33 - 4
Section E
Hydraulics
9803/6400
Section E
33 - 4
Issue 2*
Control Valve JS200/JS240
Assembly, 5-spool control valve section (continued)
13. Install the main relief valve 13 (Hexagonal 31.5 A/F) to the valve housing, with a torque of 78-88 Nm (57.84-65.07 lb/ft).
14. Install the port relief valve 31 (Hexagonal 31.5 A/F) to the valve housing, with a torque of 78-88 Nm (57.84-65.07 lb/ft).
15. Install the negative control relief valve 24 (Hexagonal 36 A/F) to the valve housing, with a torque of 88-98 Nm
(65.07-72.3 lb/ft).
16. Screw in the plug 53 (Hexagonal 36 A/F) with the 'O'-ring 54 fitted, with a torque of 83-93 Nm (61.45-68.68 lb/ft).
17. Assemble the poppet 25, spring 26 to the sleeve 3 and assemble in the valve housing.
18. Install the check valve assembly 32 (Hexagonal 36 A/F), with a torque of 265-275 Nm (195.21-202.44 lb/ft).
19. Assemble the poppet 27 and spring 22 into the valve housing and install the 'O'-ring 29 to the plug 30 (Hexagonal 27 A/F).
Screw in, with a torque of 83-93 Nm (61.45-68.68 lb/ft).
20. Assemble the poppet 46 and spring 45 to the valve housing. Install the 'O'-ring 44 to the plug 43 (Hexagonal 27 A/F) and
screw in.
If the plug 12 (Hexagonal 22 A/F) is disassembled, install the 'O'-ring 11 and tighten, with a torque of 49-59 Nm
(36.15-43.38 lb/ft).
21. If the plug 53 (Hexagonal 36 A/F) is disassembled, install the 'O'-ring 54 and tighten, with a torque of 83-93 Nm
(61.45-68.68 lb/ft).
22. If the plug 52 (Hexagonal socket 5 A/F) is disassembled, wrap seal tape around the plug periphery (leave one thread open
from the end and wrap to the right 1.5~2 times so that the tape bites into the threads). Tighten, with a torque of 6.85-8.82
Nm (5.06-6.5 lb/ft).
23. Check for any disassembled parts not reassembled and then tighten.
The above tightening torque values are for the threads lubricated with hydraulic oil.
24. Install ‘O’-ring 38 in the valve housing and fit plate 41. Secure with bolt 40 (Hexagonal 14 A/F) and washer 38 tightened to
a torque of 39-44 Nm (28.92-32.53 lb/ft).
25. If the plugs are disassembled, assemble as follows.
Plug (Hexagonal A/F) No. 'O'-ring No. Tightening Torque Nm
12 (22)................................................13.......................... 49~59 Nm (36.15-43.38 lb/ft)
34 (Hexagonal socket 6 A/F)..............33.......................... 34~39 Nm (25.3-28.92 lb/ft)
67 (19)................................................33.......................... 34~39 Nm (25.3-28.92 lb/ft)
78 (Hexagonal socket 10 A/F) ...........77.......................... 88~98 Nm (65.07-72. lb/ft)
37 (31.5) Assembly replacement....................................... 78~88 Nm (57.84-65 lb/ft)
26. When assembling the plug 35 (Hexagonal socket 5 A/F), wrap seal tape around the plug periphery (leave open one thread
from the end and wrap 1.5~2 times to the right so that the seal tape bites into the thread), torque the plug with a force
of 6.85-8.82 Nm (5.06-6.5 lb/ft).
27. Recheck for parts not reassembled and tightened.
28. When assembling the 4-spool side and 5-spool side valves, attach the 'O'-rings 18, 62, 61, 63 to the bottom of the 5-spool
side valve (21153-50103, 21153-50104) and secure with socket head bolts 3, tightening to a torque of 170-180 Nm
(122.91-130.14 lb/ft).
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