HYDRAULICS. TX420 & & lower. Hydraulic Tandem Pump Removal. 4. Remove the LH side panel (Fig. 0388).

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1 TX420 & & lower 4. Remove the LH side panel (Fig. 0388). Hydraulic Tandem Pump Removal Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material. Upon removal, all seals, o-rings, and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings, and gaskets with clean petroleum jelly prior to assembly. 1. Raise the hood assembly. Fig 0388 DSC Raise the loader arms and use the cylinder lock to secure the loader arm. 5. Remove the three bolts and nuts retaining the cooler mounting bracket to the grill assembly (Fig. 0389). 3. Remove the RH side panel (Fig. 0387). Fig 0389 DSC-3335 Fig 0387 CLR DSC-3333 TX420, TX425 Series Service Manual Rev B-1

2 6. Remove left side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0390). 8 Loosen the 4 bolts and nuts on the front counterweight (Fig. 0392). Fig 0390 DSC-3336 Fig 0392 CLR DSC Remove the right side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0391). 9. Remove the heat shield from the unit (Fig. 0393). Fig 0391 DSC-3337 Fig 0393 DSC B-2 Rev. 001 TX420, TX425 Series Service Manual

3 10. Remove 6 bolts, 3 located on each side, retaining the grill assembly to the frame (Fig. 0394). 12. On the right hand side of the pump, loosen the two hose clamps retaining the hydraulic suction hoses to the hydraulic fittings on the hydraulic pump (Fig. 0396). Fig 0394 DSC-3341 Fig 0396 DSC Lift one side of the grill assembly up and slide the grill assembly forward and off the frame (Fig. 0395). 13. Remove both hydraulic suction hoses from the hydraulic fittings on the hydraulic pump (Fig. 0397). Note: Protect the openings on the hoses by placing protective caps on the hoses. Fig 0395 DSC-3342 Fig 0397 CLR DSC-3344 TX420, TX425 Series Service Manual Rev B-3

4 14. Remove the two hydraulic lines off the hydraulic fittings located on the left side of the hydraulic pump (Fig. 0398). 16. Remove the two screws retaining the hydraulic pump to the pump mount (Fig. 0400). Fig 0398 DSC-3345 Fig 0400 DSC Remove the two locknuts located on the pump hub (Fig. 0399). Remove one locknut and rotate the engine crankshaft 180º to gain access to the other locknut. 17. Remove the hydraulic pump from the pump mount (Fig. 0401). Note: Remove both spark plug wires prior to rotating the engine. Fig 0401 DSC-3351 Fig 0399 DSC B-4 Rev. 001 TX420, TX425 Series Service Manual

5 Rubber Coupler Assembly Removal 1. Raise the hood assembly. 5. Remove the three bolts and nuts retaining the cooler mounting bracket to the grill assembly (Fig. 0404). 2. Raise the loader arms and use the cylinder lock to secure the loader arm. 3. Remove the RH side panel (Fig. 0402). Fig 0404 DSC-3335 Fig 0402 CLR DSC Remove left side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0405). 4. Remove the LH side panel (Fig. 0403). Fig 0405 DSC-3336 Fig 0403 DSC-3334 TX420, TX425 Series Service Manual Rev B-5

6 7. Remove the right side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0406). 9. Remove the heat shield from the unit (Fig. 0408). Fig 0406 DSC-3337 Fig 0408 DSC Loosen the 4 bolts and nuts on the front counterweight (Fig. 0407). 10. Remove 6 bolts, 3 located on each side, retaining the grill assembly to the frame (Fig. 0409). Note: Loosen the rear bolts on the support panel assembly on the right and left side. Fig 0407 CLR DSC-3339 Fig 0409 DSC B-6 Rev. 001 TX420, TX425 Series Service Manual

7 11. Lift one side of the grill assembly up and slide the grill assembly forward and off the frame (Fig. 0410). 13. Remove both hydraulic suction hoses from the hydraulic fittings on the hydraulic pump (Fig. 0412). Note: Protect the openings on the hoses by placing protective caps on the hoses. Fig 0410 DSC On the right hand side of the pump, loosen the two hose clamps retaining the hydraulic suction hoses to the hydraulic fittings on the hydraulic pump (Fig. 0411). Fig 0412 CLR DSC Remove the two hydraulic lines off the hydraulic fittings located on the left side of the hydraulic pump (Fig. 0413). Fig 0411 DSC-3343 Fig 0413 DSC-3345 TX420, TX425 Series Service Manual Rev B-7

8 15. Remove the two locknuts located on the pump hub (Fig. 0414). Remove one locknut and rotate the engine crankshaft 180º to gain access to the other locknut. 17. Remove the hydraulic pump from the pump mount (Fig. 0416). Note: Remove both spark plug wires prior to rotating the engine. Fig 0416 DSC-3351 Fig 0414 DSC Remove engine air cleaner (Fig. 0417). 16. Remove the two screws retaining the hydraulic pump to the pump mount (Fig. 0415). Fig 0417 CLR DSC-3359 Fig 0415 DSC B-8 Rev. 001 TX420, TX425 Series Service Manual

9 19. Remove the screw, located at the top of the engine throttle linkage bracket, retaining the heat shield (Fig. 0418). 21. Remove the two retaining screws and washers, located on the oil filter support bracket (Fig. 0420). Remove the oil filter head assembly and oil filter from the unit. Fig 0418 DSC-3360 Fig 0420 DSC Remove the right and left hydraulic lines from the oil filter head assembly (Fig. 0419). 22. Remove the two bolts and nuts retaining the filter heat shield to the oil filter support bracket (Fig. 0421). Fig 0419 CLR DSC-3362 Fig 0421 DSC-3388 TX420, TX425 Series Service Manual Rev B-9

10 23. Remove the engine dip stick. Remove the two bolts and washers at the top of the pump mount that retain the oil filter support bracket to the engine (Fig. 0422). 25. Remove the two bolts and washers retaining the pump mount to the engine (Fig. 0424). Fig 0424 DSC-3366 Fig 0422 DSC Remove the oil filter bracket and filter heat shield from the unit (Fig. 0423). 26. Remove the pump mount from the engine (Fig. 0425). Fig 0425 DSC-3367 Fig 0423 DSC B-10 Rev. 001 TX420, TX425 Series Service Manual

11 27. Loosen the two set screws on the engine hub (Fig. 0426). Rubber Coupler Assembly Installation 1. Assemble the engine hub, rubber coupler, and hardware as an assembly (Fig. 0428). B A D C Fig 0426 DSC-3368 F E Fig 0428 coupler asm1 28. Remove the engine hub and coupler assembly from the crankshaft (Fig. 0427). A. Spacer Coupling (4) D. Engine Hub B. Capscrews (4) E. Rubber Coupling (2) C. Nuts (2) F. Washers (4) 2. Apply anti-seize compound to the key and the engine crankshaft (Fig. 0429). Fig 0427 DSC-3370 Fig 0429 DSC-3371 TX420, TX425 Series Service Manual Rev B-11

12 3. Remove the set screws from the engine hub and apply thread locking compound to the threads and thread set screws back into the hub (Fig. 0430). 5. The pump mount needs to be placed on the engine with the two closely spaced bolt holes to the top (Fig. 0432). A B Fig 0430 DSC-3372 Fig 0432 CLR DSC-3379 A. Top B. Bottom 4. Slide the engine hub assembly onto the crankshaft until the end of the crankshaft is centered in between the rubber couplers. Using a 1/4 8-point socket, snug (do not tighten) the 2 set screws to hold the hub in place on the crankshaft (Fig. 0431). 6. Place the pump mount to the engine and insert the two lower bolts. Leave the two bolts loose (Fig. 0433). Fig 0431 DSC-3375 Fig 0433 DSC B-12 Rev. 001 TX420, TX425 Series Service Manual

13 7. Position the oil filter bracket and filter heat shield to the pump mount (Fig. 0434). 9. Install two bolts and nuts retaining the filter heat shield to the oil filter support bracket (Fig. 0436). Fig 0434 DSC-3386 Fig 0436 DSC Insert bolts into the heat shield assembly through the pump mount into the engine block (Fig. 0435). 10. Install the screw located on the engine throttle linkage bracket, retaining the heat shield (Fig. 0437). Fig 0435 CLR DSC-3385 Fig 0437 DSC-3360 TX420, TX425 Series Service Manual Rev B-13

