CHAPTER 9

HYDRAULIC SYSTEM
 HYDRAULIC SYSTEM

1. STRUCTURE

1.1 HYDRAULIC CIRCUIT DIAGRAM

A. CK20 (CK20H) HYDRAULIC CIRCUIT

196W901A

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 HYDRAULIC SYSTEM

1.2 OIL FILTER

A. STRUCTURE OF OIL FILTER

The suction filter (1) is a canister-type filter and should
be replace after 200 hour of use.

There is a permanent magnet installed on the center

of the element of the hydraulic filter on the inlet hydrau-
lic pump and the filter mounted on the hydraulic lift is
structured with a vacuum sensor and a thermo sensor
to distinguish obstructions.

196W904A

(1) Hydraulic Filter

(2) Filter Bracket

B. FUNCTION AND OPERATION

a . Operation
1. Function
It filters any particle or contaminated substances.

2. Operation principle
The filtering system as of an inlet filter installed on the
inlet gear pump is composed of filter bracket, magnet
ass’y and element ass’y.
The filter used for CK series is by itself applicable to
both hydraulic lift and direction control of the steering
wheel.
The hydraulic oil flows into IN port if the filter bracket 196W905A
and the transmission oil delivered into the hydraulic
element ass’y (3) and delivery out into the outlet port (1) Filter Bracket (3) Oil Filter
via the inner element flows into the hydraulic pump. All (2) Magnet Assembly
foreign substances are filtered at the element this time.
In addition, a vacuum sensor and a thermo sensor are
mounted thereon to detect blockade in the filter. The
vacuum sensor and the thermo sensor are always
turned OFF under the pressure load of 500 ± 30 mmHg
and under 53°C respectively. Two switches by applica-
tion of the transistor switch are turned ON over the flow-
ing oil temperature of 53°C and over the pressure load
of 500 ± 30 mmHg with the alarm lamp on the instru-
ment panel turned on.

3. To check
As for the hydraulic filter, the oil filter shall be replaced
if its alarm lamp on the instrument panel is turned on
to avoid damages on the hydraulic system. And the
hydraulic filter also shall be replaced every service term
of 200 hours.

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CHAPTER 9 CK20(H)

1.3 STRUCTURE

A. HYDRAULIC SCHEME.

196W902A

(1) Oil Filter (8) Hydraulic Cylinder

(2) Gear Pump (9) Charge Pump (CK20H)
(3) Priority Valve Control Flow (10) Oil Cooler (CK20H)
(4) Power Steering Unit (11) HST Filter (CK20H)
(5) One Lever Joy-Stick Valve: Optional (12) HST (CK20H)
(6) Auxiliary Valve (Detent Type): Optional (13) Steering Cylinder
(7) Control Valve (MLS Valve)

The hydraulic system consists essentially of a fluid
tank, hydraulic pump, oil filter, oil cooler (CK20H), HST
(CK20H), priority valve, Joy-stick valve, control valve,
and lift links.
The rear axle and transmission case serve as a com-
mon hydraulic fluid tank and supply fluid to the hydrau-
lic pump (2) through the filter (1) and suction tube.
The hydraulic pump supplies fluid to the system con-
trol valve through the priority valve (3) and the high-
pressure line.
The control valve, when operated, affects raise, neutral,
or lowering action of the lift arms.

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 HYDRAULIC SYSTEM

1.4 HYDRAULIC CIRCUIT DIAGRAM OF 3-POINT HUDRAULIC SYSTEM

196W903A

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CHAPTER 9 CK20(H)

1.5 PRIORITY FLOW CONTROL [HYDRAULIC BLOCK TYPE OUTLET]

When implement is not attached When implement is attached

196W906A

(1) To Hydraulic Control Valve (3-point hitch) (1) Flow Priority Valve
(2) To Power Steering (PS type only) (2) Inlet from Implements (PS 3/8″)
(3) From Gear Pump (3) Outlet to Implements (PS 3/8″)
(4) To Gear Pump (Relief Valve) (4) Directional Valve
(5) From Implement (5) Pin (Setting Position for Attaching Implements)
(6) To Implement (6) Pin (Setting Position for Attaching No
Implement)
(7) Relief Valve
(A) Out (B) In

This hydraulic block type outlet is provided to take power

out from the tractor to operate the hydraulic cylinders
on the implement, such as power steering and front
loader or front blade.

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 HYDRAULIC SYSTEM

A. FLOW PRIORITY VALVE

a . Power Steering Type
This valve is mounted on the hydraulic block type outlet
for power steering type.
The flow priority valve consists of flow divider, flow
divider, spool, spring and damper. It is a flow divider
that divides the oil flow from a single hydraulic source
(pump) to actuate two circuits at the same time.
This valve is a 6 priority flow divider in which a con-
trolled flow is fed to the “PF” port and the excessive
flow is fed to the “EF” port. The “PF” port can be option-
ally connected to the power steering. The “EF” port is
connected to the hydraulic control valve or optional
196W907A
implement’s control valve. Vibration is caused by a
change in the oil flow when the engine speed is in- (1) Flow Control Plug
creased quickly. The damper reduces the vibration of (2) Flow Control Spool
the spool.
(3) Spring
(A) Excessive Flow “EF” Port
(B) Controlled Flow “PF” Port

b. Standard Oil Circuit

The total flow of oil (27.8 /min, 7.34 U.S. GPM), pres-
sure-fed from the hydraulic pump, enters into the “IN”
port through the route as shown in diagram.
A portion of oil flow-controlled by the orifice runs to the
power steering and return to the transmission case.
On the other hand as the oil passes the orifice, a pres-
sure difference is created between the ends of the
orifice. This causes the spring to deflect causing the
spool to move downward. As a result, the excessive oil
runs into “EF” port and to the control valve.

