotating the engine.

Fig 0399 DSC-3346

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Rubber Coupler Assembly Removal

1. Raise the hood assembly.

2. Raise the loader arms and use the cylinder lock to secure the loader arm.

3. Remove the RH side panel (Fig. 0402).


4. Remove the LH side panel (Fig. 0403).

Fig 0403 DSC-3334

Fig 0405 DSC-3336

6. Remove left side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0405).

Fig 0404 DSC-3335

5. Remove the three bolts and nuts retaining the cooler mounting bracket to the grill assembly (Fig. 0404).

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Fig 0409 DSC-3341

10. Remove 6 bolts, 3 located on each side, retaining the grill assembly to the frame (Fig. 0409).

Note: Loosen the rear bolts on the support panel assembly on the right and left side.

Fig 0408 DSC-3340

9. Remove the heat shield from the unit (Fig. 0408).7. Remove the right side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0406).

Fig 0406 DSC-3337

8. Loosen the 4 bolts and nuts on the front counter-weight (Fig. 0407).


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11. Lift one side of the grill assembly up and slide the grill assembly forward and off the frame (Fig. 0410).

Fig 0410 DSC-3342

12. On the right hand side of the pump, loosen the two hose clamps retaining the hydraulic suction hoses to the hydraulic fittings on the hydraulic pump (Fig. 0411).

Fig 0411 DSC-3343

Fig 0413 DSC-3345

14. Remove the two hydraulic lines off the hydraulic fittings located on the left side of the hydraulic pump (Fig. 0413).


13. Remove both hydraulic suction hoses from the hydraulic fittings on the hydraulic pump (Fig. 0412).

Note: Protect the openings on the hoses by placing protective caps on the hoses.

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18. Remove engine air cleaner (Fig. 0417).

Fig 0416 DSC-3351

17. Remove the hydraulic pump from the pump mount (Fig. 0416).

15. Remove the two locknuts located on the pump hub (Fig. 0414). Remove one locknut and rotate the engine crankshaft 180º to gain access to the other locknut.

Note: Remove both spark plug wires prior to rotating the engine.

Fig 0414 DSC-3346

16. Remove the two screws retaining the hydraulic pump to the pump mount (Fig. 0415).

Fig 0415 DSC-3348

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19. Remove the screw, located at the top of the engine throttle linkage bracket, retaining the heat shield (Fig. 0418).

Fig 0418 DSC-3360

20. Remove the right and left hydraulic lines from the oil filter head assembly (Fig. 0419).


Fig 0421 DSC-3388

22. Remove the two bolts and nuts retaining the filter heat shield to the oil filter support bracket (Fig. 0421).

Fig 0420 DSC-3361

21. Remove the two retaining screws and washers, located on the oil filter support bracket (Fig. 0420). Remove the oil filter head assembly and oil filter from the unit.

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Fig 0425 DSC-3367

26. Remove the pump mount from the engine (Fig. 0425).

Fig 0424 DSC-3366

25. Remove the two bolts and washers retaining the pump mount to the engine (Fig. 0424).

23. Remove the engine dip stick. Remove the two bolts and washers at the top of the pump mount that retain the oil filter support bracket to the engine (Fig. 0422).

Fig 0422 DSC-3387

24. Remove the oil filter bracket and filter heat shield from the unit (Fig. 0423).

Fig 0423 DSC-3386

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27. Loosen the two set screws on the engine hub (Fig. 0426).

Fig 0426 DSC-3368

28. Remove the engine hub and coupler assembly from the crankshaft (Fig. 0427).

Fig 0427 DSC-3370

Rubber Coupler Assembly Installation

Fig 0429 DSC-3371

2. Apply anti-seize compound to the key and the engine crankshaft (Fig. 0429).

Fig 0428 coupler asm1

1. Assemble the engine hub, rubber coupler, and hardware as an assembly (Fig. 0428).

A. Spacer Coupling (4) D. Engine HubB. Capscrews (4) E. Rubber Coupling (2)C. Nuts (2) F. Washers (4)

AB

C

DE

F

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Fig 0433 DSC-3383

6. Place the pump mount to the engine and insert the two lower bolts. Leave the two bolts loose (Fig. 0433).


5. The pump mount needs to be placed on the engine with the two closely spaced bolt holes to the top (Fig. 0432).

A. Top B. Bottom

A

B

3. Remove the set screws from the engine hub and apply thread locking compound to the threads and thread set screws back into the hub (Fig. 0430).

Fig 0430 DSC-3372

4. Slide the engine hub assembly onto the crankshaft until the end of the crankshaft is centered in between the rubber couplers. Using a 1/4” 8-point socket, snug (do not tighten) the 2 set screws to hold the hub in place on the crankshaft (Fig. 0431).

Fig 0431 DSC-3375

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7. Position the oil filter bracket and filter heat shield to the pump mount (Fig. 0434).

Fig 0434 DSC-3386

8. Insert bolts into the heat shield assembly through the pump mount into the engine block (Fig. 0435).

Fig 0435 CLR DSC-3385 Fig 0437 DSC-3360

10. Install the screw located on the engine throttle linkage bracket, retaining the heat shield (Fig. 0437).

Fig 0436 DSC-3388

9. Install two bolts and nuts retaining the filter heat shield to the oil filter support bracket (Fig. 0436).

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14. Install the right and left hydraulic lines to the filter head assembly (Fig. 0440)


Hydraulic Tandem Pump fitting orientation (Fig. 0441 bottom view).

Note: Photo shows pump hub installed.

A. 5.5 gpm loader circuit C. 11.2 gpm auxiliary pump circuit pumpB. Loader circuit pump D. Auxiliary circuit pump fitting fitting E. Suction hose fitting (2)

Hydraulic Tandem Pump Installation

11. Torque the 4 bolts on the pump mount to 50 ft-lbs. (67.79 Nm) (Fig. 0438).


12. Install the engine air cleaner cover and the engine oil dip stick.

13. Install two screws through the oil filter support bracket and into the oil filter head assembly and tighten (Fig. 0439).

Fig 0439 DSC-3361

A B

DCE

E

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2. Install the pump hub and adjust the hub on the pump shaft so that it measures 1-1/4” (3.17cm) from the pump casting to the outer surface of the pump hub (Fig. 0443).

Fig 0443 DSC-3393


1. Install a square key on the hydraulic pump shaft and apply anti-seize compound (Fig. 0442).

3. Apply thread locking compound to the set screws and finger tighten (Fig. 0444).


Fig 0445 DSC-3399

4. Align the pump hub with the two bolts in the rubber coupling. Install two screws that retain the hydraulic pump to the pump mount (Fig. 0445).

Note: Tighten the two screws equally to draw the hydraulic pump up to pump mount.

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8. Install the two hydraulic suction lines located on the right side of the hydraulic pump. Tighten the two hose clamps on the hydraulic suction lines to the hydraulic fittings (Fig. 0449).


7. Install the two hydraulic lines to the hydraulic fittings located on the left side of the hydraulic pump (Fig. 0448).

5. Install nuts on the two bolts from the rubber coupling to the pump hub and tighten (Fig. 0446). Rotate the engine 180º to tighten the other bolt and nut.

Note: Reconnect both spark plug wires to the spark plugs.


6. Tighten and torque all 4 set screws to 90-110 in-lbs. (10.17-12.43 Nm) (Fig. 0447).


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9. Start the unit up and allow the engine to run at idle for a couple of minutes.

