service repair manual

2. 5-34
1. FLOW AMPLIFIER
STRUCTURE1)
1 O-ring
2 O-ring
3 O-ring
4 O-ring
5 Washer
6 Washer
7 O-ring
8 O-ring
9 Housing
9A Amplifier valve
9B Priority valve
9C Directional valve
10 Check valve
11 Screw
12 Spring washer
13 Screw
14 Spring washer
15 End cover
16 End cover
19 Relief valve
20 Plug
21 Shock, suction valve
22 Spring seat
23 Spring seat
24 Spring guide
26 Name plate
27 Orifice
28 Spring
29 Spring
30 Spring
31 Throttle check valve
34 Orifice
35 Orifice
36 Orifice
37 Plug
38 Plug
40 Spring
41 Spring
42 Orifice
13
14
11
12
8
40
10
16
1
9A
3
41
21
7 2
27
35
31
26
9
4
38
19
6
5
20
36
37
9B
30
22
1
14
13
15
2
23
29
28
24
34
9C
34
24
28
29
23
7
21
42
25
12
11
A
A
7707ASE09
GROUP 4 DISASSEMBLY AND ASSEMBLY

3. 5-35
TOOLS
Guide screws : M8×1.0
Hook : Wire
22)
·
·
Hexagon keys : 4, 5, 6, 8 and 10mm
Ratchet for socket spanners
Hex socket for external : 13, 17 & 19mm
Hex socket for internal : 8 & 10mm
Multigrip pliers
Ring spanner: 13mm
Screwdrivers : 3 and 10mm
Steel Mandrels : 3, 5 and 8mm
Torque wrench : 12.2kgf·m(88lbf·ft)
Magnetic rod
·
·
·
·
·
·
·
·
·
·
(770-3ATM) FA001
DISASSEMBLY
Disassembly counter pressure valve
Unscrew plug with O-ring(Hexagon
socket for 8mm internal hexagon).
3)
(1)
①
Take out small spring(hook).②
(770-3ATM) FA002
(770-3ATM) FA003
(770-3ATM) FA004

4. 5-36
Take out ball(magnetic rod).③
Take out piston.④
(770-3ATM) FA005
(770-3ATM) FA006
Take out spring.⑤
Counter pressure valve shown disassem-
bled.
⑥
(770-3ATM) FA007
(770-3ATM) FA008

5. 5-37
Counter pressure valve with orifice
shown disassembled.
⑦
Removing pressure relief valve
Unscrew plug with washer(Hexagon
socket for 8mm internal hexagon).
(2)
①
(770-3ATM) FA009
(770-3ATM) FA010
Screw pressure relief valve out(10mm
hexagon key).
②
Take out washer(Magnetic rod).③
(770-3ATM) FA011
(770-3ATM) FA012

6. 5-38
Disassembly pressure relief valve
Hold cartridge(Multigrip pliers) and screw
the adjustment screw out(5mm hexagon
key).
(3)
①
Pressure relief valve shown disassembled.②
(770-3ATM) FA013
(770-3ATM) FA014
(770-3ATM) FA015
Removing end cover at PP-connection
Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.
(4)
①
Remove end cover.②
(770-3ATM) FA016

7. 5-39
Remove stop and 2 springs.③
Remove spring.④
(770-3ATM) FA017
(770-3ATM) FA018
Remove plate and 6 O-rings.③
Remove spring guide.④
(770-3ATM) FA019
(770-3ATM) FA020

8. 5-40
Remove end cover.②
Removing end cover at LS-connection
Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.
(5)
①
(770-3ATM) FA021
(770-3ATM) FA022
Remove stop and 2 springs.③
Remove stop and spring.④
(770-3ATM) FA023
(770-3ATM) FA024

9. 5-41
Remove plate and 4 O-rings.⑤
Remove spring guide.⑥
(770-3ATM) FA025
(770-3ATM) FA026
Removing spools
Remove directional spool.
(6)
①
Remove amplifier spool.②
(770-3ATM) FA027
(770-3ATM) FA028

10. 5-42
Remove priority valve spool.③
Removing orifices and throttle check
valve
Unscrew orifice in LS-connection with
6mm hexagon key.
(7)
①
(770-3ATM) FA029
(770-3ATM) FA030
Unscrew throttle check valve in PP-
connection with 6mm hexagon key.
②
Unscrew orifice in housing with 4mm
hexagon key.
③
(770-3ATM) FA031
(770-3ATM) FA032