196W909A

(1) IN Port (A) EF Port

(2) Relief Valve (B) PF Port
(3) Flow Priority Valve (P) From the Pump
(4) Directional Valve (T) To the Tank

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CHAPTER 9 CK20(H)

c. Oil Circuit for Power Steering Type

The total flow of oil pressure-fed from the hydraulic
pump, enters into the “IN” port through the route as
shown in diagram.
A portion of oil flow-controlled by the orifice runs to the
power steering and returns to the transmission case.
On the other hand as the oil passes the orifice, a pres-
sure difference is created between the ends of the
orifice. This causes the spring to deflect causing the
spool to move downward. As a result, the excessive oil
runs into “EF” port and to the control valve.

196W912A

(1) IN Port (A) EF Port

(2) Relief Valve (B) PF Port
(3) Flow Priority Valve (P) From the Pump
(4) Directional Valve (T) To the Tank

d. When Using Front Loader or Implements

When using the front loader or other implements re-
move the plugs.
Connect the implement’s inlet pipe to port A. The outlet
pipe to the port B, then turn the directional valve coun-
terclockwise to the end.
The oil pressure-fed from the hydraulic pump enters
into the “IN” port.
Prior to the other control valves, the oil flow controlled
by the orifice runs to the power steering through the
“PF” port. Excessive oil pushes the spool and flows to
the front loader control valve through the “EF” port. Then
the oil returns to B port of the hydraulic block type outlet.
And this oil runs to the rear control valve.

196W914A

(1) Directional Valve

(A) A Port (C) EF Port
(B) B Port (D) PF Port

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 HYDRAULIC SYSTEM

1.6 JOYSTICK VALVE

196W917A

(1) Lever Knob (12) End cap (23) Plug

(2) Rubber (13) Spool Control Kit (24) Spool
(3) Nut (14) Ring (25) Spool
(4) Selector (15) O-Ring (26) Rod Pin
(5) Pin (16) Plug (27) Joint
(6) Body (17) Plug (28) O-Ring
(7) Ring (18) Body (29) Flange
(8) Washer (19) Plug (30) Screw
(9) Screw (20) End Cap (31) Washer
(10) Cable (21) Spool Control Kit (32) Nut
(11) Cable (22) Plug

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CHAPTER 9 CK20(H)

A. DESCRIPTION AND OPERATION

The Joystick valve is mounted on the right fender.

196W916A

(1) Joystick Valve

The double-spool remote valve also contains a spring-

loaded detent mechanism to provide a float position
for loader operation. In float position, fluid is free to
flow between piston and rod sides or the loader lift
cylinder allowing the lift arms to float over uneven terrain.

The double-spool remote control valve contains check

valves located in the valve spool passages. The check
valves function to hold the loader lift and bucket cylin-
ders in a fixed position while the valve is being initially
operated to prevent dropping the load. In operation, the
check valve is retained on its seat by spring force plus
the back side pressure of fluid contained in the loader
cylinder. During initial spool movement, pump-pres-
surized fluid fills the passage to the check valve, and 196W918A
the remaining pump fluid flows to the sump through
the open center passage. With continued spool
movement, the open center passage closes.
Pump pressure increases on the force of the check
valve, overcoming the backside pressure, and causes
the check valve to open. Pump fluid flow then flows to
the cylinder. This action prevents any backflow out of
the cylinder and provides a smooth-lifting action of the
loader.

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 HYDRAULIC SYSTEM

a . Dump Position

196W919A

(1) Lift Control Valve Spool (4) Bucket Cylinder

(2) Bucket Control Spool (5) Lift Cylinder
(3) Control Lever

When the control lever (3) is moved to the dumping The fluid contained in the rod side of the bucket cylin-
position, the bucket control spool (2) is moved inward. der flows out of the cylinder through passage “A2” exit-
Fluid flow from the hydraulic pump is directed to the ing the valve at port “T” and flows to the transmission
piston side of the bucket cylinder (4). case.

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CHAPTER 9 CK20(H)

b. ROLL BACK Position

196W921A

(1) Lift Control Valve Spool (4) Bucket Cylinder

(2) Bucket Control Spool (5) Lift Cylinder
(3) Control Lever

When the control lever (3) is moved to the roll back Fluid flow from the piston side of the cylinder flows
position, the bucket control valve spool (2) is moved through passage “B2” exiting the valve at port “T” and
outward. Fluid flow from the hydraulic pump and is flows to the transmission case.
directed to the rod side of the cylinder (4).

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 HYDRAULIC SYSTEM

c. RAISING Position

196W922A

(1) Lift Control Valve Spool (4) Bucket Cylinder

(2) Bucket Control Spool (5) Lift Cylinder
(3) Control Lever

When the control lever (3) is moved to the raising posi- Because the bucket control spool (2) is in the neutral
tion the lift control valve spool (2) is moved outward. position, the fluid trapped in the bucket cylinder (4) is
Fluid flow from the hydraulic pump and is directed to blocked by the spool, and the bucket cylinder is held in
the piston side or the lift cylinder (5). The fluid con- a fixed position.
tained in the rod side of the lift cylinder flows out of the
cylinder past port “T” to the transmission case allow-
ing the implement to raise.

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CHAPTER 9 CK20(H)

d. LOWERING Position

196W923A

(1) Lift Control Valve Spool (4) Bucket Cylinder

(2) Bucket Control Spool (5) Lift Cylinder
(3) Control Lever

When the control lever (3) is moved to the lowering

position, the lift control valve spool (1) is moved inward.
Fluid flow from the hydraulic pump is directed to the
rod side of the cylinder (5). The fluid contained in the
piston side of the lift cylinder flows out of the cylinder
past port “T” to the transmission case allowing the
implement to lower.