10. Remove the cylinder lock.

11. Purge the system. Refer to “Purging Air Procedures” on page 12-27.

12. Cycle the loader lift arms and tilt. Check for any oil leaks. Check the oil reservoir. Refer to “Checking the Hydraulic Fluid” on page 3-4

13. Install the grill assembly on the frame. Install 6 screws, 3 located on each side of the grill assembly. Install 3 screws retaining the right and left side panel support (Fig. 0450).

Fig 0450 DSC-3341


15. Tighten the 4 bolts and nuts on the front counter-weight (Fig. 0452).

Fig 0451 DSC-3340

14. Position the heat shield so that it is installed between the front counterweight and mainframe (Fig. 0451).

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19. Install the RH side panel (Fig. 0456).

Fig 0455 DSC-3334

18. Install the LH side panel (Fig. 0455).

20. Close the hood assembly.

16. Tighten the right side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0453).

Fig 0453 DSC-3337

17. Install the 3 bolts and nuts retaining the oil cooler mounting bracket to the grill assembly (Fig. 0454).

Fig 0454 DSC-3335

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Fig 0457 PICT-2776

Note: Protect all exposed sealing areas and open cavities from damage, foreign material and chemicals.

Replace all seals, o-rings and gaskets when reassembling.

1. Remove the key from the keyway of the pump shaft (Fig. 0457).

Hydraulic Tandem Pump Rebuild

TX420 & 425 240000299 & lower

Fig 0459 PICT-2760a

4. Using a 16mm socket, loosen and remove the 4 bolts securing the pump sections (Fig. 0459).

Fig 0458 PICT-2758

2. Secure the pump in a vise.

3. Mark the casing of the pump with a “V” that crosses over all sections of the pump (Fig. 0458).

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Fig 0463 PICT-2765

8. Lift the rear pump housing off of the rear pump bushing assembly (Fig. 0463).

Fig 0462 PICT-2764

7. Mark the top of the rear bushing assembly out to the pump housing with a single line (Fig. 0462).

Fig 0461 PICT-2763

6. Remove the o-ring from the rear pump housing (Fig. 0461).

Fig 0460 PICT-2762

5. Remove the rear cover of the pump from the pump assembly (Fig. 0460).

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Fig 0465 PICT-2768a

10. Remove the rear bushing assembly from the pump assembly (Fig. 0465).

Fig 0464 PICT-2766

9. Mark the rear bushing assembly down the side with a single line (Fig. 0464).

Fig 0467 PICT-2770a

12. Remove the o-ring from the front pump housing (Fig. 0467).

Fig 0466 PICT-2769a

11. Remove the middle pump plate from the pump assembly (Fig. 0466).

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Fig 0471 PICT-2778a

16. Remove the front bushing assembly (Fig. 0471).

Fig 0470 PICT-2777a

15. Mark the front bushing assembly down the side with two parallel lines (Fig. 0470).

Fig 0469 PICT-2773a

14. Remove the front pump housing from the center bushing assembly (Fig. 0469).

Fig 0468 PICT-2772

13. Mark the top of the front bushing assembly out to the pump housing with 2 parallel lines (Fig. 0468).

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Fig 0473 PICT-2784a

18. Secure the pump cover in a vise so the inside of the cover is facing up.

19. Remove the shaft seal from the inside of the pump cover (Fig. 0473).

Fig 0472 PICT-2783a

17. Using a snap ring pliers, remove the snap ring from the inside of the pump cover (Fig. 0472).

Fig 0475 PICT-2786a

21. Carefully drive the seal into the cover until it is seated (Fig. 0475).

Fig 0474 PICT-2785

20. Install a new shaft seal in the pump cover so that the spring side of the seal is facing the housing side of the pump cover (Fig. 0474).

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Fig 0479 PICT-2791a

3. Remove the drive gear from the lower bushing (Fig. 0479).

Fig 0478 PICT-2790a

2. Remove the upper bushing from the drive gear and intermediate gear shafts (Fig. 0478).

Fig 0477 PICT-2789a

Note: Lubricate all surfaces on reassembly.

1. Remove the drive link from the upper bushing (Fig. 0477).

Fig 0476 PICT-2788a

22. Install the snap ring into the groove on the inside of the pump cover (Fig. 0476).

11 gpm Pump Assembly Rebuild

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Fig 0481 PICT-2793a

5. Remove the backup ring from the top and bottom surfaces of the 2 bushings (Fig. 0481).

Fig 0480 PICT-2792a

4. Remove the intermediate gear from the lower bushing (Fig. 0480).

Fig 0483 PICT-2796a

7. Inspect the gear surface of both of the bushings for damage (Fig. 0483).

Fig 0482 PICT-2793a

6. Remove the gear seal from the top and bottom surfaces of the 2 bushings (Fig. 0482).

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Fig 0487 PICT-2804a

Fig 0486 PICT-2805

10. Install the back-up ring into the bushing. Note that the tab in the center portion of the back-up ring is flush to one surface. That flush surface should be installed up so the webbing is resting on the center of the gear seal while lying flat in the groove of the bushing (Fig. 0486 and Fig. 0487).

Fig 0485 PICT-2800a

9. Install the gear seal with the curved side of the gasket down in the groove of the bushing (Fig. 0485).

Fig 0484 PICT-2797a

8. Inspect the drive gear and intermediate gear for damage (Fig. 0484).

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Fig 0489 PICT-2791a

13. Install the drive gear onto the bushing (Fig. 0489).

Fig 0488 PICT-2792a

11. Repeat the above 2 steps for the second bushing, gear seal and back-up ring.

12. Making note of the markings on the bushing assembly, install the intermediate gear into the bushing (Fig. 0488).

Fig 0491 PICT-2789a

15. Install the drive link into the drive gear (Fig. 0491).

Fig 0490 PICT-2790a

14. Install the second bushing onto the 2 gears (Fig. 0490).

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Fig 0495 PICT-2807a

19. Install the gasket on the rear surface of the front pump housing body (Fig. 0495).

Fig 0494 PICT-2773a

18. Install the front housing body over the front bushing and gear assembly and onto the pump cover (Fig. 0494).

Fig 0493 PICT-2806a

17. Install the gasket into the groove on the front surface of the front housing body (Fig. 0493).

Fig 0492 PICT-2778a

16. Install the front bushing and gear assembly into the pump cover through hole (Fig. 0492).

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Fig 0497 PICT-2809a

Note: Lubricate all surfaces on reassembly.

1. Remove one of the bushings (Fig. 0497).

Fig 0496 PICT-2808a

20. Install the center plate onto the front housing body. Note the markings on the plate and housing should match up (Fig. 0496).

5 gpm Pump Assembly Rebuild

Fig 0499 PICT-2811a

3. Remove the drive gear (Fig. 0499).

Fig 0498 PICT-2810a

2. Remove the intermediate gear (Fig. 0498).

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Fig 0503 PICT-2816a

7. Inspect the drive and intermediate gears for damage (Fig. 0503).

Fig 0502 PICT-2814a

6. Inspect the gear surfaces of both bushings for damage (Fig. 0502).

Fig 0501 PICT-2813a

5. Remove the gear seal from the both of the bushings (Fig. 0501).

Fig 0500 PICT-2812a

4. Remove the back-up ring from both of the bushings (Fig. 0500).

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Fig 0505 PICT-2805

9. Install the back-up ring into the bushing. Note that the tab in the center portion of the back-up ring is flush to one surface. That flush surface should be installed up so the webbing is resting on the center of the gear seal while lying flat in the groove of the bushing (Fig. 0505 and Fig. 0506).

