Hydraulic Manifold (Optional High Flow Hydraulic Kit)
Removal (Fig. 41)
1.
gine off and engage the parking brake.
Park vehicle on a level surface, raise bed, shut en-
RIGHT
FRONT
2.
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
Read the General Precautions for Removing and
2
4
6
1
4
7
3
5
CAUTION
3
Before performing any service or repair on hy-
draulic system components, relieve system
pressure to avoid injury from pressurized hy-
draulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
2
Figure 41
1.
2.
3.
4.
Hydraulic manifold
O–ring
Hydraulic fitting
O–ring
5.
6.
7.
Cap screw
3.
Label and disconnect hydraulic hoses from hydraulic
Lock nut (2 used)
manifold. Install caps or plugs in hoses to prevent con-
tamination and leakage of hydraulic oil. Install plugs in
manifold ports.
Engine mount bracket
4.
guide.
Remove manifold from vehicle using Figure 41 as a
1
2
Installation (Fig. 41)
50 to 55 in–lb
(5.6 to 6.2 N–m)
3
1.
Install manifold to vehicle using Figure 41 as a guide.
2
4
2.
Replace o–rings on hydraulic hoses and fittings. Re-
move caps and plugs from hoses and fittings. Connect
hydraulic hoses to manifold.
30
(41
to 35 ft–lb
to 47 N–m)
5
3.
Check oil level in reservoir (see High Flow Hydraulic
6
8
Kit Installation Instructions). Add correct oil if necessary.
30
(41 to 47 N–m)
to 35 ft–lb
Valve Cartridge Service (Fig. 42)
7
1.
Make sure the entire outer surface of the manifold is
clean before removing the valve.
2.
For solenoid cartridge valve, remove nut securing
solenoid to the cartridge valve. Carefully slide solenoid
off the valve. Locate and retrieve seals from top and bot-
tom of coil.
Figure 42
1.
2.
3.
4.
Retaining nut
Solenoid seal
Solenoid coil
5.
6.
7.
Seal kit
Manifold body
Seal kit
IMPORTANT: Use care when handling the valve car-
tridge. Slight bending or distortion of the stem tube
can cause binding and malfunction.
Solenoid cartridge valve
8.
Relief valve cartridge
3.
Remove cartridge valve with a deep socket wrench.
Note correct location for o–rings, sealing rings, and
backup rings. Remove and discard seal kit.
Hydraulic System
Page 9 – 46
Workman 3000/4000 Series
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