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 HYDRAULIC SYSTEM

e . FLOATING Position

196W924A

(1) Lift Control Valve Spool (4) Bucket Cylinder

(2) Bucket Control Spool (5) Lift Cylinder
(3) Control Lever

When the lift control lever (3) is moved to the detent
position (float), the control valve spool is moved in-
ward beyond the normal lowering position. In this
position, passage “B1” and “A1” are connected, and
fluid is free to move between the lift cylinder rod and
piston ends.
The loader lift arms then move up and down as the
loader passage over uneven terrain. Pump fluid pres-
sure is directed out through the “T” port to the trans-
mission case.

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CHAPTER 9 CK20(H)

1.7 AUXILIARY CONTROL VALVE (IF EQUIPPED)

A double acting detent type secondary control valve is

used. When the secondary control valve operating le-
ver is moved to the implement cylinder actuating
position, the spool is moved and the oil from the pump
port flows through A to B, causing the implement cylin-
der to operate.
The return oil from the implement cylinder flows out of
the tank port through A to B and returns to the transmis-
sion case.
This special non-return type ensures that oil under pres-
sure is held where necessary. This guarantees that
implements will be held at a steady height with no
chance of lowering.

196W925A

(1) Body (17) Elastic Pin

(2) Nut (18) Plug
(3) Screw (19) O-Ring
(4) Cover (20) Spring
(5) Nut (21) Ball
(6) O-Ring (22) Ball
(7) O-Ring (23) Articulation
(8) Screw (24) Pin
(9) Washer (25) Seal Ring
(10) Screw (26) O-Ring
(11) Cover (27) Pilot Spool
(12) Seal Cover (28) Washer
(13) Valve Seat (29) Spring
(14) Spring
(15) Valve
(16) Valve Seat

196W927A

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 HYDRAULIC SYSTEM

a . Quick Couplers
Quick couplers are proven with these tractors connect-
able even under pressure with either half or both halves
pressurized. To connect the male half to the body, slide
the sleeve to the rear on the body half and insert the
male half into the body half.
Move the sleeve (5) forward to sent the steel balls (4)
for locking the male half (1) into the body half (2). The
male half (1) is locked in place by a ring of steel balls
(4) which is held in a groove on the inserted male half
by the outer sleeve (5).

196W928A

(1) Male Half (4) Steel Ball

(2) Body Half (Female Half) (5) Sleeve
(3) Poppet

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CHAPTER 9 CK20(H)

1.8 CONTROL (MLS) VALVE

196W932A

(A) Charge (C) Neutral Position 109 ± 0.15

(B) Discharge

A. OPERATION OF MLS CONTROL VALVE

The Control Valve has three distinct functioning phases:
1. Neutral Phase
2. Delivery Phase
3. Discharge Phase

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 HYDRAULIC SYSTEM

a . Neutral Phase

196W933A

(1) Control Spool (18) Annular Duct

(2) Regulator Piston (22) Pump Feeds Chamber
(3) Check Valve (23) Chamber
(4) Discharge Valve (26) Position to Connect Chamber
(5) Safety Valve (27) Pilot Valve
(16) Discharge Through Hole (28) Hole
(17) Hole

In this phase the control valve keeps under pressure
the oil in the cylinder bearing the load while the oil
coming from the pump flows freely into the tank.
This control spool “1” is in the position to connect cham-
ber “26” of the pilot valve “27” directly to the discharge
through hole “16”. Thus allowing the same valve to open
hole “28” which discharges chamber “15” by means of
the duct “29” of the regulator piston “2”. Thus the oil
coming from the pump feeds chamber “22” and allows
the regulator piston “2” to open the holes “17” and the
oil flows to the tank.
The oil contained in the cylinder (chamber “23”) re-
mains under pressure by means of the check valve “3”,
by the discharge valve “4” and by the safety valve “5”
which are connected to the cylinder by the annular duct
“18” and thus sustains the load applied to the lifting
arms.
The safety valve “5” protects the cylinder from the pos-
sibility of eventual over- pressure due to the oscillation
of the load during road transport.

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CHAPTER 9 CK20(H)
b. Delivery Phase
(1) Control Spool
(2) Regulator Piston
(3) Check Valve
(17) Hole
(18) Annular Duct
(19) Annular Duct
(20) Hole
During this phase the Control Valve supplies oil under
pressure to the cylinder (chamber “23”) and this con-
sequently lifts the arms.
The control spool “1” is in the position to connect cham-
ber “26” of the pilot valve “27” with the oil coming from
the pump through the annular duct “19” and the holes
“20”, “21” and “30”; thus allowing the same valve to close
itself. The oil coming from the pump feeds at the same
pressure chamber “22” and chamber “15” (through duct
“29”) of the regulator piston “2” that closes the discharge
holes “17” due to the upward push of the return spring.
The oil under pressure flows to the cylinder through
the annular duct “19”; enters in hole “20” through the
fixed throat “6” and the variable throat made by the con-
trol spool “1” with the hole “21”, opens the check valve
“3”, enters in the annular duct “18” and feeds chamber
“23” of the cylinder.
9-22
196W934A
(21) Hole
(22) Chamber
(23) Chamber
(26) Position to Connect Chamber
(27) Pilot Valve
(29) Duct
The regulator piston “2” regulates the oil flow of the
cylinder because chambers “15” and “22” are subject
to the difference in pressure created by the oil in the
passage through the fixed throat “6” and the variable
throat “31” which is opened or closed by the control
spool “1”, in function of its movement caused by inter-
nal levers of the rockshaft.
The excessive flow is deviated on the rising pressure
from holes “17”, thus regulating the maximum lifting speed
and allowing a slow starting and arrival of the lifting arms.
The maximum lifting pressure is controlled by a relief
valve external to the rockshaft control valve or by using
the one already esisting in the auxiliary control valves.
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 HYDRAULIC SYSTEM

c. Discharge Phase

196W935A

(1) Control Spool (18) Annular Duct

(2) Regulator Piston (23) Chamber
(4) Discharge Valve (24) Hole
(5) Safety Valve (25) Hole
(8) Lowering Regulator (26) Position to Connect Chamber
(15) Chamber (27) Pilot Valve
(16) Discharge Through Hole (28) Hole
(17) Discharge Hole (32) Hole