Fig 0504 PICT-2800a

8. Install the gear seal with the curved side of the gasket down in the groove of the bushing (Fig. 0504).

Fig 0507 PICT-2817a

10. Repeat the above 2 steps for the second bushing, gear seal and back-up ring.

11. Install the 2 o-rings into the 5 gpm housing body (Fig. 0507).

Fig 0506 PICT-2804a

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Fig 0511 PICT-2776a

15. Insert the key into the keyway of the pump shaft (Fig. 0511).

Fig 0510 PICT-2821a

14. Using a 16mm socket, install the 4 bolts that secure the pump sections. Torque the 4 bolts to 38-43 ft-lbs. (51.5-58.3 Nm) (Fig. 0510).

Fig 0509 PICT-2820a

13. Install the pump cover onto the 5 gpm pump as-sembly (Fig. 0509).

Fig 0508 PICT-2819a

12. Install the 5 gpm housing body onto the pump as-sembly over the 5 gpm bushing and gear assembly (Fig. 0508).

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Tilt Cylinder Replacement

1. Remove any attachment from traction unit.

2. Park the unit on a level surface.

3. Extend the tilt cylinder so the attach plate lays parallel to the floor.

4. Rest the quick attach assembly on wood blocks (Fig. 0512).

Fig 0512 DSC-3546

5. Shut the engine off.

6. Stroke the loader valve from dump to curl to remove pressure from the hydraulic lines.

7. Let the hydraulic oil cool.

8. Place a drain pan under the tilt cylinder fittings.

TX420 & 425 250000399 & lower

Fig 0514 DSC-3548

10. Remove the bolt securing the pivot pin at the quick attach assembly on the ram end of the tilt cylinder (Fig. 0514).

Fig 0513 DSC-3547

9. Loosen and remove the two hydraulic lines from the cylinder fittings. Place protective caps onto the hydraulic fittings and lines (Fig. 0513).

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Fig 0518 DSC-3552

14. Remove the cylinder (Fig. 0518).

Fig 0517 DSC-3551

13. Using hammer and punch, remove the pivot pin from the loader arm and cylinder barrel (Fig. 0517).

11. Remove the pivot pin from the cylinder and quick attach assembly (Fig. 0515).

Fig 0515 DSC-3549

12. Remove the bolt and nut from the pivot pin at the barrel end of the tilt cylinder (Fig. 0516).

Fig 0516 DSC-3550

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15. Remove the hydraulic fittings from the cylinder (Fig. 0519).



16. Replace the o-rings on the hydraulic fittings.

17. Insert hydraulic fittings into new hydraulic cylinder (Fig. 0520).

Fig 0521 DSC-3554

18. Place the barrel end of the tilt cylinder into the opening in the loader arm and insert the pivot pin (Fig. 0521).

19. Align the pivot pin hole with loader arm hole and insert a bolt and nut to secure pivot pin. Torque bolt and nut to 16 ft-lbs. (21.7 Nm) (Fig. 0522).


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22. Install and torque the screw to 16 ft-lbs (21.7 Nm) (Fig. 0525).


23. Reconnect and tighten the hydraulic lines to the tilt cylinder (Fig. 0526).

Fig 0526 DSC-3547

20. Remove the protective caps from the hydraulic fittings and pull on the ram of hydraulic cylinder to extend it. Align the clevis opening to the quick attach assembly (Fig. 0523).

Fig 0523 DSC-3555


21. Insert the pivot pin through the hydraulic cylinder and quick attach assembly.

Note: Insertthepivotpinsotheflangeofthepivotpin is on the same side as the threaded hole in the clevis of the ram end of hydraulic cylinder (Fig. 0524).

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24. Grease the pivot pins. Refer to “Greasing the Trac-tion Unit” on page 3-2.

25. Start the unit and inspect for leaks. Purge the air from the hydraulic system. Refer to “Purging Air Procedures” on page 12-27.

26. Remove blocks of wood.

Fig 0527 PICT-2900

1. Extend the ram of the tilt cylinder out approximately 6” to 12” (15.24 to 30.48cm).

2. Clean away all dirt and other foreign substance from openings, particularly at the head of the hydraulic cylinder.

3. Clamp the tilt cylinder in a vise so that the locking ring slot is facing up.

4. Clean out all material from the locking slot (Fig. 0527).

Tilt Cylinder Assembly Rebuild

TX420 & 425 230000599 & lower

Fig 0529 PICT-2905

5. Use a spanner wrench installed in the holes pro-vided. Rotate the head clockwise until the edge of the retaining ring appears in the milled opening of the tube. Insert a flat blade screwdriver between the beveled edge of the retaining ring and the cylinder barrel to start the retaining ring through the opening (Fig. 0529).

Fig 0528 PICT-2902

Note: If excessive wear due to side-loads or binding is a possibility, mark or note the piston and head relationship to the rod and tube. This condition will usually show up as a highly polished surface on the piston and head 90° to the pin rotation axis (Fig. 0528).

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8. Remove the barrel from the vise.

INSPECT ROD: There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable. Scratches that catch the fingernail but are not to the base metal, less than 0.5” long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal. Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable. In the event that an unacceptable condition occurs, the cylinder should be replaced.

INSPECT HEAD: Visually inspect the inside bore for scratches or polishing. Deep scratches are unac-ceptable. Polishing indicates uneven loading and when this occurs, the bore should be checked for out of-roundness. If out-of-roundness exceeds 0.007” (.18mm), this is unacceptable. Check the condition of the dynamic seals, looking particularly for metallic particles embedded in the piston seal surface. Remove the seals. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the cylinder should be replaced.

Fig 0531 PICT-2910a

7. Pull out on the ram to remove the piston and head assembly from the barrel (Fig. 0531).

Fig 0530 PICT-2951

6. Continue to rotate the head counter-clockwise until the retaining ring is completely removed (Fig. 0530).

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Fig 0532 PICT-2911a

INSPECT TUBE ASSEMBLY: Visually inspect the inside bore for scratches and pits. There should be no scratches or pits deep enough to catch the finger-nail. Scratches that catch the fingernail but are less than 0.5” long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal. In the event that an unacceptable condition occurs, the cylinder should be replaced (Fig. 0532).

A. Tube D. HeadB. Retaining Ring E. RamC. Piston

A B

CD E

Fig 0534 PICT-2913a

2. Remove the back-up piston seal from the ram assembly (Fig. 0534).

Fig 0533 PICT-2912a

1. Remove the piston seal from the ram assembly (Fig. 0533).

Tilt Cylinder Disassembly

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Fig 0538 PICT-2918a

6. Remove the inner o-ring from the inside of the piston (Fig. 0538).

Fig 0537 PICT-2916a

5. Slide the piston off the end of the ram (Fig. 0537).

Fig 0536 PICT-2915a

4. Using a 1-1/8” socket, remove the nut from the ram assembly (Fig. 0536).

Fig 0535 PICT-2914

3. Carefully remove the wear ring from the ram assembly (Fig. 0535).

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Fig 0540 PICT-2922a

8. Remove the flat back-up ring from the head on the ram assembly (Fig. 0540).

Fig 0539 PICT-2921

7. Remove the o-ring from the head on the ram assembly (Fig. 0539).

Fig 0542 PICT-2924a

10. Remove the wiper seal from inside the head (Fig. 0542).

Fig 0541 PICT-2923a

9. Slide the head off the end of the ram (Fig. 0541).

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Fig 0546 PICT-2928a

Note: Lubricate the head and all seals with 10W-30 oil prior to installation.

