MANIFOLD AS-HPL 3784207 - Caterpillar

Image3.2.1
4. Remove the pilot hose and install a new 132-2453 Straight Adapter and 510-7281 Check Valve Group onto the XAs port. Once installed, reconnect the pilot hose. Refer to Image3.3.1.
5. Once all orifice check valve groups and adapters are installed, operate the machine and check for leaks.
Note: The operator may notice slower boom, stick, and swing functions when the hydraulic oil is cold. Once the oil is up to operating temperature there should be no difference in function speeds.
Image3.3.1
6. The stabilizer cylinders will need to be removed from the machine so that the rod end port welds can be needle peened. The needle peening increases the life at this weld port since we are raising the pressures internal to the cylinders with the new counterbalance valves. Refer to UENR0394, Disassembly and Assembly, for stabilizer cylinder removal and installation instructions.
IMPORTANT: Unless the cylinders have all had the peening procedure applied, installing the 516-6827 Counterbalance Valve Assembly is not allowed on any machine with screw in cylinder glands.
7. Once the cylinder has been removed, cap all ports, and secure onto a working surface with the rod port facing up to be accessed.
8. Inspect the rod end port weld for visible cracks.
9. The tool used for needle peening should have needles 3mm diameter and must have a radius on the end which contacts the surface to be peened. Peening should not be done if the temperature is below 5 degrees Celsius. Set the air pressure between 550 kPa (80PSI) minimum and 690 kPa (100PSI) maximum. Refer to Image3.4.1 for more detail on the needle peener and needles.
10. Treatment area at weld toe all around welded port. Begin peening using a tool angle shown in Image3.4.2.
Image3.4.1
Image3.4.2
11. The peening time should be 5 seconds per 25mm minimum and will cover the entire weld toe at this port location. The weld should be peened for a sufficient period of time and pressure to obtain fully dimpled weld toe. The dimpled areas should extend into the parent material a minimum of 5mm from weld toe. Refer to Image3.5.1 and 3.5.2 for proper peening of weld toe.
12. Refer to Images3.5.3 and 3.5.4 for examples of incomplete peening of the weld port.
13. Once the peening is complete, sand and paint edge to feather edge. Use medium gloss black paint.
Image3.5.1
Image3.5.2
Image3.5.3
Image3.5.4
14. Before installing the stabilizer cylinder back into the machine, it is advised to replace the existing 166-6381 Counterbalance Valve with the new 516-6827 Counterbalance Valve Assembly. Tighten the counterbalance valve to a specified torque of 45-50 Ft/lbs. Refer to Image3.6.1 for the counterbalance valve location.
It is advised that the Technician speak to the operator and inquire about any cylinders collapsing during operation. If this is the case, the technician should also inspect the PO check valves in the stabilizer lock valves for any valve or seal damage. The technician should always carry with them at least one spare 390-6998 Check Valve and 470-4558 Seal, when performing this Rework Procedure.
Image3.6.1
15. After installing all four counterbalance valves and installing all