During this phase the Control Valves supplies to the
discharge both the oil coming from the pump as well
as the oil coming from chamber “23” of the cylinder,
with the consequential lowering of the lifting arms.
The control spool “1” is in the position to connect cham-
ber “26” of the pilot valve “27” directly to the discharge
through hole “16”; thus allowing the same valve to open
hole “28” that flows to the discharge through duct “29”
chamber “15” of the regulator piston “2”. The oil com-
ing from the pump, as in the neutral phase, is able to
more the regulator piston towards chamber “15”
that opens the discharge holes “17” causing oil to flow
to the tank. At the same time the oil from the cylinder
under pressure (chamber “23”) enters in the annular
duct “18” passes through the holes “32”, the lowering
regulator “8” and hole “24” enters in the discharge valve
“4” flowing to the tank from hole 25, causing the lower-
ing of the arms.
In this phase the lowering speed of the arms can be
regulated with the manual lever (RD); by screwing it
the lowering speed can be reduced.
For safety during road transport, against the accidental
movement of the control lever of the rockshaft, screw
the lever “RD” to the end so as to close the valve “8”
completely against its seat so as to close the duct be-
tween chamber “23” of the cylinder and the discharge
valve “4”.
When the safety mechanism is inserted the cylinder is
always protected by accidental over-pressure by the
safety valve “5”.

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CHAPTER 9 CK20(H)
1.9 OPERATION OF INTERNAL LEVERS IN CONTROLLED POSITION
Moving the control lever “L” (In the direction of the arrow)
one can raise the arms and the internal levers affect
the Control Valve in the following way;
The cam shaft “2” welded to lever “L” turns clockwise
and rotates the cam lever “3” anticlockwise. This, push-
ing on the roller cam bowl “4”, rotates anticlockwise
the toggle lever “5” which due to the position of the
push rod “6” moves the shaft “1” of the Control Valve in
delivery phase (C) which consequently raises the arms
of the Rockshaft.
With the raising movement the crank “7” with its pin “8”
rotate anticlockwise and by means of lever “9” they ro-
tate the balance lever “10” in the same direction. The
lever “10” with its roller cam bowl “11” cause a clock-
wise rotation of the cam lever “3”.
(1) Shaft
(2) Cam Shaft
(3) Cam Lever
(4) Roller Cam Bowl
(5) Toggle Lever
(6) Push Rod
9-24
The roller cam bowl “4” remains in contact with the
lever by effect of the springs of the shaft “1”, so the
toggle lever “5” rotates clockwise returning, by means
of the push rod “6”, the Control Valve in its neutral phase
(N) and blocking the raising of the arms.
When the arms are lowered the movement of the inter-
nal levers are in the opposite direction as described
above.
The push rod “6” is kept in a fixed position with the
toggle lever “5” by the spring seat “12”. The spring seat
“12” has the function of absorbing the extra strokes of
the internal levers when lever “L” is moved from its
lowest position to its highest position and vice-versa.
196W936A
(7) Crank
(8) Pin
(9) Lever
(10) Lever
(11) Roller Cam Bowl
(12) Spring Seat
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 HYDRAULIC SYSTEM

A. ROCKSHAFT ADJUSTMENT
In case of revision of the Rockshaft or Control Valve it is
opportune to do again the adjustments in the sequence
found below.

1. Sensibility adjustment of the control valve.

2. Adjustment of the control lever with respect

to the rockshaft arms.

a . Sensibility Adjustment.
Position the rockshaft lifting arms, with a weight applied,
so that they reach about half their angular movement
range.
In this way the Control Valve is positioned in its neutral
phase.
Loosen nut “A” and turn the embedded hexagonal
screw “B” in an anti-clockwise direction until the lifting
arms start swaying continuously.
With a slow movement stop the movement of the arms
by rotating screw “B” in a clockwise direction.
When the arms remain blocked in their position, which
can be controlled with the relevant instrument posi-
196W937A
tioned on the end of the lifting arm, rotate clockwise the
screw “B” for 1/2 ~ 3/4 of a turn max. And block the
position with the self-locking nut “A”.
In this way the Control Valve is sensitivity adjusted.

b. Adjustment of Position Control Lever

Completely lower the arms and apply a weight.
The adjustment is carried out in order to establish the
maximum raised position of the rockshaft lifting arms.
Loosen the fastening screw “1” so as to free the lever
“L” from the position control shaft “2”.
Raise the lever “L” all the way toward backstop “F” with-
out rotating shaft “2”
With a 13 mm open end wrench, rotate slowly in an
anticlockwise direction the position control shaft “2” so
as to raise the arms. Continue the rotation until reach-
0
ing the degree of 75° - 2° (The maximum raised
position).
196W938A
Take care to maintain the position control shaft “2”
blocked and the lever “L” against the backstop “F”. (1) Screw
Fix the lever to the shaft by tightening completely the (2) Shaft 2
clamp with the fastening screw “1”. (3) Lifting Arm in Mechanic Lock
Control by raising and lowering the lever “L” 3 or 4
times so that the arms always reach the same position
at their highest position.
After concluding the adjustment, always verify that there
exists a security distance (minimum 3°) between the
maximum raised position and the position of the me-
chanical backstop.
If the lifting arms reach the position of the mechanical
backstop, the safety valve (relief valve 160 kgf/cm²) in-
tervenes with the danger of damaging the pump.
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CHAPTER 9 CK20(H)