14. Twist the wear seal into a “C” shape and allow it to snap into the groove (Fig. 0546).

Note: The groove of the seal faces toward the barrel

side of the head.

Fig 0545 PICT-2927a

A. Locknut D. Back up piston sealB. Inner o-ring E. PistonC. Piston seal F. Wear ring

A B C D E F

Fig 0544 PICT-2926a

12. Thoroughly rinse the inside of the head with a cleaning solvent. Rinse and clean all internal com-ponents of any foreign material with a lint-free rag.

13. Visually inspect for material defects and contami-nation. All seals and O-rings must be replaced with new parts (Head Assembly, Fig. 0544, and Piston Assembly, Fig. 0545).

Fig 0543 PICT-2925a

11. Remove the wear seal from inside the head (Fig. 0543).

A. Wiper D. Static back-upB. Wear seal E. Static o-ringC. Head

A B C D E

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Fig 0548 PICT-2941a

16. Install the flat back-up ring into the deepest groove in the head. The flat back-up seal is installed up against the ram side of the groove (Fig. 0548).

Fig 0547 PICT-2930a

15. Install the wiper seal so that the lip of the seal is installed in the groove inside the head (Fig. 0547).

Fig 0550 PICT-2937a

18. Install the inner o-ring into the groove on the inside of the piston (Fig. 0550).

Fig 0549 PICT-2933a

17. Install the o-ring into the deepest groove in the head. The o-ring is installed on the barrel side of the groove (Fig. 0549).

Note: If possible, the head/seal assembly should sit for at least one hour to allow the seals to normalize.

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Fig 0554 PICT-2943a

Note: Lubricate all parts during assembly.

1. Secure the cylinder ram into a vise.

2. Slide the head onto the cylinder ram (Fig. 0554).

Fig 0553 PICT-2940a

21. Install the piston seal into the narrowest groove of the piston on top of the back-up ring (Fig. 0553).

Tilt Cylinder Assembly

Fig 0552 PICT-2939a

20. Install the back-up ring into the narrowest groove on the piston (Fig. 0552).

Fig 0551 PICT-2938a

19. Install the wear ring into the widest groove on the piston (Fig. 0551).

HYDRAULICS


Fig 0556 PICT-2945a

4. Install the nut onto the end of the ram. Using a 1-1/8” socket, torque the nut to 100 - 120 ft-lbs. (135.6 - 162.7 Nm) (Fig. 0556).

Fig 0555 PICT-2944a

3. Slide the piston onto the cylinder ram (Fig. 0555).

Fig 0558 PICT-2947

7. Continue rotating the head until the ring hole in the ring groove is within the slot on the barrel (Fig. 0558).

Fig 0557 PICT-2946

5. Remove the ram from the vise and secure the cylinder barrel into the vise.

6. Install the ram assembly into the cylinder barrel by rotating the head assembly while pushing the head into the barrel (Fig. 0557).

HYDRAULICS


TX420 & 425 230000999 & lower

Fig 0561 DSC-3569

Note: The following procedure applies to both left and right side lift cylinders.

1. Remove any attachment from traction unit.

2. Park the unit on level surface.

3. Raise the loader arms approximately 5” (12.7cm) from the frame stops.

4. Place two jack stands under the attach plate as-sembly. Lower the loader arms onto jack stands to support the loader arm (Fig. 0561).

Lift Cylinder Replacement

Fig 0560 PICT-2950

9. Begin rotating the spanner wrench so that the head pulls the ring inside the barrel. Continue rotating until the ring is completely installed inside the barrel on the head assembly (Fig. 0560).

Fig 0559 PICT-2949

8. Insert the end of the retaining ring through the notch in the barrel and into the hole in the groove. Place the spanner wrench onto the head assembly (Fig. 0559).

HYDRAULICS


5. Shut the engine off.

6. Stroke the loader valve from raise to lower position to remove pressure from the hydraulic lines.

7. Loosen and remove the two hydraulic lines from the cylinder fittings. Place protective caps onto the hydraulic fittings and lines (Fig. 0562).

Fig 0562 DSC-3570


8. Cut and remove the two plastic ties from the hydraulic lines (Fig. 0563).

Fig 0564 DSC-3571

9. Remove the bolt and nut from the front pivot pins (Fig. 0564).

10. Support the ram end of the lift cylinder while removing the pivot pin from the loader arm (Fig. 0565).

Fig 0565 DSC-3572

HYDRAULICS



13. Support the lift cylinder and remove the pivot pin from the tower assembly (Fig. 0568).

14. Remove the lift cylinder from the frame (Fig. 0569).


11. Remove the bolt and nut from the rear pivot pin (Fig. 0566).


Fig 0567 DSC-3576

12. Remove the pivot pin on the barrel end of the lift cylinder: To get the pivot pin started out of the tower assembly, use a round steel rod approximately 30” (76.2cm) long and a hammer. Insert the rod between the engine and pump belt from the opposite side of the lift cylinder being removed. Using the hammer, tap on the rod striking the pin from inside the tower assembly toward the outside of tower assembly (Fig. 0567).

HYDRAULICS


15. Remove the hydraulic line from the barrel end fitting of the cylinder (Fig. 0570).



16. Remove both fittings from the cylinder (Fig. 0571).

17. Replace the o-rings on the hydraulic fittings.

18. Reinstall the fittings into cylinder (Fig. 0572).


19. Reinstall the hydraulic line onto the barrel end fitting of the cylinder (Fig. 0573).


HYDRAULICS


22. Install the bolt through the frame and pivot pin. In-stall the nut and torque to 16 ft-lbs. (21.7 Nm) (Fig. 0576).


23. Remove the protective caps from the hydraulic fittings. Pull the ram out of the cylinder barrel until the pivot pin opening lines up in the loader arm (Fig. 0577).

Note: Greasefittingshouldbefacingdown.

Fig 0577 DSC-3590


20. Place the lift cylinder into the frame with the fittings facing down (Fig. 0574).


21. Install the pivot pin into the frame and then through the barrel end of the cylinder (Fig. 0575).

HYDRAULICS


24. Install the pivot pin into the loader arm and through the cylinder (Fig. 0578).

Fig 0578 DSC-3572

25. Install the bolt through loader arm and pivot pin. Install the nut and torque to 16 ft-lbs. (21.7 Nm) (Fig. 0579).

Fig 0579 CLR DSC-3592 Fig 0581 DSC-3600

27. Install two cable ties around cylinder barrel, hydraulic line to front fitting and the metal line (Fig. 0581).

Fig 0580 DSC-3595

26. Connect the two hydraulic lines to the cylinder (Fig. 0580).

28. Purge the air from the system. Refer to “Purging Air Procedures”, page 12-27.

29. Remove the jack stands.

HYDRAULICS


Fig 0584 PICT-2998

5. Use a spanner wrench installed in the holes provid-ed. Rotate the head counterclockwise until the edge of the retaining ring appears in the milled opening of the tube. Insert a flat blade screwdriver between the beveled edge of the retaining ring and the cylinder barrel to start the retaining ring through the opening (Fig. 0584).

Fig 0583 PICT-2997

Note: If excessive wear due to side-loads or binding is a possibility, mark or note the piston and head relationship to the rod and tube. This condition will usually show up as a highly polished surface on the piston and head 90° to the pin rotation axis (Fig. 0583).

Fig 0582 PICT-29582

1. Extend the ram of the tilt cylinder out approximately 6” to 12” (15.24 to 30.48cm).

2. Clean away all dirt and other foreign substance from the openings, particularly at the head of the hydraulic cylinder.