14 11. Torque the 4 bolts on the pump mount to 50 ft-lbs. (67.79 Nm) (Fig. 0438). 14. Install the right and left hydraulic lines to the filter head assembly (Fig. 0440) Fig 0438 CLR DSC-3389 Fig 0440 CLR DSC Install the engine air cleaner cover and the engine oil dip stick. 13. Install two screws through the oil filter support bracket and into the oil filter head assembly and tighten (Fig. 0439). Hydraulic Tandem Pump Installation Hydraulic Tandem Pump fitting orientation (Fig bottom view). Note: Photo shows pump hub installed. E E A C B D Fig 0439 DSC-3361 Fig 0441 CLR DSC-3356 A. 5.5 gpm loader circuit C gpm auxiliary pump circuit pump B. Loader circuit pump D. Auxiliary circuit pump fitting fitting E. Suction hose fitting (2) 7B-14 Rev. 001 TX420, TX425 Series Service Manual

15 1. Install a square key on the hydraulic pump shaft and apply anti-seize compound (Fig. 0442). 3. Apply thread locking compound to the set screws and finger tighten (Fig. 0444). Fig 0442 CLR DSC-3390 Fig 0444 CLR DSC Install the pump hub and adjust the hub on the pump shaft so that it measures 1-1/4 (3.17cm) from the pump casting to the outer surface of the pump hub (Fig. 0443). 4. Align the pump hub with the two bolts in the rubber coupling. Install two screws that retain the hydraulic pump to the pump mount (Fig. 0445). Note: Tighten the two screws equally to draw the hydraulic pump up to pump mount. Fig 0443 DSC-3393 Fig 0445 DSC-3399 TX420, TX425 Series Service Manual Rev B-15

16 5. Install nuts on the two bolts from the rubber coupling to the pump hub and tighten (Fig. 0446). Rotate the engine 180º to tighten the other bolt and nut. 7. Install the two hydraulic lines to the hydraulic fittings located on the left side of the hydraulic pump (Fig. 0448). Note: Reconnect both spark plug wires to the spark plugs. Fig 0448 CLR DSC-3404 Fig 0446 CLR DSC Tighten and torque all 4 set screws to in-lbs. ( Nm) (Fig. 0447). 8. Install the two hydraulic suction lines located on the right side of the hydraulic pump. Tighten the two hose clamps on the hydraulic suction lines to the hydraulic fittings (Fig. 0449). Fig 0447 CLR DSC-3403 Fig 0449 CLR DSC B-16 Rev. 001 TX420, TX425 Series Service Manual

17 9. Start the unit up and allow the engine to run at idle for a couple of minutes. 14. Position the heat shield so that it is installed between the front counterweight and mainframe (Fig. 0451). 10. Remove the cylinder lock. 11. Purge the system. Refer to Purging Air Procedures on page Cycle the loader lift arms and tilt. Check for any oil leaks. Check the oil reservoir. Refer to Checking the Hydraulic Fluid on page Install the grill assembly on the frame. Install 6 screws, 3 located on each side of the grill assembly. Install 3 screws retaining the right and left side panel support (Fig. 0450). Fig 0451 DSC Tighten the 4 bolts and nuts on the front counterweight (Fig. 0452). Fig 0450 DSC-3341 Fig 0452 CLR DSC-3339 TX420, TX425 Series Service Manual Rev B-17

18 16. Tighten the right side carriage bolt and nut retaining the heat shield to the grill assembly (Fig. 0453). 18. Install the LH side panel (Fig. 0455). Fig 0453 DSC-3337 Fig 0455 DSC Install the 3 bolts and nuts retaining the oil cooler mounting bracket to the grill assembly (Fig. 0454). 19. Install the RH side panel (Fig. 0456). Fig 0456 CLR DSC-3333 Fig 0454 DSC Close the hood assembly. 7B-18 Rev. 001 TX420, TX425 Series Service Manual

19 TX420 & & lower Hydraulic Tandem Pump Rebuild 2. Secure the pump in a vise. 3. Mark the casing of the pump with a V that crosses over all sections of the pump (Fig. 0458). Note: Protect all exposed sealing areas and open cavities from damage, foreign material and chemicals. Replace all seals, o-rings and gaskets when reassembling. 1. Remove the key from the keyway of the pump shaft (Fig. 0457). Fig 0458 PICT Using a 16mm socket, loosen and remove the 4 bolts securing the pump sections (Fig. 0459). Fig 0457 PICT-2776 Fig 0459 PICT-2760a TX420, TX425 Series Service Manual Rev B-19

20 5. Remove the rear cover of the pump from the pump assembly (Fig. 0460). 7. Mark the top of the rear bushing assembly out to the pump housing with a single line (Fig. 0462). Fig 0460 PICT-2762 Fig 0462 PICT Remove the o-ring from the rear pump housing (Fig. 0461). 8. Lift the rear pump housing off of the rear pump bushing assembly (Fig. 0463). Fig 0461 PICT-2763 Fig 0463 PICT B-20 Rev. 001 TX420, TX425 Series Service Manual

21 9. Mark the rear bushing assembly down the side with a single line (Fig. 0464). 11. Remove the middle pump plate from the pump assembly (Fig. 0466). Fig 0464 PICT-2766 Fig 0466 PICT-2769a 10. Remove the rear bushing assembly from the pump assembly (Fig. 0465). 12. Remove the o-ring from the front pump housing (Fig. 0467). Fig 0465 PICT-2768a Fig 0467 PICT-2770a TX420, TX425 Series Service Manual Rev B-21

22 13. Mark the top of the front bushing assembly out to the pump housing with 2 parallel lines (Fig. 0468). 15. Mark the front bushing assembly down the side with two parallel lines (Fig. 0470). Fig 0468 PICT-2772 Fig 0470 PICT-2777a 14. Remove the front pump housing from the center bushing assembly (Fig. 0469). 16. Remove the front bushing assembly (Fig. 0471). Fig 0469 PICT-2773a Fig 0471 PICT-2778a 7B-22 Rev. 001 TX420, TX425 Series Service Manual

23 17. Using a snap ring pliers, remove the snap ring from the inside of the pump cover (Fig. 0472). 20. Install a new shaft seal in the pump cover so that the spring side of the seal is facing the housing side of the pump cover (Fig. 0474). Fig 0472 PICT-2783a Fig 0474 PICT Secure the pump cover in a vise so the inside of the cover is facing up. 19. Remove the shaft seal from the inside of the pump cover (Fig. 0473). 21. Carefully drive the seal into the cover until it is seated (Fig. 0475). Fig 0475 PICT-2786a Fig 0473 PICT-2784a TX420, TX425 Series Service Manual Rev B-23

24 22. Install the snap ring into the groove on the inside of the pump cover (Fig. 0476). 2. Remove the upper bushing from the drive gear and intermediate gear shafts (Fig. 0478). Fig 0476 PICT-2788a Fig 0478 PICT-2790a 11 gpm Pump Assembly Rebuild Note: Lubricate all surfaces on reassembly. 3. Remove the drive gear from the lower bushing (Fig. 0479). 1. Remove the drive link from the upper bushing (Fig. 0477). Fig 0479 PICT-2791a Fig 0477 PICT-2789a 7B-24 Rev. 001 TX420, TX425 Series Service Manual

25 4. Remove the intermediate gear from the lower bushing (Fig. 0480). 6. Remove the gear seal from the top and bottom surfaces of the 2 bushings (Fig. 0482). Fig 0480 PICT-2792a Fig 0482 PICT-2793a 5. Remove the backup ring from the top and bottom surfaces of the 2 bushings (Fig. 0481). 7. Inspect the gear surface of both of the bushings for damage (Fig. 0483). Fig 0481 PICT-2793a Fig 0483 PICT-2796a TX420, TX425 Series Service Manual Rev B-25

26 8. Inspect the drive gear and intermediate gear for damage (Fig. 0484). 10. Install the back-up ring into the bushing. Note that the tab in the center portion of the back-up ring is flush to one surface. That flush surface should be installed up so the webbing is resting on the center of the gear seal while lying flat in the groove of the bushing (Fig and Fig. 0487). Fig 0484 PICT-2797a 9. Install the gear seal with the curved side of the gasket down in the groove of the bushing (Fig. 0485). Fig 0486 PICT-2805 Fig 0485 PICT-2800a Fig 0487 PICT-2804a 7B-26 Rev. 001 TX420, TX425 Series Service Manual