1.10 ASSEMBLY MEASUREMENT OF

PUSH ROD

This is an important measurement of the good func-

tioning of the rockshaft.
If the rockshaft is adjusted and if the hydraulic group in
the drawing is disassembled one must always restore
the measurement of 19 mm.
This measure is obtained by keeping the push rod “A”
fixed and screwing or unscrewing the self-locking nut
“B” until one reaches the specified measurement.

196W939A

(1) Stop Rod (3) Yoke

(2) Body (4) Spring

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 HYDRAULIC SYSTEM

2. SERVICING

2.1 TROUBLECHOOTING

A. POWER LIFT ASSEMBLY

Symptom Provable Causes Solution

The rockshaft lifts • Insufficient oil level in the tank. Top up the level.
jerkily. • Pump inlet filter clogged. Clean or replace the filter.
• Infiltration of air into the pump inlet pipe. Check the inlet pipe and
any coupling and gasket.
Rockshaft does not • Adjusting piston of pilot valve stuck. Remove the control valve
operate. and unblock the pilot valve
and adjusting piston
(9.49 and 50)
The rockshaft does • Sensibility adjusted badly Adjust sensitivity of Control
not descend over its Valve (page 9-25)
entire travel. • Faulty adjustment of the control lever Adjust control position
lever (page 9-25)
The rockshaft does • Hydraulic block switched on. Unscrew the manual lever
not descend. (RD, page 9-25)
• Outlet valve spring damaged. Change the spring
(page 9-50)
• Piston Blocked Check piston and cylinder
Lifting capacity • Safety and over-pressure valves out of calibration Control calibration of the 2
does not match that valves.
prescribed. • Poor pump efficiency. Replace the pump.
• Poor Control Valve efficiency Overhaul the Control Valve.
• Deterioration of the Control Valve seal rings. Remove the Control Valve
and replace the external
seal rings.
The rockshaft • Piston gasket worn. Replace the gasket.
supports loads with • Oil leakage from cylinder. Overhaul the cylinder.
difficulty; there is a
rhythmic oscillation • Oil leakage from one of the following Control Valves Remove the Control Valve
when the motor is valves: non-return valve outlet valve safety valve, and overhaul the following
on; the load de- protecting the cylinder. valves: page 9-25,
scends when the page 9.48 to 9.55
motor is off. In case of leakage over-
haul the Control Valve.

When the arms are in • Faulty adjustment of the max. Upper position of lift arms. Adjust the control lever,
the upper position, limiting the max. upper
the safety valve position travel. (page 9-25,
(relief valve) placed page 9-41).
on the body of the
rockshaft starts
operating

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CHAPTER 9 CK20(H)

B. JOYSTICK VALVE

Symptom Provable Causes Solution

External leakage • Worn spool seal due to mechanical actuation or Locate the leakage and
control kit or opposite high back pressure. replace the seal.
side. Check back pressure level.
Excessive internal • Increase clearance between spools and body due Replace the direction
leakage on A and B to high wear control valve and check the
ports. oil contamination level.
Dropping load during • High leakage of the load check valve. Remove the load check
transition while raising. valve and clean the seat.
Inability to build • Main pressure relief valve blocked open. Remove and clean or
pressure on A and B replace the main relief valve.
ports.
• Port relief valve open. Remove and clean or
replace the port relief valve.
• Low pump pressure and flow. Check the pump and circuit.

9-28 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

2.2 SPECIFICATION

Item Reference Dimension

Hydraulic pump Type Gear
Pump capacity 27.8 /min (7.34 gpm)
Pump gear ratio 1/0.8056
Main hydraulic lift Micron rating (micron) Max. Pore Dia: 110 ± 8
Min Pore Dia: 92 ± 4
Area 2,772 cm² (429.7 in²)
HST hydraulic filter Micron rating (micron) 10 [BETA 10 = 1.2 (Min.BETA)]
(CK20H only)
Priority valve Priority valve control flow 6 /min (1.58 gpm)
Relief valve setting pressure 160 kgf/cm² (15.7 MPa)
Joy-stick valve Type 4way 5Position
Nominal flow rating 45 /min (11.9 MPa)
Auxiliary valve (optional) Type Double acting Control
Valve 2way 3Position

A. CONTROL (MLS) VALVE

a . Technical Features
• Functioning at controlled position
• Three point linkage fixed
• Possibility to regulate the lowering speed of implement
• Manual hydraulic stop against accidental lowering of implement during road transport
• Limit stop of lifting arms in position of maximum height determined by position lever
• Sector control with lever
• Functions with oil of transmission
• Oil filter not built-in
• Required degree of filtering : 20 ∼ 25 µm
• Oil temperature : 80°C

S196-WOO Jul. 2003 9-29

CHAPTER 9 CK20(H)

B. DIMENSIONAL FEATURES

Item Reference Dimension

Piston diameter 65 mm (2.56 in)
Working stroke 92 mm (3.62 in)
Piston displacement 305 cm³ (18.6 in3 )
Angular excursion of lifting arms in controlled position 75°
Angular excursion of lifting arms in internal mechani-
78°
cal limit stop
Excursion of control lever 42°
The position relifef valve is external of the rockshaft
160 kgf/cm² (15.7 MPa)
calibration of relifef valve
Calibration of cylinder safety valve 200 kgf/cm² (19.6 MPa)

9-30 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

2.3 DISASSEMBLING AND ASSEMBLING

A. FLOW CONTROL VALVE

a . Bonnet
1. After open the bonnet (1) and disconnect the
connector, remove the bolt (2) and the bonnet.
2. Remove the side cover (LH/RH) (3).
3. Disconnect the battery terminal (-) (4).