3. Clamp the tilt cylinder in a vise so that the locking ring slot is facing up.

4. Clean out all material from the locking slot (Fig. 0582).

TX420 & 425 230000999 & lower

Lift Cylinder Rebuild

HYDRAULICS


Fig 0586 PICT-3000a

7. Pull on the ram to remove the piston and head assembly from the barrel (Fig. 0586).

Fig 0585 PICT-2999

6. Continue to rotate the head counterclockwise until the retaining ring is completely removed (Fig. 0585).

8. Remove the barrel from the vise.

INSPECT ROD: There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable. Scratches that catch the fingernail but are not to the base metal, less than 0.5” long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal. Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable. In the event that an unacceptable condition occurs, the cylinder should be replaced.

INSPECT HEAD: Visually inspect the inside bore for scratches or polishing. Deep scratches are unacceptable. Polishing indicates uneven loading and when this occurs, the bore should be checked for out of-roundness. If out-of-roundness exceeds 0.007” (.18mm), this is unacceptable. Check the condition of the dynamic seals, looking particularly for metallic particles embedded in the piston seal surface. Remove the seals. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the cylinder should be replaced.

HYDRAULICS


Fig 0589 PICT-3003a

2. Remove the back-up piston seal from the ram assembly (Fig. 0589).

Fig 0588 PICT-3002a

1. Secure the pivot pin end of the ram in a vise. Remove the piston seal from the ram assembly (Fig. 0588).

Lift Cylinder Disassembly

Fig 0587 PICT-3001a

INSPECT TUBE ASSEMBLY: Visually inspect the inside bore for scratches and pits. There should be no scratches or pits deep enough to catch the fingernail. Scratches that catch the fingernail but are less the 0.5” long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal. In the event that an unacceptable condition occurs, the cylinder should be replaced (Fig. 0587).

A. Barrel D. HeadB. Retaining Ring E. RamC. Piston

A B

C D E

HYDRAULICS


Fig 0591 PICT-3006a

4. Slide the piston off the end of the ram (Fig. 0591).

Fig 0590 PICT-3005a

3. Using a 1-1/8” socket, remove the nut from the ram assembly (Fig. 0590).

5. Remove the inner o-ring from the inside of the piston (Fig. 0592).

Fig 0592 PICT-3007a

6. Remove the o-ring from the head on the ram assembly (Fig. 0593).

Fig 0593 PICT-3008a

HYDRAULICS


Fig 0597 PICT-3012a

10. Remove the wear seal from inside the head (Fig. 0597).

Fig 0596 PICT-3011a

9. Remove the wiper seal from inside the head (Fig. 0596).

Fig 0595 PICT-3010a

8. Slide the head off the end of the ram (Fig. 0595).

Fig 0594 PICT-3009a

7. Remove the flat back-up ring from the head on the ram assembly (Fig. 0594).

HYDRAULICS


Fig 0599 PICT-3014a

Fig 0598 PICT-3013a

11. Thoroughly rinse the inside of the head with a clean solvent. Rinse and clean all internal components of all foreign material using a lint-free rag.

12. Visually inspect for material defects and contamina-tion. All seals and o-rings must be replaced (Head Assembly, Fig. 0598, and Piston Assembly, Fig. 0599).

A. Wiper D. Static back-upB. Wear seal E. Static o-ringC. Head

A. Inner piston o-ring C. Backup piston sealB. Piston D. Piston seal

A B C D E

A B C D Fig 0601 PICT-3017a

14. Install the wiper seal so that the lip of the seal is installed in the groove inside the head (Fig. 0601).

Fig 0600 PICT-3016a

13. Lubricate the head and all seals with 10W-30 oil prior to installation. Twist the wear seal into a “C” shape and allow it to snap into the groove (Fig. 0600).

Note: The groove of the seal faces toward the barrel

side of the head.

HYDRAULICS


Fig 0605 PICT-3021a

18. Install the back-up ring into the narrowest groove on the piston (Fig. 0605).

Fig 0604 PICT-3020a

17. Install the inner o-ring into the groove on the inside of the piston (Fig. 0604).

Fig 0603 PICT-3019a

16. Install the o-ring into the deepest groove in the head. The o-ring is installed on the barrel side of the groove (Fig. 0603).

Note: If possible, the head/seal assembly should sit for at least one hour to allow the seals to normalize.

Fig 0602 PICT-3018a

15. Install the flat back-up ring into the deepest groove in the head. The flat back-up seal is installed up against the ram side of the groove (Fig. 0602).

HYDRAULICS


Lift Cylinder Assembly

Fig 0607 PICT-3023a

Note: Lubricate all parts during assembly.

1. Secure the cylinder ram into a vise.

2. Slide the head onto the cylinder ram (Fig. 0607).

Fig 0606 PICT-3022a

19. Install the piston seal on top of the back-up ring (Fig. 0606).

Fig 0609 PICT-3026a

4. Install the nut onto the end of the ram. Using a 1-1/8” socket, torque the nut to 100-120 ft-lbs. (135.6-162.7 Nm) (Fig. 0609).

Fig 0608 PICT-3025a

3. Slide the piston onto the cylinder ram (Fig. 0608).

HYDRAULICS


Fig 0612 PICT-3031

8. Insert the end of the ring through the notch in the barrel and into the hole in the groove. Place the spanner wrench onto the head assembly (Fig. 0612).

Fig 0613 PICT-3033

9. Begin rotating the spanner wrench so that the head pulls the ring inside the barrel. Continue rotating until the ring is completely installed inside the barrel on the head assembly (Fig. 0613).

Fig 0611 PICT-3030

7. Rotate the head until the ring hole in the ring groove is within the slot on the barrel (Fig. 0611).

Fig 0610 PICT-3027a

5. Remove the ram from the vise and secure the cylinder barrel into the vise.

6. Install the ram assembly into the cylinder barrel by rotating the piston assembly while pushing the piston into the barrel (Fig. 0610).

HYDRAULICS


Fig 0614 DSC-3632

Before disassembly of any hydraulic component, use a clean, dirt-free work surface and clean solvent to prevent system contamination.

1. Allow unit to cool down prior to removal. Open the rear cover assembly.

2. Remove the LH panel assembly (Fig. 0614).

Auxiliary Valve Removal

TX420 & 425 240000299 & lower

Fig 0616 DSC-3634

4. After removing the nut and washer, apply tension on the torsion spring and then slide the auxiliary lever assembly up and off the auxiliary valve. Remove the torsion spring (Fig. 0616).

Fig 0615 DSC-3636

3. Remove the auxiliary lever by removing the retention nut and washer located at the top of the lever (Fig. 0615).

HYDRAULICS



8. With a 15/16” 15º/60º offset open end wrench, loosen and remove the two hydraulic lines from the auxiliary valve fittings (Fig. 0620).

Fig 0619 DSC-3640

7. Using a 1-1/8” 15º/60º offset open end wrench, loosen and disconnect the hydraulic pressure hose from the auxiliary valve fitting (Fig. 0619).

Fig 0618 DSC-3637

6. With a 1-1/8” 15º/60º offset open end wrench, loosen and disconnect the hydraulic return hose from the auxiliary valve fitting (Fig. 0618).

Fig 0617 DSC-3635

5. Remove the two bolts and nuts retaining the aux-iliary stop assembly to the control panel. Remove the auxiliary stop from the control panel (Fig. 0617).