27 11. Repeat the above 2 steps for the second bushing, gear seal and back-up ring. 14. Install the second bushing onto the 2 gears (Fig. 0490). 12. Making note of the markings on the bushing assembly, install the intermediate gear into the bushing (Fig. 0488). Fig 0490 PICT-2790a Fig 0488 PICT-2792a 15. Install the drive link into the drive gear (Fig. 0491). 13. Install the drive gear onto the bushing (Fig. 0489). Fig 0491 PICT-2789a Fig 0489 PICT-2791a TX420, TX425 Series Service Manual Rev B-27

28 16. Install the front bushing and gear assembly into the pump cover through hole (Fig. 0492). 18. Install the front housing body over the front bushing and gear assembly and onto the pump cover (Fig. 0494). Fig 0492 PICT-2778a Fig 0494 PICT-2773a 17. Install the gasket into the groove on the front surface of the front housing body (Fig. 0493). 19. Install the gasket on the rear surface of the front pump housing body (Fig. 0495). Fig 0493 PICT-2806a Fig 0495 PICT-2807a 7B-28 Rev. 001 TX420, TX425 Series Service Manual

29 20. Install the center plate onto the front housing body. Note the markings on the plate and housing should match up (Fig. 0496). 2. Remove the intermediate gear (Fig. 0498). Fig 0498 PICT-2810a Fig 0496 PICT-2808a 3. Remove the drive gear (Fig. 0499). 5 gpm Pump Assembly Rebuild Note: Lubricate all surfaces on reassembly. 1. Remove one of the bushings (Fig. 0497). Fig 0499 PICT-2811a Fig 0497 PICT-2809a TX420, TX425 Series Service Manual Rev B-29

30 4. Remove the back-up ring from both of the bushings (Fig. 0500). 6. Inspect the gear surfaces of both bushings for damage (Fig. 0502). Fig 0500 PICT-2812a Fig 0502 PICT-2814a 5. Remove the gear seal from the both of the bushings (Fig. 0501). 7. Inspect the drive and intermediate gears for damage (Fig. 0503). Fig 0501 PICT-2813a Fig 0503 PICT-2816a 7B-30 Rev. 001 TX420, TX425 Series Service Manual

31 8. Install the gear seal with the curved side of the gasket down in the groove of the bushing (Fig. 0504). Fig 0506 PICT-2804a Fig 0504 PICT-2800a 10. Repeat the above 2 steps for the second bushing, gear seal and back-up ring. 9. Install the back-up ring into the bushing. Note that the tab in the center portion of the back-up ring is flush to one surface. That flush surface should be installed up so the webbing is resting on the center of the gear seal while lying flat in the groove of the bushing (Fig and Fig. 0506). 11. Install the 2 o-rings into the 5 gpm housing body (Fig. 0507). Fig 0507 PICT-2817a Fig 0505 PICT-2805 TX420, TX425 Series Service Manual Rev B-31

32 12. Install the 5 gpm housing body onto the pump assembly over the 5 gpm bushing and gear assembly (Fig. 0508). 14. Using a 16mm socket, install the 4 bolts that secure the pump sections. Torque the 4 bolts to ft-lbs. ( Nm) (Fig. 0510). Fig 0508 PICT-2819a Fig 0510 PICT-2821a 13. Install the pump cover onto the 5 gpm pump assembly (Fig. 0509). 15. Insert the key into the keyway of the pump shaft (Fig. 0511). Fig 0509 PICT-2820a Fig 0511 PICT-2776a 7B-32 Rev. 001 TX420, TX425 Series Service Manual

33 TX420 & & lower Tilt Cylinder Replacement 9. Loosen and remove the two hydraulic lines from the cylinder fittings. Place protective caps onto the hydraulic fittings and lines (Fig. 0513). 1. Remove any attachment from traction unit. 2. Park the unit on a level surface. 3. Extend the tilt cylinder so the attach plate lays parallel to the floor. 4. Rest the quick attach assembly on wood blocks (Fig. 0512). Fig 0513 DSC Remove the bolt securing the pivot pin at the quick attach assembly on the ram end of the tilt cylinder (Fig. 0514). Fig 0512 DSC Shut the engine off. 6. Stroke the loader valve from dump to curl to remove pressure from the hydraulic lines. 7. Let the hydraulic oil cool. 8. Place a drain pan under the tilt cylinder fittings. Fig 0514 DSC-3548 TX420, TX425 Series Service Manual Rev B-33

34 11. Remove the pivot pin from the cylinder and quick attach assembly (Fig. 0515). 13. Using hammer and punch, remove the pivot pin from the loader arm and cylinder barrel (Fig. 0517). Fig 0515 DSC-3549 Fig 0517 DSC Remove the bolt and nut from the pivot pin at the barrel end of the tilt cylinder (Fig. 0516). 14. Remove the cylinder (Fig. 0518). Fig 0516 DSC-3550 Fig 0518 DSC B-34 Rev. 001 TX420, TX425 Series Service Manual

35 15. Remove the hydraulic fittings from the cylinder (Fig. 0519). 18. Place the barrel end of the tilt cylinder into the opening in the loader arm and insert the pivot pin (Fig. 0521). Fig 0519 CLR DSC-3553 Fig 0521 DSC Replace the o-rings on the hydraulic fittings. 17. Insert hydraulic fittings into new hydraulic cylinder (Fig. 0520). 19. Align the pivot pin hole with loader arm hole and insert a bolt and nut to secure pivot pin. Torque bolt and nut to 16 ft-lbs. (21.7 Nm) (Fig. 0522). Fig 0520 CLR DSC-3553 Fig 0522 CLR DSC-3560 TX420, TX425 Series Service Manual Rev B-35

36 20. Remove the protective caps from the hydraulic fittings and pull on the ram of hydraulic cylinder to extend it. Align the clevis opening to the quick attach assembly (Fig. 0523). 22. Install and torque the screw to 16 ft-lbs (21.7 Nm) (Fig. 0525). Fig 0525 CLR DSC-3559 Fig 0523 DSC Insert the pivot pin through the hydraulic cylinder and quick attach assembly. 23. Reconnect and tighten the hydraulic lines to the tilt cylinder (Fig. 0526). Note: Insert the pivot pin so the flange of the pivot pin is on the same side as the threaded hole in the clevis of the ram end of hydraulic cylinder (Fig. 0524). Fig 0526 DSC-3547 Fig 0524 CLR DSC B-36 Rev. 001 TX420, TX425 Series Service Manual

37 24. Grease the pivot pins. Refer to Greasing the Traction Unit on page Start the unit and inspect for leaks. Purge the air from the hydraulic system. Refer to Purging Air Procedures on page Note: If excessive wear due to side-loads or binding is a possibility, mark or note the piston and head relationship to the rod and tube. This condition will usually show up as a highly polished surface on the piston and head 90 to the pin rotation axis (Fig. 0528). 26. Remove blocks of wood. TX420 & & lower Tilt Cylinder Assembly Rebuild 1. Extend the ram of the tilt cylinder out approximately 6 to 12 (15.24 to 30.48cm). 2. Clean away all dirt and other foreign substance from openings, particularly at the head of the hydraulic cylinder. 3. Clamp the tilt cylinder in a vise so that the locking ring slot is facing up. Fig 0528 PICT Clean out all material from the locking slot (Fig. 0527). 5. Use a spanner wrench installed in the holes provided. Rotate the head clockwise until the edge of the retaining ring appears in the milled opening of the tube. Insert a flat blade screwdriver between the beveled edge of the retaining ring and the cylinder barrel to start the retaining ring through the opening (Fig. 0529). Fig 0527 PICT-2900 Fig 0529 PICT-2905 TX420, TX425 Series Service Manual Rev B-37