(For assembly)
When connect the battery terminal (-), apply a little of
grease to it.

196W9B4A

(1) Bonnet (3) Side Cover

(2) Connector (4) Battery Terminal (-)
b. Flow Control Valve
1. Remove the hoses (6, 7) and hydraulic pipe (P1)
2. Remove the joint bolt (2) and remove the flow con-
trol valve assembly (1).

(When reassembling)
• Install the flow control valve assembly to the pump,
taking care not to damage the O-ring.

Item Tightening torque

Joint bolt 44.1 N·m
4.5 kgf·m
32.5 lbf·ft

196W940A

(1) Flow Control Valve (5) Pipe Band

(2) Joint Bolt (6) Steering Hose (T)
(3) O-Ring (7) Steering Hose (P)
(4) Elbow (8) Hydraulic Pipe (P1)

S196-WOO Jul. 2003 9-31

CHAPTER 9 CK20(H)

c. Relief Valve Assembly

1. Separate the relief valve assembly (1).

(When reassembling)
• Install the relief valve assembly to the outlet, taking
care not to damage the O-ring

Item Tightening torque

Relief valve assembly 49.0 ~ 58.8 N·m
5.0 ~ 6.0 kgf·m
36 ~ 43 lbf·ft

196W942A
d. Flow Divider Assembly
1. Separate the flow divider assembly(2). (1) Relief Valve Assembly
(2) Flow Divider Assembly
(When reassembling)
• Install the flow divider assembly (2) to the outlet,
using care not to damage the O-Ring.

Item Tightening torque

Flow divider assembly 40.0 ~ 50.0 N·m
4.0 ~ 5.0 kgf·m
8.9 ~ 11.2 lbf·ft

e . Directional Valve
1. Remove the external snap ring (2).
2. Remove the directional valve (3)

(When reassembling)
• Install the O-ring to the directional valve, taking care
not to damage the O-ring.
Apply grease to them before installation.

196W943A

(1) Straight Pin (3) Directional Valve

(2) Snap Ring

9-32 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

B. JOY-STICK VALVE DISASSEMBLY, INSPEC-

TION AND ASSEMBLY
a. Disassemble the Joy-stick Valve
1. Remove the step mat (1).
2. Loosen the joy-stick bolts and remove the cover (2).
3. Remove the frame (3) and push the joy-stick down.
4. Remove the parking brake lever grip (4) and the
speed set lever grip (5).
5. Remove the transmission cover (6) (CK20).
6. Remove the instrument panel cover (down) (7).
7. Remove the step (RH) (8).
196W9B5A

(1) Step Mat

(2) Cover
(3) Frame
(4) Parking Brake Lever Grip
(5) Speed Set Lever Grip
(6) Transmission Cover
(7) Instrument Panel Cover
(8) Step
8. Remove the hydraulic pipe P1 (9), hydraulic pipe
P2 (10), and return pipe (11).
9. Unscrew the bolts and remove the valve (12).

Item Tightening torque

Joint bolt 44.1 N·m
4.5 kgf·m
32.5 lbf·ft

196W9A3A

(9) Hydraulic Pipe P1 (11) Return Pipe

(10) Hydraulic Pipe P2 (12) Valve

S196-WOO Jul. 2003 9-33

CHAPTER 9 CK20(H)

b. Disassembly the Joy-Stic Valve

196W944A

(1) Lever Knob (7) Ring (13) Spool Control Kit (19) Plug (25) Spool (31) Washer
(2) Rubber (8) Washer (14) Ring (20) End Cap (26) Red Pin (32) Nut
(3) Nut (9) Screw (15) O-Ring (21) Spool Control Kit (27) Joint
(4) Selector (10) Cable (16) Plug (22) Plug (28) O-Ring
(5) Pin (11) Cable (17) Plug (23) Plug (29) Flange
(6) Body (12) End Cap (18) Body (24) Spool (30) Screw

1. Loosen the nuts (32) of cable and remove the Inspection:

screws (30), rod pins (26) and cables (11, 10).
1. Inspection the spools and the spool bores for pitting,
2. Remove End cap screws, End cap (12) from the scratches, of excess wear. If found defective, re-
float spool (24). place the Joy-stick valve assembly.
3. Remove End cap screws, End cap (20) from the 2. Check that the spool moves freely in the spool bore.
spool (25). 3. Inspect the load check valve poppets for pitting or
4. Gently slide the float spool (24) with spool control scratches.
kit (13), Ring (14) and O-ring (15) out of the valve 4. Inspect all springs for distortion. Replace of found
body. to be defective
5. Replace all O-rings and seals during reassembly
and lightly lubricate with petroleum jelly.
IMPORTANT
• The float spool (24) and spool (25) are not inter-
changeable and will only work in their respective
bores.
Ensure that the spools are inserted into the proper
bores during reassembly.
5. Disassemble the spool (25) in the same maner as
the float spool using step through 4.
6. Remove the load check plugs (17) with O-rings,
springs and load check poppets from the check
valve ports.

9-34 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

c. Joy-stick Valve Assembly

1. Install the plug (19).
Item Tightening torque
Blocking plug 42 N·m
4.3 kgf·m
31 lbf·ft

196W946A

(1) Plug

2. Install the load check poppets: with O-rings, springs

and check plugs (17).