HYDRAULICS


Fig 0622 DSC-3650

10. Remove the two bolts and nuts retaining the aux-iliary valve to the control panel (Fig. 0622).

Fig 0621 DSC-3649

9. Disconnect the neutral ball switch at the harness connector (Fig. 0621).


12. Auxiliary valve with fitting layout (Fig. 0624).

Fig 0623 DSC-3652

11. Remove the auxiliary valve from the control panel (Fig. 0623).

A. Handle D. Neutral switchB. Output/return to E. Relief couplers F. InletC. Return 1

AB

C

DE

F

HYDRAULICS



4. Connect the two hydraulic lines to the side auxiliary valve fittings and tighten with a 15/16” 15º/60º offset open end wrench (Fig. 0628).

Fig 0627 DSC-3649

3. Connect the neutral ball switch at the harness connector (Fig. 0627).

Fig 0626 DSC-3650

2. Loosely install the two bolts and nuts securing the auxiliary valve to the control panel (Fig. 0626).

Note: Leave the bolts and nuts loose until the hydraulic hoses and lines are connected.

Fig 0625 DSC-3652

Note: As a reminder, prior to connecting the hydraulic hoses and lines, the o-rings should be replaced with new ones and lightly lubricated with petroleum jelly.

1. Position the auxiliary valve in the control panel (Fig. 0625).

Auxiliary Valve Installation

HYDRAULICS


Fig 0630 DSC-3637

6. Connect the hydraulic return hose to the front fitting on the auxiliary valve with a 1-1/8” 15º/60º offset open end wrench (Fig. 0630).

Fig 0629 DSC-3640

5. Connect the hydraulic pressure hose to the rear fitting on the auxiliary valve and tighten using a

1-1/8” 15º/60º offset open end wrench (Fig. 0629).

Fig 0632 DSC-3635

8. Install the auxiliary stop assembly to the control panel with 2 bolts and nuts (Fig. 0632).

Fig 0631 DSC-3650

7. Tighten the bolts and nuts securing the auxiliary valve to the control panel (Fig. 0631).

HYDRAULICS


Fig 0635 DSC-3636

11. Install the washer and retention nut on the top of the auxiliary lever and tighten (Fig. 0635).

14. Close the rear cover.

Fig 0636 DSC-3632

12. Start the unit and check the hydraulic fittings for any leaks. Install a hydraulic attachment and operate the auxiliary valve in both forward and reverse flow to purge any air out of the system. Also, operate the loader arm valve up, down, and tilt to help purge the system of any air. Refer to “Purging Air Procedures” on page 12-27. Recheck for leaks.

13. Install the LH panel assembly (Fig. 0636).

Fig 0633 DSC-3657

9. Slide the torsion spring over the control shaft, with the large hook end of the spring facing down (Fig. 0633).

Fig 0634 DSC-3655

10. Turn the torsion spring clockwise and hold. Slide the auxiliary lever over the control shaft and hook the spring end over the auxiliary lever (Fig. 0634).

HYDRAULICS


Fig 0637 PICT-2424a

Note: Protect all exposed sealing areas and open cavities from damage, foreign material and chemicals.

1. Using a 3/8” socket, remove the 4 screws securing the top right control panel cover to the control panel (Fig. 0637).

TX420 & 425 240000299 & lower

2 Spool Loader Valve Removal

Fig 0638 PICT-2425a

2. Remove the top right control panel cover from the control panel (Fig. 0638).

Fig 0639 PICT-2426

3. Open the rear access door.

4. Mark the 2 spool valve port fittings and lines with the letters A – F as follows: (Fig. 0639).

A. Hydraulic oil inlet line D. Hydraulic oil return lineB. Tilt cylinder E. Lift cylinder (below C)C. Lift cylinder F. Tilt cylinder (below B)

Fig 0640 PICT-2427

5. Using a 15/16” wrench, disconnect the hydraulic line marked with the letter A from the 2 spool loader valve fitting (Fig. 0640).

HYDRAULICS


Fig 0643 PICT-2431

8. Using a 13/16” wrench, disconnect the hydraulic line marked B from the 2 spool loader valve fitting (Fig. 0643).

Fig 0644 PICT-2432

9. Using a 13/16” wrench, disconnect the hydraulic line marked C from the 2 spool loader valve fitting (Fig. 0644).

Fig 0641 PICT-2429

6. Using a 13/16” wrench, disconnect the hydraulic line marked E from the 2 spool loader valve fitting (Fig. 0641).

Fig 0642 PICT-2430

7. Using a 13/16” wrench, disconnect the hydraulic line marked F from the 2 spool loader valve fitting (Fig. 0642).

HYDRAULICS


Fig 0645 PICT-2433

10. Using a 15/16” wrench, disconnect the hydraulic line marked with the letter D from the 2 spool loader valve fitting (Fig. 0645).

Fig 0646 PICT-2435

11. Using a 1/2” wrench and socket, remove the 3 mounting bolts and nuts that secure the 2 spool loader valve to the control panel (Fig. 0646).

Fig 0647 DSC-3628

Remove the 2 spool loader valve from the control panel assembly (Fig. 0647).

Note: Capallthehydrauliclinesandfittingssothatdebris does not enter the system.

13. Transfer all fittings, the test port and the handle over to the new 2 spool loader valve.


12. 2 Spool Loader Valve (Fig. 0648).

A. Lift cylinder (2) E. ReliefB. Return F. Pressure test portC. Return to neutral & G. Inlet float detent H. Tilt cylinder (2)D. Return to neutral

A

B

CDE

F

HG

HYDRAULICS


Fig 0651 PICT-2433

4. Using a 15/16” wrench, connect the hydraulic line marked with the letter D to the 2 spool loader valve fitting marked D (Fig. 0651).

Fig 0652 PICT-2432

5. Using a 13/16” wrench, connect the hydraulic line marked C to the 2 spool loader valve fitting marked C (Fig. 0652).

Fig 0649 PICT-2436

1. Remove the caps from the hydraulic lines and fittings.

2. Position the 2 spool loader valve into the control panel (Fig. 0649).

2 Spool Loader Valve Installation

Fig 0650 PICT-2435

3. Install the 3 mounting bolts and nuts to secure the 2 spool loader valve to the control panel. Use a 1/2” socket and wrench to tighten the 3 mounting bolts and nuts (Fig. 0650).

HYDRAULICS


Fig 0653 PICT-2431

6. Using a 13/16” wrench, connect the hydraulic line marked B to the 2 spool loader valve fitting marked B (Fig. 0653).

Fig 0654 PICT-2430

7. Using a 13/16” wrench, connect the hydraulic line marked F to the 2 spool loader valve fitting marked F (Fig. 0654).

Fig 0655 PICT-2429

8. Using a 13/16” wrench, connect the hydraulic line marked E to the 2 spool loader valve fitting marked E (Fig. 0655).

Fig 0656 PICT-2427

9. Using a 15/16” wrench, connect the hydraulic line marked with the letter A to the 2 spool loader valve fitting marked A (Fig. 0656).

HYDRAULICS


15. After the loader valve is installed, and the hydraulic lines are reconnected, a pressure test will need to be performed to properly set the relief valve to 2450 psi (169 bar). Refer to “Loader Circuit Pressure Testing” as follows:

• TX420 & 425 210000501 & up on page 12-10 • TX420 210000499 & lower on page 12-13

A. Rubber bellows F. Spring cap (tilt spool)B. Loader cylinder G. Relief valve port (2) H. Tilt cylinder port (2)C. Plug (2) I. Oil inletD. Oil out J. Check valveE. Detent spring cap (loader spool)

TX420 & 425 240000300 & lower

Two Spool Loader Valve Rebuild

Before disassembly of any hydraulic component, use a clean, dirt-free work surface and clean solvent to prevent system contamination (Fig. 0659).