38 6. Continue to rotate the head counter-clockwise until the retaining ring is completely removed (Fig. 0530). Fig 0530 PICT Pull out on the ram to remove the piston and head assembly from the barrel (Fig. 0531). 8. Remove the barrel from the vise. INSPECT ROD: There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable. Scratches that catch the fingernail but are not to the base metal, less than 0.5 long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal. Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable. In the event that an unacceptable condition occurs, the cylinder should be replaced. INSPECT HEAD: Visually inspect the inside bore for scratches or polishing. Deep scratches are unacceptable. Polishing indicates uneven loading and when this occurs, the bore should be checked for out of-roundness. If out-of-roundness exceeds (.18mm), this is unacceptable. Check the condition of the dynamic seals, looking particularly for metallic particles embedded in the piston seal surface. Remove the seals. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the cylinder should be replaced. Fig 0531 PICT-2910a 7B-38 Rev. 001 TX420, TX425 Series Service Manual

39 INSPECT TUBE ASSEMBLY: Visually inspect the inside bore for scratches and pits. There should be no scratches or pits deep enough to catch the finger-nail. Scratches that catch the fingernail but are less than 0.5 long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal. In the event that an unacceptable condition occurs, the cylinder should be replaced (Fig. 0532). Tilt Cylinder Disassembly 1. Remove the piston seal from the ram assembly (Fig. 0533). A B C Fig 0532 D A. Tube D. Head B. Retaining Ring E. Ram C. Piston E PICT-2911a Fig Remove the back-up piston seal from the ram assembly (Fig. 0534). PICT-2912a Fig 0534 PICT-2913a TX420, TX425 Series Service Manual Rev B-39

40 3. Carefully remove the wear ring from the ram assembly (Fig. 0535). 5. Slide the piston off the end of the ram (Fig. 0537). Fig 0535 PICT-2914 Fig 0537 PICT-2916a 4. Using a 1-1/8 socket, remove the nut from the ram assembly (Fig. 0536). 6. Remove the inner o-ring from the inside of the piston (Fig. 0538). Fig 0536 PICT-2915a Fig 0538 PICT-2918a 7B-40 Rev. 001 TX420, TX425 Series Service Manual

41 7. Remove the o-ring from the head on the ram assembly (Fig. 0539). 9. Slide the head off the end of the ram (Fig. 0541). Fig 0539 PICT-2921 Fig 0541 PICT-2923a 8. Remove the flat back-up ring from the head on the ram assembly (Fig. 0540). 10. Remove the wiper seal from inside the head (Fig. 0542). Fig 0540 PICT-2922a Fig 0542 PICT-2924a TX420, TX425 Series Service Manual Rev B-41

42 11. Remove the wear seal from inside the head (Fig. 0543). A B C D E F Fig 0545 PICT-2927a Fig 0543 PICT-2925a A. Locknut D. Back up piston seal B. Inner o-ring E. Piston C. Piston seal F. Wear ring 12. Thoroughly rinse the inside of the head with a cleaning solvent. Rinse and clean all internal components of any foreign material with a lint-free rag. 13. Visually inspect for material defects and contamination. All seals and O-rings must be replaced with new parts (Head Assembly, Fig. 0544, and Piston Assembly, Fig. 0545). Note: Lubricate the head and all seals with 10W-30 oil prior to installation. 14. Twist the wear seal into a C shape and allow it to snap into the groove (Fig. 0546). Note: The groove of the seal faces toward the barrel side of the head. A B C D E Fig 0544 A. Wiper D. Static back-up B. Wear seal E. Static o-ring C. Head PICT-2926a Fig 0546 PICT-2928a 7B-42 Rev. 001 TX420, TX425 Series Service Manual

43 15. Install the wiper seal so that the lip of the seal is installed in the groove inside the head (Fig. 0547). 17. Install the o-ring into the deepest groove in the head. The o-ring is installed on the barrel side of the groove (Fig. 0549). Note: If possible, the head/seal assembly should sit for at least one hour to allow the seals to normalize. Fig 0547 PICT-2930a 16. Install the flat back-up ring into the deepest groove in the head. The flat back-up seal is installed up against the ram side of the groove (Fig. 0548). Fig 0549 PICT-2933a 18. Install the inner o-ring into the groove on the inside of the piston (Fig. 0550). Fig 0548 PICT-2941a Fig 0550 PICT-2937a TX420, TX425 Series Service Manual Rev B-43

44 19. Install the wear ring into the widest groove on the piston (Fig. 0551). 21. Install the piston seal into the narrowest groove of the piston on top of the back-up ring (Fig. 0553). Fig 0551 PICT-2938a Fig 0553 PICT-2940a 20. Install the back-up ring into the narrowest groove on the piston (Fig. 0552). Tilt Cylinder Assembly Note: Lubricate all parts during assembly. 1. Secure the cylinder ram into a vise. 2. Slide the head onto the cylinder ram (Fig. 0554). Fig 0552 PICT-2939a Fig 0554 PICT-2943a 7B-44 Rev. 001 TX420, TX425 Series Service Manual

45 3. Slide the piston onto the cylinder ram (Fig. 0555). 5. Remove the ram from the vise and secure the cylinder barrel into the vise. 6. Install the ram assembly into the cylinder barrel by rotating the head assembly while pushing the head into the barrel (Fig. 0557). Fig 0555 PICT-2944a 4. Install the nut onto the end of the ram. Using a 1-1/8 socket, torque the nut to ft-lbs. ( Nm) (Fig. 0556). Fig 0557 PICT Continue rotating the head until the ring hole in the ring groove is within the slot on the barrel (Fig. 0558). Fig 0556 PICT-2945a Fig 0558 PICT-2947 TX420, TX425 Series Service Manual Rev B-45

46 8. Insert the end of the retaining ring through the notch in the barrel and into the hole in the groove. Place the spanner wrench onto the head assembly (Fig. 0559). TX420 & & lower Lift Cylinder Replacement Note: The following procedure applies to both left and right side lift cylinders. 1. Remove any attachment from traction unit. 2. Park the unit on level surface. 3. Raise the loader arms approximately 5 (12.7cm) from the frame stops. 4. Place two jack stands under the attach plate assembly. Lower the loader arms onto jack stands to support the loader arm (Fig. 0561). Fig 0559 PICT Begin rotating the spanner wrench so that the head pulls the ring inside the barrel. Continue rotating until the ring is completely installed inside the barrel on the head assembly (Fig. 0560). Fig 0561 DSC-3569 Fig 0560 PICT B-46 Rev. 001 TX420, TX425 Series Service Manual

47 5. Shut the engine off. 6. Stroke the loader valve from raise to lower position to remove pressure from the hydraulic lines. 9. Remove the bolt and nut from the front pivot pins (Fig. 0564). 7. Loosen and remove the two hydraulic lines from the cylinder fittings. Place protective caps onto the hydraulic fittings and lines (Fig. 0562). Fig 0564 DSC-3571 Fig 0562 DSC Support the ram end of the lift cylinder while removing the pivot pin from the loader arm (Fig. 0565). 8. Cut and remove the two plastic ties from the hydraulic lines (Fig. 0563). Fig 0565 DSC-3572 Fig 0563 CLR DSC-3573 TX420, TX425 Series Service Manual Rev B-47

48 11. Remove the bolt and nut from the rear pivot pin (Fig. 0566). 13. Support the lift cylinder and remove the pivot pin from the tower assembly (Fig. 0568). Fig 0566 CLR DSC-3574 Fig 0568 CLR DSC Remove the pivot pin on the barrel end of the lift cylinder: To get the pivot pin started out of the tower assembly, use a round steel rod approximately 30 (76.2cm) long and a hammer. Insert the rod between the engine and pump belt from the opposite side of the lift cylinder being removed. Using the hammer, tap on the rod striking the pin from inside the tower assembly toward the outside of tower assembly (Fig. 0567). 14. Remove the lift cylinder from the frame (Fig. 0569). Fig 0569 CLR DSC-3581 Fig 0567 DSC B-48 Rev. 001 TX420, TX425 Series Service Manual

49 15. Remove the hydraulic line from the barrel end fitting of the cylinder (Fig. 0570). 17. Replace the o-rings on the hydraulic fittings. 18. Reinstall the fittings into cylinder (Fig. 0572). Fig 0570 CLR DSC-3586 Fig 0572 CLR DSC Remove both fittings from the cylinder (Fig. 0571). 19. Reinstall the hydraulic line onto the barrel end fitting of the cylinder (Fig. 0573). Fig 0571 CLR DSC-3587 Fig 0573 CLR DSC-3586 TX420, TX425 Series Service Manual Rev B-49

