FILTER AS 5544809 - Caterpillar

At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed.
1. Release the pressure in the hydraulic system as follows: a. Fully retract the rod in the stick cylinder.b. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.c. Lower the boom until the bucket is flat on the ground.d. Stop the engine, and put the hydraulic activation control lever in the "Lock" position.e. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.f. Slowly loosen the Fill/Vent plug on the hydraulic oil tank to release the pressure.g. Tighten the Fill/Vent plug on the hydraulic oil tank.h. The pressure in the hydraulic system has now been released. Lines and components can now be removed. 2. Slide rubber bellows (1) up on the control lever.3. Remove truss head screws (3), the washers and spacers.4. Remvoe cover (2) from the left hand console. 5. Remove the two bolts (not shown) from under the front of cover (6).6. Remove the socket head bolts and grip (4) from the left hand console.7. Remove screws (5) and cover (7) from the left hand console. 8. Pull the wire harness through the grommet in the console to gain access to the two electrical connectors for wires (9). Put identification marks on two wire assemblies (9) for installation purposes. Disconnect the two wire assemblies.9. Remove three bolts (8) that hold the pilot control valve to the console. 10. Put identification marks on six hose assemblies (11) that are connected to the pilot control valve. Disconnect the hose assemblies. Remove pilot control valve (10). Install the pilot control valve in the reverse order of removal.11. Check the oil level in the hydraulic oil tank. Fill the hydraulic oil tank with oil to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.Disassemble & Assemble Pilot Control Valves (Swing & Stick Control/Bucket & Boom Control)
Start By:a. remove pilot control valve (swing & stick control)b. remove pilot control valve (bucket & boom control) The disassembly and assembly procedure for both pilot control valves (implement) is the same.
Typical Example1. Thoroughly clean the outside of the pilot control valve prior to disassembly.2. Loosen the setscrew, and remove the lever from the pilot control valve.3. Remove two socket head screws (22), washers (21) and plate (20).4. Remove bushing (18) and O-ring seal (17) from the casing.5. Remove actuator plate (12), joint (13) and plate (14) from the casing.
Put identification marks on the two valve assemblies as they are being removed from the body assembly. Also, identify each component of the valve assemblies so they can be reinstalled in their original location.
6. Disassemble the valve assemblies. Remove spool