Fig 0659 PICT-0074a

AJ

I

H

BC

C D

H

EG F

Fig 0657 PICT-2425a

10. Start the unit and check for leaks. Operate the loader valve up, down and tilt to purge any air out of the system.

11. Purge air from the system. Refer to “Purging Air Procedures” on page 12-27

12. Close and latch the rear access door.

13. Position the top right control panel cover onto the control panel (Fig. 0657).

Fig 0658 PICT-2424a

14. Using a 3/8” socket, install the 4 screws securing the top right control panel cover to the control panel (Fig. 0658).

HYDRAULICS


1. Secure the valve into a vise so that the rubber bellows is facing up.

2. Remove the cable tie from around the rubber bellows (Fig. 0660).

Fig 0660 PICT-0075

3. Remove the rubber bellows from the valve assembly (Fig. 0661). Wipe the excess grease from the joystick assembly.

Fig 0661 PICT-0076a

Disassembly 4. Using a 5mm Allen wrench, loosen the 3 hex head screws (Fig. 0662).

Fig 0662 PICT-0077a

5. Remove the articulated holder, screws and washers from the valve assembly (Fig. 0663).

Fig 0663 PICT-0078a

HYDRAULICS


8. Using 13mm wrenches, remove the nut and washer holding the tilt operation articulated joint to the joystick pivot (Fig. 0666).

Fig 0666 PICT-0082a

9. Rotate the tilt spool and remove the tilt operation articulated joint from the spool (Fig. 0667).

Fig 0667 PICT-0084a

6. Pictured below are the articulated joystick joints (Fig. 0664):

Fig 0664 PICT-0080

7. Slide the end rod off the joystick pin (Fig. 0665).

A. Loader Cylinder operationB. Tilt Cylinder operationC. Pivot for Loader and Tilt operation

Fig 0665 PICT-0081a

AB

C

HYDRAULICS


10. Using 13mm wrenches, remove the nut and washer securing the loader operation articulated joint to the pivot (Fig. 0668).

Fig 0668 PICT-0085a

11. Slide the loader operation articulated joint out of the pivot (Fig. 0669).

Fig 0669 PICT-0086a

12. Using a 3mm Allen wrench, remove the 2 screws securing the pivot to the valve housing (Fig. 0670).

Fig 0670 PICT-0088a

13. Remove the pivot from the valve assembly (Fig. 0671).

Fig 0671 PICT-0089a

HYDRAULICS


16. Using a 4mm Allen wrench, remove the 2 screws and washers securing the retainer plate to the valve housing (Fig. 0674).

Fig 0674 PICT-0093a

17. Remove the retainer plate (Fig. 0675).

Fig 0675 PICT-0094a

14. Using 13mm wrenches, remove the nut and washer securing the joystick pin to the loader spool (Fig. 0672).

Fig 0672 PICT-0090a

15. Remove the joystick pin (Fig. 0673).

Fig 0673 PICT-0092a

HYDRAULICS


18. Remove the seal from the valve (Fig. 0676).

Fig 0676 PICT-0095a

19. Using a 6mm Allen wrench, loosen the check valve (Fig. 0677).

Fig 0677 PICT-0096a

20. Remove the check valve (Fig. 0678).

Fig 0678 PICT-0097a

21. The 2 plugged ports are not used in this application. The plugs have o-ring seals. If the valve is leaking at the plug location(s), remove the plug using a 6mm Allen wrench and replace the o-ring (Fig. 0679).

Fig 0679 PICT-0099

HYDRAULICS


25. Remove the plunger from the relief valve port (Fig. 0682).

Fig 0682 PICT-0104a

26. Remove the bonnet from the from the relief valve port (Fig. 0683).

Fig 0683 PICT-0106a

22. Rotate the valve in the vise so that the spools are facing to the side.

23. Using a 19mm wrench, loosen the relief valve from the valve assembly (Fig. 0680).

Fig 0680 PICT-0100

24. Remove the relief valve assembly from the valve (Fig. 0681).

Fig 0681 PICT-0101

HYDRAULICS


Fig 0685 PICT-0103

28. Remove the spool cap and screw assembly (Fig. 0685).

Fig 0684 PICT-0102

27. Using a 4mm Allen wrench, loosen the 2 screws securing the tilt spool cap to the valve housing (Fig. 0684).

Fig 0687 PICT-0108

30. Remove the detent spring (Fig. 0687).

Fig 0686 PICT-0107

29. Using a drift punch to hold the top end of the spool, loosen the detent spring assembly from the bottom end of the tilt spool using a 5mm wrench (Fig. 0686).

HYDRAULICS


33. Using a 4mm Allen wrench, loosen the 2 screws securing the loader spool cap to the valve housing (Fig. 0690).

Fig 0690 PICT-0112

34. Remove the spool cap and screw assembly (Fig. 0691).

Fig 0691 PICT-0113a

31. Remove the spacer plate from the tilt spool (Fig. 0688).

Fig 0688 PICT-0109

32. Remove the tilt spool by carefully twisting and pulling the spool out of the top of the valve housing (Fig. 0689).

Fig 0689 PICT-0110a

HYDRAULICS


35. Using a drift punch to hold the top end of the loader spool, loosen the stem securing the detent spring to the spool using a 6mm wrench (Fig. 0692).

Fig 0692 PICT-0114

36. Remove the detent spring assembly (Fig. 0693).

Fig 0693 PICT-0115a

37. Remove the loader spool by carefully twisting and pulling the spool out the top of the valve (Fig. 0694).

Fig 0694 PICT-0116a

38. Remove the 4 o-rings from the spool ports (1 o-ring located at each end of the spool ports) (Fig. 0695).

Note: The spool port with the brass insert has a smaller size o-ring than the 3 other ports.

Fig 0695 PICT-0117a

HYDRAULICS


2 Spool Loader Valve (Fig. 0697):

A. Return Spring Cap F. Check ValveB. Relief Valve G. Tilt SpoolC. Return Spring H. Loader SpoolD. Spacer Plate I. Detent SpringE. Plugged Port (2) J. Detent Spring Cap

Fig 0697 PICT-0135a

34. Replace all o-rings.

35. Using 19mm and 13mm wrenches, loosen the adjusting nut on the relief valve (Fig. 0698).

Fig 0698 PICT-0119a

AB C D

E

E

FG

HIJ

Spools and o-rings (Fig. 0696):

Note: Visually inspect spool outside surfaces for scratches. Deep scratches are unacceptable and the spool needs to be replaced. Scratches that are deep enough to catch the fingernailarealsounacceptable,andthespool needs to be replaced.

Before replacing the spool, clean and inspect

the inner bore for damage. Check the con-dition of the o-rings, particularly for metallic particles embedded in the o-ring surface. Damage to o-ring grooves, particularly on the sealing surface, is unacceptable. In the event that an unacceptable condition occurs, the valve needs to be replaced.

A. Tilt SpoolB. Loader Spool with small relief notches

Fig 0696 PICT-0132a

A

B

HYDRAULICS


36. Remove the adjusting nut and stud (Fig.0699).

Fig 0699 PICT-0120a

37. Using a punch, push the plunger out of the relief valve body (Fig, 0700).

38. Remove and replace all relief valve o-rings.

Fig 0700 PICT-0122a

Relief Valve (Fig. 0701)

The relief valve is used to adjust to the specified system pressure (2450 psi or 169 bar) by increasing or decreas-ing the load on the spring against the disc. Loosen the lock nut; turn screw inward to increase the pressure or outward to decrease the pressure.