50 20. Place the lift cylinder into the frame with the fittings facing down (Fig. 0574). 22. Install the bolt through the frame and pivot pin. Install the nut and torque to 16 ft-lbs. (21.7 Nm) (Fig. 0576). Fig 0574 CLR DSC-3581 Fig 0576 CLR DSC Install the pivot pin into the frame and then through the barrel end of the cylinder (Fig. 0575). 23. Remove the protective caps from the hydraulic fittings. Pull the ram out of the cylinder barrel until the pivot pin opening lines up in the loader arm (Fig. 0577). Note: Grease fitting should be facing down. Fig 0575 CLR DSC-3574 Fig 0577 DSC B-50 Rev. 001 TX420, TX425 Series Service Manual

51 24. Install the pivot pin into the loader arm and through the cylinder (Fig. 0578). 26. Connect the two hydraulic lines to the cylinder (Fig. 0580). Fig 0578 DSC-3572 Fig 0580 DSC Install the bolt through loader arm and pivot pin. Install the nut and torque to 16 ft-lbs. (21.7 Nm) (Fig. 0579). 27. Install two cable ties around cylinder barrel, hydraulic line to front fitting and the metal line (Fig. 0581). Fig 0579 CLR DSC-3592 Fig 0581 DSC Purge the air from the system. Refer to Purging Air Procedures, page Remove the jack stands. TX420, TX425 Series Service Manual Rev B-51

52 TX420 & & lower Lift Cylinder Rebuild 1. Extend the ram of the tilt cylinder out approximately 6 to 12 (15.24 to 30.48cm). Note: If excessive wear due to side-loads or binding is a possibility, mark or note the piston and head relationship to the rod and tube. This condition will usually show up as a highly polished surface on the piston and head 90 to the pin rotation axis (Fig. 0583). 2. Clean away all dirt and other foreign substance from the openings, particularly at the head of the hydraulic cylinder. 3. Clamp the tilt cylinder in a vise so that the locking ring slot is facing up. 4. Clean out all material from the locking slot (Fig. 0582). Fig 0583 PICT-2997 Fig 0582 PICT Use a spanner wrench installed in the holes provided. Rotate the head counterclockwise until the edge of the retaining ring appears in the milled opening of the tube. Insert a flat blade screwdriver between the beveled edge of the retaining ring and the cylinder barrel to start the retaining ring through the opening (Fig. 0584). Fig 0584 PICT B-52 Rev. 001 TX420, TX425 Series Service Manual

53 6. Continue to rotate the head counterclockwise until the retaining ring is completely removed (Fig. 0585). Fig Pull on the ram to remove the piston and head assembly from the barrel (Fig. 0586). PICT Remove the barrel from the vise. INSPECT ROD: There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable. Scratches that catch the fingernail but are not to the base metal, less than 0.5 long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal. Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable. In the event that an unacceptable condition occurs, the cylinder should be replaced. INSPECT HEAD: Visually inspect the inside bore for scratches or polishing. Deep scratches are unacceptable. Polishing indicates uneven loading and when this occurs, the bore should be checked for out of-roundness. If out-of-roundness exceeds (.18mm), this is unacceptable. Check the condition of the dynamic seals, looking particularly for metallic particles embedded in the piston seal surface. Remove the seals. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the cylinder should be replaced. Fig 0586 PICT-3000a TX420, TX425 Series Service Manual Rev B-53

54 INSPECT TUBE ASSEMBLY: Visually inspect the inside bore for scratches and pits. There should be no scratches or pits deep enough to catch the fingernail. Scratches that catch the fingernail but are less the 0.5 long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal. In the event that an unacceptable condition occurs, the cylinder should be replaced (Fig. 0587). Lift Cylinder Disassembly 1. Secure the pivot pin end of the ram in a vise. Remove the piston seal from the ram assembly (Fig. 0588). A B C D E Fig 0588 PICT-3002a Fig 0587 A. Barrel D. Head B. Retaining Ring E. Ram C. Piston PICT-3001a 2. Remove the back-up piston seal from the ram assembly (Fig. 0589). Fig 0589 PICT-3003a 7B-54 Rev. 001 TX420, TX425 Series Service Manual

55 3. Using a 1-1/8 socket, remove the nut from the ram assembly (Fig. 0590). 5. Remove the inner o-ring from the inside of the piston (Fig. 0592). Fig 0590 PICT-3005a Fig 0592 PICT-3007a 4. Slide the piston off the end of the ram (Fig. 0591). 6. Remove the o-ring from the head on the ram assembly (Fig. 0593). Fig 0591 PICT-3006a Fig 0593 PICT-3008a TX420, TX425 Series Service Manual Rev B-55

56 7. Remove the flat back-up ring from the head on the ram assembly (Fig. 0594). 9. Remove the wiper seal from inside the head (Fig. 0596). Fig 0594 PICT-3009a Fig 0596 PICT-3011a 8. Slide the head off the end of the ram (Fig. 0595). 10. Remove the wear seal from inside the head (Fig. 0597). Fig 0595 PICT-3010a Fig 0597 PICT-3012a 7B-56 Rev. 001 TX420, TX425 Series Service Manual

57 11. Thoroughly rinse the inside of the head with a clean solvent. Rinse and clean all internal components of all foreign material using a lint-free rag. 12. Visually inspect for material defects and contamination. All seals and o-rings must be replaced (Head Assembly, Fig. 0598, and Piston Assembly, Fig. 0599). 13. Lubricate the head and all seals with 10W-30 oil prior to installation. Twist the wear seal into a C shape and allow it to snap into the groove (Fig. 0600). Note: The groove of the seal faces toward the barrel side of the head. A B C D E Fig 0598 PICT-3013a Fig 0600 PICT-3016a A. Wiper D. Static back-up B. Wear seal E. Static o-ring C. Head 14. Install the wiper seal so that the lip of the seal is installed in the groove inside the head (Fig. 0601). A B C D Fig 0599 PICT-3014a Fig 0601 PICT-3017a A. Inner piston o-ring C. Backup piston seal B. Piston D. Piston seal TX420, TX425 Series Service Manual Rev B-57

58 15. Install the flat back-up ring into the deepest groove in the head. The flat back-up seal is installed up against the ram side of the groove (Fig. 0602). 17. Install the inner o-ring into the groove on the inside of the piston (Fig. 0604). Fig 0602 PICT-3018a Fig 0604 PICT-3020a 16. Install the o-ring into the deepest groove in the head. The o-ring is installed on the barrel side of the groove (Fig. 0603). 18. Install the back-up ring into the narrowest groove on the piston (Fig. 0605). Note: If possible, the head/seal assembly should sit for at least one hour to allow the seals to normalize. Fig 0605 PICT-3021a Fig 0603 PICT-3019a 7B-58 Rev. 001 TX420, TX425 Series Service Manual

59 19. Install the piston seal on top of the back-up ring (Fig. 0606). 3. Slide the piston onto the cylinder ram (Fig. 0608). Fig 0606 PICT-3022a Fig 0608 PICT-3025a Lift Cylinder Assembly Note: Lubricate all parts during assembly. 4. Install the nut onto the end of the ram. Using a 1-1/8 socket, torque the nut to ft-lbs. ( Nm) (Fig. 0609). 1. Secure the cylinder ram into a vise. 2. Slide the head onto the cylinder ram (Fig. 0607). Fig 0609 PICT-3026a Fig 0607 PICT-3023a TX420, TX425 Series Service Manual Rev B-59

60 5. Remove the ram from the vise and secure the cylinder barrel into the vise. 6. Install the ram assembly into the cylinder barrel by rotating the piston assembly while pushing the piston into the barrel (Fig. 0610). 8. Insert the end of the ring through the notch in the barrel and into the hole in the groove. Place the spanner wrench onto the head assembly (Fig. 0612). Fig 0612 PICT-3031 Fig 0610 PICT-3027a 7. Rotate the head until the ring hole in the ring groove is within the slot on the barrel (Fig. 0611). 9. Begin rotating the spanner wrench so that the head pulls the ring inside the barrel. Continue rotating until the ring is completely installed inside the barrel on the head assembly (Fig. 0613). Fig 0611 PICT-3030 Fig 0613 PICT B-60 Rev. 001 TX420, TX425 Series Service Manual