Item Tightening torque

Check plugs 24 N·m
1.8 kgf·m
17.7 lbf·ft

3. Install O-ring (15) in their grooves in the valve body

and carefully slide the spool (25) into its bore.
4. Install the end cap (20) and secure the assembly
with cap screws.

Item Tightening torque

End cap mounting 6.6 N·m
screw 0.7 kgf·m
4.9 lbf·ft

5. Assemble the float spool in the same manner us-

ing steps 4 through 5.

196W947A

(1) Wrench Bolt (2) Spool Control Kit

196W948A

(1) Wrench Bolt (2) Spool Control Kit

S196-WOO Jul. 2003 9-35

CHAPTER 9 CK20(H)

6. Install the cables (10, 11), pins (26) and screws

(30) into the assembly and tighten its locknut.
Waterproof cap prearranged for remote control with
flexible cable.

Item Tightening torque

Wrench bolt 6.6 N·m
0.7 kgf·m
4.9 lbf·ft

196W945A

(1) Wrench Bolt

9-36 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

C. HYDRAULIC LIFT CYLINDER CK20

a . Draining the Transmission Fluid

CAUTION
To avoid personal injury:
• Allow engine to cool down sufficiently, oil can be
hot and can burn.

1. To drain the used oil, remove the drain plug at the

bottom of the transmission case and drain the oil
completely into the oil pan.
2. After draining reinstall the drain plug.
3. Fill with the new KIOTI TF65 fluid up to the upper
196W502A
line of the gauge.
(See “LUBRICANTS” in Maintenance Section)
4. After running the engine for a few minutes, stop it CK20H
and check the oil level again; add oil to prescribed
level.
18.5
CK20H
(4.89 U.S.gal.)
Oil capacity
21.6
CK20
(5.71 U.S.gal.)

IMPORTANT
• Do not operate the tractor immediately after
changing the transmission fluid.
Run the engine at medium speed for a few min-
196W511A
utes to prevent damage to the transmission.
(1) Oil Filling Plug (2) Gauge
(A) Oil Level is Acceptable Within this Range

196W512A

(1) Drain Plugs

S196-WOO Jul. 2003 9-37

CHAPTER 9 CK20(H)

b. Step
1. Remove the step mat (LH/RH) (1).
2. Remove the joystick mounting bolts and disconnect
the cover (2).
3. Remove the frame (3).
4. Remove the step (LH/RH) (4).

196W9A5A

(1) Step Mat (3) Frame

(2) Cover (4) step

c. Separating ROPS and tires

1. Remove the lynch pin (2) and the lock pin (1) from
the ROPS frame.
2. Loosen the lock nuts (3) and remove the pin (4).
3. Place to fix the jacket to the bottom of the rear axle.
4. Remove the nuts & bolts from the wheel.

Item Spec. Tightening torque

ROPS lock M10 48.1 ~ 55.8 N·m
bolt
4.9 ~ 5.7 kgf·m
35.5 ~ 41.2 lbf·ft
Rear Wheel M16 215 N·m
196W9A6A
Blot
22 kgf·m
(1) Lock Pin (3) Bolt
160 lbf·ft
(2) Lynch Pin (4) Pin

d. Seat
1. Remove the cover under seat and then remove the
seat (1).
2. Remove the return spring and the front cover (2).

196W9A7A

(1) Seat
(2) Lynch Pin

9-38 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

e . Hand brake (CK20-EU)

196W9B6A

(1) Sprit Pin (4) Parking Brake Wire (7) Parking Brake Bracket 1
(2) Plain Washer (5) Grommet (8) Parking Brake Wire 1
(3) Joint Pin (6) Parking Brake Bracket (9) Parking Brake Wire 3
(10) Bolt

1. Remove the sprit pin (1), plain washer (2) and joint (When reassembling)
pin (3). 1. Please adjust the parking brake wire by following
2. Loosen the lock nut (a) of the parking brake wire (4) the assembling dimensions as shown.
on the parking brake bracket 1 (7). (A) : 19 mm (B) : 17 mm
3. Remove the grommet (5), parking brake wire 1 (8) (C) : 15 mm (D) : End play Adjustment
and parking brake wire 3 (9) on the parking brake
bracket (6). (E) : End play Adjustment
4. Loosen the lock nut (b) of the parking brake wire 1 2. Please be careful not to bend the parking brake wire
(8) and parking brake wire 3 (9) on the parking brake for assembling it.
bracket 1 (7). 3. Please fasten the nut securely not to be loosen the
5. Loosen the bolts (10) and remove the parking brake parking brake wire.
bracket 1 (7). 4. Please assemble the ballof wire to keep on moving
freely.

CAUTION
• The adjustment of the parking brake wire should
be followed by adjusting the end play of the brake
pedal.

S196-WOO Jul. 2003 9-39

CHAPTER 9 CK20(H)

f. Fender
1. Rmove the connect of the rear combi lamp, turn sigal
lamp and working lamp.
2. Remove the ROPS mounting bracket (1).
3. Remove the grip (2) from the levers and then re-
move the lever guide (3).
4. Remove the fender (4).
5. Remove the fender support (5).
NOTE:
• For installation, follow the same procedure in re-
verse order.

Item Spec. Tightening torque 196W9A8A

Fender M12 77.5 ~ 90.1 N·m (1) Bracket (4) Fender

support bolt 7.9 ~ 9.2 kgf·m (2) Handle Grip (5) Fender Support
57.2 ~ 66.5 lbf·ft (3) Lever Guide
M14 124 ~ 147 N·m
12.6 ~ 15.0 kgf·m
91.2 ~ 108 lbf·ft

g. Link
1. Remove the lifter rod (1).
2. Remove the check chain (2).
3. Remove the lower link (3).
4. Remove the check change bracket (4).
5. Disconnect the brake rod (5).