Fig 0701 PICT-0125a

A. Bonnet E. Plunger o-ringB. Poppet F. BodyC. Spring G. Body o-ringD. Plunger H. Adjusting nut & stud

ABC

DF

GH E

HYDRAULICS


41. Insert the spring into the relief (Fig. 0704).

Fig 0704 PICT-0128

42. Insert the plunger into the main relief (Fig. 0705).

Fig 0705 PICT-0129

39. Insert the plunger into the relief (Fig. 0702).

Fig 0702 PICT-0126

40. Install the adjusting nut and stud into the relief (Fig. 0703).

Fig 0703 PICT-0127

HYDRAULICS


Assembly

43. Install the bonnet onto the plunger (Fig. 0706).

A. Return Spring Cap F. Check ValveB. Relief Valve G. Tilt SpoolC. Return Spring H. Loader SpoolD. Spacer Plate I. Detent SpringE. Plugged Port (2) J. Detent Spring Cap

Fig 0706 PICT-0130

Replace all seals and o-rings with new parts. Lubricate the valve, o-rings, and spools with 10W-30 oil prior to installation (Fig. 0707).

Fig 0707 PICT-0135a

AB C D

E

E

FG

HIJ

1. Lubricate and install the small spool seal into the loader spool port with the brass insert (Fig. 0708).

Fig 0708 PICT-0136

2. Lubricate the 3 remaining o-rings and install them in the other three spool ports (the other end of the loader spool port and 1 on each end of the tilt spool port) (Fig. 0709).

Fig 0709 PICT-0137

HYDRAULICS


5. Thread the detent spring assembly onto the loader spool (Fig. 0712).

Fig 0712 PICT-0185a

6. Using a drift punch to hold the top end of the loader spool, tighten the detent spring stem securing the detent spring to the loader spool using a 6mm wrench. Torque to 5 ft-lbs. (6.8 Nm) (Fig. 0713).

Fig 0713 PICT-0187a

3. Lubricate the tilt spool. Install the spool into the port closest to the relief; twist and push gently, so you do not damage the o-ring (Fig. 0710).

Fig 0710 PICT-0140a

4. Lubricate and install the loader spool into the port furthest away from the relief, twist and push gently, so you do not damage the o-ring (Fig. 0711).

Fig 0711 PICT-0141a

HYDRAULICS


7. Lubricate the spring with synthetic based grease grade NLG12 (Fig. 0714).

Fig 0714 PICT-0189

8. Slide the spool cap over the stem and detent spring assembly up to the valve housing (Fig. 0715).

Fig 0715 PICT-0190

9. Using a 4mm Allen wrench, tighten the 2 screws securing the spool cap to the valve housing. Torque the screws to 5 ft-lbs. (6.8 Nm) (Fig. 0716).

Fig 0716 PICT-0191

10. Slide the spacer plate over the tilt spool and up to the valve housing (Fig. 0717).

Fig 0717 PICT-0192

HYDRAULICS


13. Lubricate the spring with synthetic based grease grade NLG12 (Fig. 0720).

Fig 0720 PICT-0196a

14. Slide the spool cap over the spring assembly up to the valve housing (Fig. 0721).

Fig 0721 PICT-0218

11. Thread the spring onto the end of the tilt spool (Fig. 0718).

Fig 0718 PICT-0193

12. Using a drift punch to hold the top end of the tilt spool, tighten the spring assembly onto the bottom of the spool using a 5mm wrench. Torque to 5 ft-lbs. (6.8 Nm) (Fig. 0719).

Fig 0719 PICT-0194a

HYDRAULICS


15. Using a 4mm Allen wrench, tighten the 2 screws securing the spool caps to the valve housing. Torque to 5 ft-lbs. (6.8 Nm) (Fig. 0722).

Fig 0722 PICT-0102

16. Thread the relief into the valve housing relief port (Fig. 0723).

Fig 0723 PICT-0219a

17. Using a 19mm socket, torque the relief to 31 ft-lbs. (42 Nm) (Fig. 0724).

Fig 0724 PICT-0202a

18. Replace the check valve o-ring (Fig. 0725).

Fig 0725 PICT-0205

HYDRAULICS


21. Install the retainer plate over the spools and onto the valve. Ensure the retainer plate is offset so that it hangs over the mounting surface side of the valve (Fig. 0728).

Fig 0728 PICT-0208

22. Using a 4mm Allen wrench, loosely install 2 screws and washers securing the retainer plate to the valve housing (Fig. 0729).

Fig 0729 PICT-0093a

19. Using a 6mm Allen wrench, install the check valve into the valve housing. Torque the check valve to 18 ft-lbs. (24 Nm) (Fig. 0726).

Fig 0726 PICT-0206a

20. Install the retainer gasket over the spools and onto the valve housing (Fig. 0727).

Fig 0727 PICT-0207

HYDRAULICS


23. Apply thread locking compound to 2 screws that will secure the joystick pivot to the valve housing (Fig. 0730).

Fig 0730 PICT-0209a

24. Position the joystick pivot into the retainer plate. Install the 2 screws securing the joystick pivot to the valve housing using a 3mm Allen wrench. Torque all 4 screws to 5 ft-lbs (6.8 Nm) (Fig. 0731).

Fig 0731 PICT-0210a

25. Apply thread locking compound to the 3 articulated joint stud threads (Fig. 0732).

Fig 0732 PICT-2648a

26. Insert the articulated joint stud into the pivot. Install a washer and nut onto the articulated joint stud. Torque to 10 ft-lbs (13.5 Nm) (Fig. 0733).

Fig 0733 PICT-0215a

HYDRAULICS


29. Insert the joint stud into the loader spool. Install a washer and nut onto the joint stud. Slide the articulated joint onto the joint stud (Fig. 0736).

Fig 0736 PICT-0223a

30. Torque the nut to 10 ft-lbs (13.5 Nm) (Fig. 0737).

Fig 0737 PICT-0224

27. Install the articulated joint stud into the tilt spool. Secure using a washer and nut (Fig. 0734).

Fig 0734 PICT-0221a

28. Torque the nut to 10 ft-lbs (13.5 Nm) (Fig. 0735).

Fig 0735 PICT-0222a

HYDRAULICS


31. Lubricate the articulated joint pivots and retainer with synthetic based grease grade NLG12 (Fig. 0738).

Fig 0738 PICT-0226a

32. Position the articulated holder onto the articulated joints so that the screws thread into each of the articulated joints (Fig. 0739).

Note: The plugged hole in the articulated holder is located above the loader spool.

Fig 0739 PICT-0227

33. Using a 5mm Allen wrench, tighten all 3 screws securing the articulated holder to the valve assembly. Torque each screw to 10 ft-lbs (13.5 Nm) (Fig. 0740).

Fig 0740 PICT-0228a

34. Apply additional grease around each of the pivot joints.

35. Slide the rubber bellows over the articulated holder and onto the retainer plate with the bellows installed around the outside of the retainer plate (Fig. 0741).

Fig 0741 PICT-0229a

HYDRAULICS


36. Install a cable tie around the retainer plate securing the rubber bellows to it. Trim the excess off the cable tie (Fig. 0742).

Fig 0742 PICT-0230a

Date post:	22-May-2018
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HYDRAULICS - Toro TX420, TX425 Series Service Manual Rev. 000 7B-3 10. Remove 6 bolts, 3 located on...

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