61 TX420 & & lower Auxiliary Valve Removal 3. Remove the auxiliary lever by removing the retention nut and washer located at the top of the lever (Fig. 0615). Before disassembly of any hydraulic component, use a clean, dirt-free work surface and clean solvent to prevent system contamination. 1. Allow unit to cool down prior to removal. Open the rear cover assembly. 2. Remove the LH panel assembly (Fig. 0614). Fig 0615 DSC After removing the nut and washer, apply tension on the torsion spring and then slide the auxiliary lever assembly up and off the auxiliary valve. Remove the torsion spring (Fig. 0616). Fig 0614 DSC-3632 Fig 0616 DSC-3634 TX420, TX425 Series Service Manual Rev B-61

62 5. Remove the two bolts and nuts retaining the auxiliary stop assembly to the control panel. Remove the auxiliary stop from the control panel (Fig. 0617). 7. Using a 1-1/8 15º/60º offset open end wrench, loosen and disconnect the hydraulic pressure hose from the auxiliary valve fitting (Fig. 0619). Fig 0617 DSC-3635 Fig 0619 DSC With a 1-1/8 15º/60º offset open end wrench, loosen and disconnect the hydraulic return hose from the auxiliary valve fitting (Fig. 0618). 8. With a 15/16 15º/60º offset open end wrench, loosen and remove the two hydraulic lines from the auxiliary valve fittings (Fig. 0620). Fig 0618 DSC-3637 Fig 0620 CLR DSC B-62 Rev. 001 TX420, TX425 Series Service Manual

63 9. Disconnect the neutral ball switch at the harness connector (Fig. 0621). 11. Remove the auxiliary valve from the control panel (Fig. 0623). Fig 0621 DSC-3649 Fig 0623 DSC Remove the two bolts and nuts retaining the auxiliary valve to the control panel (Fig. 0622). 12. Auxiliary valve with fitting layout (Fig. 0624). A F E D B C Fig 0622 DSC-3650 Fig 0624 CLR DSC-3653 A. Handle D. Neutral switch B. Output/return to E. Relief couplers F. Inlet C. Return 1 TX420, TX425 Series Service Manual Rev B-63

64 Auxiliary Valve Installation Note: As a reminder, prior to connecting the hydraulic hoses and lines, the o-rings should be replaced with new ones and lightly lubricated with petroleum jelly. 3. Connect the neutral ball switch at the harness connector (Fig. 0627). 1. Position the auxiliary valve in the control panel (Fig. 0625). Fig 0627 DSC-3649 Fig 0625 DSC Connect the two hydraulic lines to the side auxiliary valve fittings and tighten with a 15/16 15º/60º offset open end wrench (Fig. 0628). 2. Loosely install the two bolts and nuts securing the auxiliary valve to the control panel (Fig. 0626). Note: Leave the bolts and nuts loose until the hydraulic hoses and lines are connected. Fig 0628 CLR DSC-3642 Fig 0626 DSC B-64 Rev. 001 TX420, TX425 Series Service Manual

65 5. Connect the hydraulic pressure hose to the rear fitting on the auxiliary valve and tighten using a 1-1/8 15º/60º offset open end wrench (Fig. 0629). 7. Tighten the bolts and nuts securing the auxiliary valve to the control panel (Fig. 0631). Fig 0629 DSC-3640 Fig 0631 DSC Connect the hydraulic return hose to the front fitting on the auxiliary valve with a 1-1/8 15º/60º offset open end wrench (Fig. 0630). 8. Install the auxiliary stop assembly to the control panel with 2 bolts and nuts (Fig. 0632). Fig 0632 DSC-3635 Fig 0630 DSC-3637 TX420, TX425 Series Service Manual Rev B-65

66 9. Slide the torsion spring over the control shaft, with the large hook end of the spring facing down (Fig. 0633). 11. Install the washer and retention nut on the top of the auxiliary lever and tighten (Fig. 0635). Fig 0633 DSC-3657 Fig 0635 DSC Turn the torsion spring clockwise and hold. Slide the auxiliary lever over the control shaft and hook the spring end over the auxiliary lever (Fig. 0634). 12. Start the unit and check the hydraulic fittings for any leaks. Install a hydraulic attachment and operate the auxiliary valve in both forward and reverse flow to purge any air out of the system. Also, operate the loader arm valve up, down, and tilt to help purge the system of any air. Refer to Purging Air Procedures on page Recheck for leaks. 13. Install the LH panel assembly (Fig. 0636). Fig 0634 DSC-3655 Fig 0636 DSC Close the rear cover. 7B-66 Rev. 001 TX420, TX425 Series Service Manual

67 TX420 & & lower 2 Spool Loader Valve Removal 3. Open the rear access door. 4. Mark the 2 spool valve port fittings and lines with the letters A F as follows: (Fig. 0639). Note: Protect all exposed sealing areas and open cavities from damage, foreign material and chemicals. 1. Using a 3/8 socket, remove the 4 screws securing the top right control panel cover to the control panel (Fig. 0637). Fig 0639 PICT-2426 A. Hydraulic oil inlet line D. Hydraulic oil return line B. Tilt cylinder E. Lift cylinder (below C) C. Lift cylinder F. Tilt cylinder (below B) Fig 0637 PICT-2424a 2. Remove the top right control panel cover from the control panel (Fig. 0638). 5. Using a 15/16 wrench, disconnect the hydraulic line marked with the letter A from the 2 spool loader valve fitting (Fig. 0640). Fig 0640 PICT-2427 Fig 0638 PICT-2425a TX420, TX425 Series Service Manual Rev B-67

68 6. Using a 13/16 wrench, disconnect the hydraulic line marked E from the 2 spool loader valve fitting (Fig. 0641). 8. Using a 13/16 wrench, disconnect the hydraulic line marked B from the 2 spool loader valve fitting (Fig. 0643). Fig 0641 PICT-2429 Fig 0643 PICT Using a 13/16 wrench, disconnect the hydraulic line marked F from the 2 spool loader valve fitting (Fig. 0642). 9. Using a 13/16 wrench, disconnect the hydraulic line marked C from the 2 spool loader valve fitting (Fig. 0644). Fig 0642 PICT-2430 Fig 0644 PICT B-68 Rev. 001 TX420, TX425 Series Service Manual

69 10. Using a 15/16 wrench, disconnect the hydraulic line marked with the letter D from the 2 spool loader valve fitting (Fig. 0645). Remove the 2 spool loader valve from the control panel assembly (Fig. 0647). Note: Cap all the hydraulic lines and fittings so that debris does not enter the system. Fig 0645 PICT-2433 Fig 0647 DSC Using a 1/2 wrench and socket, remove the 3 mounting bolts and nuts that secure the 2 spool loader valve to the control panel (Fig. 0646) Spool Loader Valve (Fig. 0648). G H A F E D C B Fig 0646 PICT-2435 Fig 0648 CLR DSC-3627 A. Lift cylinder (2) E. Relief B. Return F. Pressure test port C. Return to neutral & G. Inlet float detent H. Tilt cylinder (2) D. Return to neutral 13. Transfer all fittings, the test port and the handle over to the new 2 spool loader valve. TX420, TX425 Series Service Manual Rev B-69

70 2 Spool Loader Valve Installation 1. Remove the caps from the hydraulic lines and fittings. 4. Using a 15/16 wrench, connect the hydraulic line marked with the letter D to the 2 spool loader valve fitting marked D (Fig. 0651). 2. Position the 2 spool loader valve into the control panel (Fig. 0649). Fig 0651 PICT-2433 Fig 0649 PICT Using a 13/16 wrench, connect the hydraulic line marked C to the 2 spool loader valve fitting marked C (Fig. 0652). 3. Install the 3 mounting bolts and nuts to secure the 2 spool loader valve to the control panel. Use a 1/2 socket and wrench to tighten the 3 mounting bolts and nuts (Fig. 0650). Fig 0652 PICT-2432 Fig 0650 PICT B-70 Rev. 001 TX420, TX425 Series Service Manual