11. 5-43
Removing shock valves
Remove shock valve with screwdriver
and hexagon key.
(8)
①
Overview of disassembled parts
Housing and end cover with accessories.
(9)
①
(770-3ATM) FA033
(770-3ATM) FA034
Spool with accessories.②
(770-3ATM) FA035
Disassembly of directional spool
Unscrew orifice with 4mm hexagon key.
Use a mandrel.
(10)
①
(770-3ATM) FA036

12. 5-44
Directional spool shown disassembled.②
Disassembly of priority valve spool
Unscrew plug or throttle check valve with
8mm hexagon key.
(11)
①
(770-3ATM) FA037
(770-3ATM) FA038
Priority valve spool with plug for external
PP shown disassembled.
②
Priority valve spool with throttle check
valve for internal PP shown disassembled.
③
(770-3ATM) FA039
(770-3ATM) FA040

13. 5-45
Disassembly of amplifier spool
Carefully remove the spring ring from the
recess with 3mm screwdriver.
Avoid damage to the spring ring.
(12)
①
※
Carefully guide the spring ring back.②
(770-3ATM) FA041
(770-3ATM) FA042
Carefully take the spring ring from the
recess and guide it back with 3mm
screwdriver.
Avoid damage to the spring ring.
③
※
Press pin out gently with finger.④
(770-3ATM) FA043
(770-3ATM) FA044

14. 5-46
Take out plug.⑤
Take out spring.⑥
(770-3ATM) FA045
(770-3ATM) FA046
Take out pin 3mm screwdriver.⑦
Take out inner spool.⑧
(770-3ATM) FA047
(770-3ATM) FA048

15. 5-47
Unscrew check valve with hexagon
socket for 17mm external hexagon and
mandrel in the pin hole.
Avoid damaging the spool surface.
⑨
※
Unscrew orifice out of plug with 4mm
hexagon key. Use a mandrel.
⑩
(770-3ATM) FA049
(770-3ATM) FA050
Amplifier spool shown disassembled.⑪
DDisassembly of check valve
Unscrew plug with 4mm hexagon key and
hexagon socket for 17mm external
hexagon.
(13)
①
(770-3ATM) FA051
(770-3ATM) FA052

16. 5-48
Check valve shown disassembled.②
Disassembly of shock valve / suction
valve
Unscrew locknut with hexagon socket for
13mm external hexagon. Use a mandrel.
When readjusting shock valve hold
locknut with 13mm ring spanner.
(14)
①
※
(770-3ATM) FA053
(770-3ATM) FA054
Take out disc and spring.②
Take off housing.③
(770-3ATM) FA055
(770-3ATM) FA056

17. 5-49
Unscrew pilot valve with hexagon socket
for 19mm external hexagon. Use a
mandrel.
④
Take out pilot valve and spring.⑤
(770-3ATM) FA057
(770-3ATM) FA058
Take out spool.⑥
Unscrew adjustment screw and take out
spring and ball.
⑦
(770-3ATM) FA059
(770-3ATM) FA060

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19. 5-50
Shock valve / suction valve shown
disassembled.
⑧
Cleaning
Clean all parts carefully with low aromatic
kerosene.
Inspection and replacement
Replace all gaskets and sealing washers.
Check all other parts carefully and
replace if necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
※
※
※
(770-3ATM) FA061

20. 5-51
ASSEMBLY
Assembly of shock valve / suction
valve
Guide spring with cone into housing.
4)
(1)
①
Fit adjustment screw.②
Fit spool.③
Fit spring.④
(770-3ATM) FA062
(770-3ATM) FA063
(770-3ATM) FA064
(770-3ATM) FA065

21. 5-52
Fit pilot valve.
Remember O-ring.
⑤
Tighten with torque wrench for 19mm
external hexagon. Use a mandrel.
·Tightening torque : 2 ± 0.5kgf·m
(14.5 ± 3.6lbf·ft)
⑥
Fit housing.⑦
Fit spring.⑧
(770-3ATM) FA066
(770-3ATM) FA067
(770-3ATM) FA068
(770-3ATM) FA069

22. 5-53
Fit disc.⑨
Fit locknut.
·Tightening torque : 1.5 ± 0.2kgf·m
(10.8 ± 1.4lbf·ft)
⑩
AAssembly of check valve
Fit ball, spring and plug.
·Tightening torque : 0.5 ± 0.1kgf·m
(3.6 ± 0.7lbf·ft)
((2)
①
Assembly of amplifier spool
Fit orifice in plug.
·Tightening torque : 0.5 ± 0.1kgf·m
(3.6 ± 0.7lbf·ft)
((3)
①
(770-3ATM) FA070
(770-3ATM) FA071
(770-3ATM) FA072
(770-3ATM) FA073