71 6. Using a 13/16 wrench, connect the hydraulic line marked B to the 2 spool loader valve fitting marked B (Fig. 0653). 8. Using a 13/16 wrench, connect the hydraulic line marked E to the 2 spool loader valve fitting marked E (Fig. 0655). Fig 0653 PICT-2431 Fig 0655 PICT Using a 13/16 wrench, connect the hydraulic line marked F to the 2 spool loader valve fitting marked F (Fig. 0654). 9. Using a 15/16 wrench, connect the hydraulic line marked with the letter A to the 2 spool loader valve fitting marked A (Fig. 0656). Fig 0654 PICT-2430 Fig 0656 PICT-2427 TX420, TX425 Series Service Manual Rev B-71

72 10. Start the unit and check for leaks. Operate the loader valve up, down and tilt to purge any air out of the system. 11. Purge air from the system. Refer to Purging Air Procedures on page Close and latch the rear access door. 13. Position the top right control panel cover onto the control panel (Fig. 0657). 15. After the loader valve is installed, and the hydraulic lines are reconnected, a pressure test will need to be performed to properly set the relief valve to 2450 psi (169 bar). Refer to Loader Circuit Pressure Testing as follows: TX420 & & up on page TX & lower on page TX420 & & lower Two Spool Loader Valve Rebuild Before disassembly of any hydraulic component, use a clean, dirt-free work surface and clean solvent to prevent system contamination (Fig. 0659). Fig 0657 PICT-2425a 14. Using a 3/8 socket, install the 4 screws securing the top right control panel cover to the control panel (Fig. 0658). J H I C H G A F Fig 0659 E B C D PICT-0074a A. Rubber bellows F. Spring cap (tilt spool) B. Loader cylinder G. Relief valve port (2) H. Tilt cylinder port (2) C. Plug (2) I. Oil inlet D. Oil out J. Check valve E. Detent spring cap (loader spool) Fig 0658 PICT-2424a 7B-72 Rev. 001 TX420, TX425 Series Service Manual

73 Disassembly 1. Secure the valve into a vise so that the rubber bellows is facing up. 4. Using a 5mm Allen wrench, loosen the 3 hex head screws (Fig. 0662). 2. Remove the cable tie from around the rubber bellows (Fig. 0660). Fig 0662 PICT-0077a Fig 0660 PICT Remove the articulated holder, screws and washers from the valve assembly (Fig. 0663). 3. Remove the rubber bellows from the valve assembly (Fig. 0661). Wipe the excess grease from the joystick assembly. Fig 0663 PICT-0078a Fig 0661 PICT-0076a TX420, TX425 Series Service Manual Rev B-73

74 6. Pictured below are the articulated joystick joints (Fig. 0664): A B 8. Using 13mm wrenches, remove the nut and washer holding the tilt operation articulated joint to the joystick pivot (Fig. 0666). C Fig 0664 A. Loader Cylinder operation B. Tilt Cylinder operation C. Pivot for Loader and Tilt operation PICT-0080 Fig 0666 PICT-0082a 9. Rotate the tilt spool and remove the tilt operation articulated joint from the spool (Fig. 0667). 7. Slide the end rod off the joystick pin (Fig. 0665). Fig 0667 PICT-0084a Fig 0665 PICT-0081a 7B-74 Rev. 001 TX420, TX425 Series Service Manual

75 10. Using 13mm wrenches, remove the nut and washer securing the loader operation articulated joint to the pivot (Fig. 0668). 12. Using a 3mm Allen wrench, remove the 2 screws securing the pivot to the valve housing (Fig. 0670). Fig 0668 PICT-0085a Fig 0670 PICT-0088a 11. Slide the loader operation articulated joint out of the pivot (Fig. 0669). 13. Remove the pivot from the valve assembly (Fig. 0671). Fig 0669 PICT-0086a Fig 0671 PICT-0089a TX420, TX425 Series Service Manual Rev B-75

76 14. Using 13mm wrenches, remove the nut and washer securing the joystick pin to the loader spool (Fig. 0672). 16. Using a 4mm Allen wrench, remove the 2 screws and washers securing the retainer plate to the valve housing (Fig. 0674). Fig 0672 PICT-0090a Fig 0674 PICT-0093a 15. Remove the joystick pin (Fig. 0673). 17. Remove the retainer plate (Fig. 0675). Fig 0673 PICT-0092a Fig 0675 PICT-0094a 7B-76 Rev. 001 TX420, TX425 Series Service Manual

77 18. Remove the seal from the valve (Fig. 0676). 20. Remove the check valve (Fig. 0678). Fig 0676 PICT-0095a Fig 0678 PICT-0097a 19. Using a 6mm Allen wrench, loosen the check valve (Fig. 0677). 21. The 2 plugged ports are not used in this application. The plugs have o-ring seals. If the valve is leaking at the plug location(s), remove the plug using a 6mm Allen wrench and replace the o-ring (Fig. 0679). Fig 0677 PICT-0096a Fig 0679 PICT-0099 TX420, TX425 Series Service Manual Rev B-77

78 22. Rotate the valve in the vise so that the spools are facing to the side. 25. Remove the plunger from the relief valve port (Fig. 0682). 23. Using a 19mm wrench, loosen the relief valve from the valve assembly (Fig. 0680). Fig 0682 PICT-0104a Fig 0680 PICT Remove the bonnet from the from the relief valve port (Fig. 0683). 24. Remove the relief valve assembly from the valve (Fig. 0681). Fig 0683 PICT-0106a Fig 0681 PICT B-78 Rev. 001 TX420, TX425 Series Service Manual

79 27. Using a 4mm Allen wrench, loosen the 2 screws securing the tilt spool cap to the valve housing (Fig. 0684). 29. Using a drift punch to hold the top end of the spool, loosen the detent spring assembly from the bottom end of the tilt spool using a 5mm wrench (Fig. 0686). Fig 0684 PICT-0102 Fig 0686 PICT Remove the spool cap and screw assembly (Fig. 0685). 30. Remove the detent spring (Fig. 0687). Fig 0685 PICT-0103 Fig 0687 PICT-0108 TX420, TX425 Series Service Manual Rev B-79

80 31. Remove the spacer plate from the tilt spool (Fig. 0688). 33. Using a 4mm Allen wrench, loosen the 2 screws securing the loader spool cap to the valve housing (Fig. 0690). Fig 0688 PICT-0109 Fig 0690 PICT Remove the tilt spool by carefully twisting and pulling the spool out of the top of the valve housing (Fig. 0689). 34. Remove the spool cap and screw assembly (Fig. 0691). Fig 0689 PICT-0110a Fig 0691 PICT-0113a 7B-80 Rev. 001 TX420, TX425 Series Service Manual

81 35. Using a drift punch to hold the top end of the loader spool, loosen the stem securing the detent spring to the spool using a 6mm wrench (Fig. 0692). 37. Remove the loader spool by carefully twisting and pulling the spool out the top of the valve (Fig. 0694). Fig 0692 PICT-0114 Fig 0694 PICT-0116a 36. Remove the detent spring assembly (Fig. 0693). 38. Remove the 4 o-rings from the spool ports (1 o-ring located at each end of the spool ports) (Fig. 0695). Note: The spool port with the brass insert has a smaller size o-ring than the 3 other ports. Fig 0693 PICT-0115a Fig 0695 PICT-0117a TX420, TX425 Series Service Manual Rev B-81

82 Spools and o-rings (Fig. 0696): 2 Spool Loader Valve (Fig. 0697): Note: Visually inspect spool outside surfaces for scratches. Deep scratches are unacceptable and the spool needs to be replaced. Scratches that are deep enough to catch the fingernail are also unacceptable, and the spool needs to be replaced. Before replacing the spool, clean and inspect the inner bore for damage. Check the condition of the o-rings, particularly for metallic particles embedded in the o-ring surface. Damage to o-ring grooves, particularly on the sealing surface, is unacceptable. In the event that an unacceptable condition occurs, the valve needs to be replaced. A B C D J I E E F G H Fig 0697 PICT-0135a A A. Return Spring Cap F. Check Valve B. Relief Valve G. Tilt Spool C. Return Spring H. Loader Spool D. Spacer Plate I. Detent Spring E. Plugged Port (2) J. Detent Spring Cap B 34. Replace all o-rings. 35. Using 19mm and 13mm wrenches, loosen the adjusting nut on the relief valve (Fig. 0698). Fig 0696 PICT-0132a A. Tilt Spool B. Loader Spool with small relief notches Fig 0698 PICT-0119a 7B-82 Rev. 001 TX420, TX425 Series Service Manual

83 36. Remove the adjusting nut and stud (Fig.0699). Relief Valve (Fig. 0701) The relief valve is used to adjust to the specified system pressure (2450 psi or 169 bar) by increasing or decreasing the load on the spring against the disc. Loosen the lock nut; turn screw inward to increase the pressure or outward to decrease the pressure. H G E C B A Fig 0699 PICT-0120a F D 37. Using a punch, push the plunger out of the relief valve body (Fig, 0700). Fig 0701 PICT-0125a A. Bonnet E. Plunger o-ring B. Poppet F. Body C. Spring G. Body o-ring D. Plunger H. Adjusting nut & stud Fig 0700 PICT-0122a 38. Remove and replace all relief valve o-rings. TX420, TX425 Series Service Manual Rev B-83

84 39. Insert the plunger into the relief (Fig. 0702). 41. Insert the spring into the relief (Fig. 0704). Fig 0702 PICT-0126 Fig 0704 PICT Install the adjusting nut and stud into the relief (Fig. 0703). 42. Insert the plunger into the main relief (Fig. 0705). Fig 0703 PICT-0127 Fig 0705 PICT B-84 Rev. 001 TX420, TX425 Series Service Manual

85 43. Install the bonnet onto the plunger (Fig. 0706). 1. Lubricate and install the small spool seal into the loader spool port with the brass insert (Fig. 0708). Fig 0706 PICT-0130 Fig 0708 PICT-0136 Assembly Replace all seals and o-rings with new parts. Lubricate the valve, o-rings, and spools with 10W-30 oil prior to installation (Fig. 0707). 2. Lubricate the 3 remaining o-rings and install them in the other three spool ports (the other end of the loader spool port and 1 on each end of the tilt spool port) (Fig. 0709). A B C D E F G J I E H Fig 0707 PICT-0135a Fig 0709 PICT-0137 A. Return Spring Cap F. Check Valve B. Relief Valve G. Tilt Spool C. Return Spring H. Loader Spool D. Spacer Plate I. Detent Spring E. Plugged Port (2) J. Detent Spring Cap TX420, TX425 Series Service Manual Rev B-85

86 3. Lubricate the tilt spool. Install the spool into the port closest to the relief; twist and push gently, so you do not damage the o-ring (Fig. 0710). 5. Thread the detent spring assembly onto the loader spool (Fig. 0712). Fig 0710 PICT-0140a Fig 0712 PICT-0185a 4. Lubricate and install the loader spool into the port furthest away from the relief, twist and push gently, so you do not damage the o-ring (Fig. 0711). 6. Using a drift punch to hold the top end of the loader spool, tighten the detent spring stem securing the detent spring to the loader spool using a 6mm wrench. Torque to 5 ft-lbs. (6.8 Nm) (Fig. 0713). Fig 0711 PICT-0141a Fig 0713 PICT-0187a 7B-86 Rev. 001 TX420, TX425 Series Service Manual

87 7. Lubricate the spring with synthetic based grease grade NLG12 (Fig. 0714). 9. Using a 4mm Allen wrench, tighten the 2 screws securing the spool cap to the valve housing. Torque the screws to 5 ft-lbs. (6.8 Nm) (Fig. 0716). Fig 0714 PICT-0189 Fig 0716 PICT Slide the spool cap over the stem and detent spring assembly up to the valve housing (Fig. 0715). 10. Slide the spacer plate over the tilt spool and up to the valve housing (Fig. 0717). Fig 0715 PICT-0190 Fig 0717 PICT-0192 TX420, TX425 Series Service Manual Rev B-87

88 11. Thread the spring onto the end of the tilt spool (Fig. 0718). 13. Lubricate the spring with synthetic based grease grade NLG12 (Fig. 0720). Fig 0718 PICT-0193 Fig 0720 PICT-0196a 12. Using a drift punch to hold the top end of the tilt spool, tighten the spring assembly onto the bottom of the spool using a 5mm wrench. Torque to 5 ft-lbs. (6.8 Nm) (Fig. 0719). 14. Slide the spool cap over the spring assembly up to the valve housing (Fig. 0721). Fig 0721 PICT-0218 Fig 0719 PICT-0194a 7B-88 Rev. 001 TX420, TX425 Series Service Manual

89 15. Using a 4mm Allen wrench, tighten the 2 screws securing the spool caps to the valve housing. Torque to 5 ft-lbs. (6.8 Nm) (Fig. 0722). 17. Using a 19mm socket, torque the relief to 31 ft-lbs. (42 Nm) (Fig. 0724). Fig 0722 PICT-0102 Fig 0724 PICT-0202a 16. Thread the relief into the valve housing relief port (Fig. 0723). 18. Replace the check valve o-ring (Fig. 0725). Fig 0725 PICT-0205 Fig 0723 PICT-0219a TX420, TX425 Series Service Manual Rev B-89

90 19. Using a 6mm Allen wrench, install the check valve into the valve housing. Torque the check valve to 18 ft-lbs. (24 Nm) (Fig. 0726). 21. Install the retainer plate over the spools and onto the valve. Ensure the retainer plate is offset so that it hangs over the mounting surface side of the valve (Fig. 0728). Fig 0726 PICT-0206a Fig 0728 PICT Install the retainer gasket over the spools and onto the valve housing (Fig. 0727). 22. Using a 4mm Allen wrench, loosely install 2 screws and washers securing the retainer plate to the valve housing (Fig. 0729). Fig 0727 PICT-0207 Fig 0729 PICT-0093a 7B-90 Rev. 001 TX420, TX425 Series Service Manual

91 23. Apply thread locking compound to 2 screws that will secure the joystick pivot to the valve housing (Fig. 0730). 25. Apply thread locking compound to the 3 articulated joint stud threads (Fig. 0732). Fig 0730 PICT-0209a Fig 0732 PICT-2648a 24. Position the joystick pivot into the retainer plate. Install the 2 screws securing the joystick pivot to the valve housing using a 3mm Allen wrench. Torque all 4 screws to 5 ft-lbs (6.8 Nm) (Fig. 0731). 26. Insert the articulated joint stud into the pivot. Install a washer and nut onto the articulated joint stud. Torque to 10 ft-lbs (13.5 Nm) (Fig. 0733). Fig 0733 PICT-0215a Fig 0731 PICT-0210a TX420, TX425 Series Service Manual Rev B-91

92 27. Install the articulated joint stud into the tilt spool. Secure using a washer and nut (Fig. 0734). 29. Insert the joint stud into the loader spool. Install a washer and nut onto the joint stud. Slide the articulated joint onto the joint stud (Fig. 0736). Fig 0734 PICT-0221a Fig 0736 PICT-0223a 28. Torque the nut to 10 ft-lbs (13.5 Nm) (Fig. 0735). 30. Torque the nut to 10 ft-lbs (13.5 Nm) (Fig. 0737). Fig 0735 PICT-0222a Fig 0737 PICT B-92 Rev. 001 TX420, TX425 Series Service Manual

93 31. Lubricate the articulated joint pivots and retainer with synthetic based grease grade NLG12 (Fig. 0738). 33. Using a 5mm Allen wrench, tighten all 3 screws securing the articulated holder to the valve assembly. Torque each screw to 10 ft-lbs (13.5 Nm) (Fig. 0740). Fig 0738 PICT-0226a Fig 0740 PICT-0228a 32. Position the articulated holder onto the articulated joints so that the screws thread into each of the articulated joints (Fig. 0739). Note: The plugged hole in the articulated holder is located above the loader spool. 34. Apply additional grease around each of the pivot joints. 35. Slide the rubber bellows over the articulated holder and onto the retainer plate with the bellows installed around the outside of the retainer plate (Fig. 0741). Fig 0739 PICT-0227 Fig 0741 PICT-0229a TX420, TX425 Series Service Manual Rev B-93

94 36. Install a cable tie around the retainer plate securing the rubber bellows to it. Trim the excess off the cable tie (Fig. 0742). Fig 0742 PICT-0230a 7B-94 Rev. 001 TX420, TX425 Series Service Manual

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