196W9B2A

(1) Lifter Rod (4) Bracket

(2) Check Chain (5) Brake Rod
(3) Lower Link
h. Fuel Tank
1. Drain the fuel tank.
2. Disconnect the fuel hose from the engine.
3. Disconnect the fender wire harness.
4. Remove the fuel filter (1).
5. Remove the nuts (2).
6. Remove the fuel tank assembly (3) & the socket
fixture.

196W9A9A

(1) Plug (2) Dipstick

9-40 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

i. Lever & Hydraulic Pipe Removal

1. Remove the position lever (1).
2. Remove the joint bolt and the hydraulic pipe a (2) &
b (3).
3. Remove the double acting valve (4) & the lever (5).
4. Remove the hydraulic pipe(p) (6).
5. Remove the PTO lever (7).
6. Remove the oil filling pipe (8).
7. Remove the top link bracket (9).
8. Remove the mounting bolt from the hydraulic cylin-
der (10).
196W9B3A

(1) Position Lever

(2) Hydraulic Pipe a
(3) Hydraulic Pipe b
(4) Double Acting Valve
(5) Lever
(6) Hydraulic Pipe(p)
(7) PTO Lever
(8) Oil Filling Pipe
(9) Top Link Bracket
(10) Oil Filling Pipe

S196-WOO Jul. 2003 9-41

CHAPTER 9 CK20(H)

D. LIFT ARMS REMOVAL AND INSTALLATION

1. Remove external snap (1) ring from end splined
shaft.
2. Use wire brush to clean paint and any dirt from end
of splined shaft.
3. Mark end of splined shaft and lift arm (2) for ease of
reassembly.
4. Use soft face hammer to tap inside of lift arm to
remove lift arm from splined shaft.

Installation:
1. Align marks on splined shaft and lift arm and slide
lift arms onto splines on rockshaft. If marks are not 196W959A
available (new lift arms or shaft) use following
procedure: (1) Ring Snap (3) Marks
• Rotate rockshaft manually until upper mechani- (2) Lift Arm
cal stop is reached.
• Align lift arm, so that ball end center measures
279 ~ 281 mm (10.984 ~ 11.063 in.) from base,
with splines on rockshaft and install.
• Secure with C-clip.
2. Align second lift arm with first and install on
rockshaft. Secure with C-clip. Check angle of both
lift arms, they should be within 5° of each other. If
not, reset lift arms on splines and/or replace
rockshaft.
3. Once rockshaft assembly is installed on vehicle be
sure to perform lift arm upper stop adjustment
procedure. (See “Adjustment of position control lever”
on page 9-25.)

196W960A

9-42 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

E. POWER LIFT ASSY ASSEMBLY, DISSEMBLY

AND INSTALLATION
a . Cylinder Removal
1. Remove socket head cap screw (1) securing cylin-
der to body.
2. Support cylinder and remove cylinder bolt (2) se-
curing front of cylinder to body.

196W961A

(1) Socket Head Cap Screw

(2) Bolt

3. Carefully rotate cylinder (1) out of body and sepa-

rate cylinder (1) from plunger (2).

196W962A

(1) Cylinder (2) Plunger

4. Hold cylinder with large opening down and remove

piston from bore.
5. Inspect cylinder bore, piston and piston seal for
damage. Replace as necessary.
6. Replace O-ring and seal washer.

196W964A

(1) Piston (4) O-Ring

(2) Piston Seal (5) Seal Washer
(3) Cylinder (6) Joint Bolt

S196-WOO Jul. 2003 9-43

CHAPTER 9 CK20(H)

b. Depth Control Mechanism Removal.

1. Remove nylock nut and socket head cap screw (1)

from bracket (2). Remove bracket from end of ec-
centric actuator.
2. Remove two socket head cap screw (3) securing
plate to housing. Remove plate (4).

196W965A

(1) Socket Head Cap Screw (2) Bracket

(3) Socket Head Cap Screw (4) Plate

3. Remove Nylock nut (5) from end of socket head cap

screw (1).
4. Remove stack of Belleville washers (4) and washer
(2) from socket head cap screw (1).
5. Remove plate (3).
6. Inspect component for wear of damage paying spe-
cial attention to make sure that Belleville washers
are not flattened. Replace as required.

IMPORTANT
• Do not force components during disassembly or
assembly. Clearances are tight and components
must be free to move for depth control mecha-
196W966A
nism to function correctly.
(1) Socket Head Cap Screw
(2) Washer
(3) Plate
(4) Belleville Washers
(5) Nylock Nut

7. When reassembling make sure that Belleville wash-

ers are installed as shown in illustration so they act
like a spring. Tighten Nylock nut until correct friction
is achieved between washers and plate.

196W967A

(1) Washer (3) Belleville Washers

(2) Plate (4) Nylock Nut

9-44 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

8. Remove E-clip (4) retaining plunger assembly to

pivot bolt (3).
9. Unscrew pin from outside of body marking sure that
plunger assembly does not bind on shaft of pin
during removal.
10.Slide plunger from guide and remove plunger as-
sembly from body.

196W968A

(1) Guide (3) Pin

(2) Stop Rod Assembly (4) E-Clip

11. Remove push rod assembly from lever by removing

plug (10) from either side of lever.
12.Remove stop rod from spring set by removing lock
nut from end of threaded push rod.
13.Remove roller from lever by removing E-clip from
pin (located between roller and lever).
14.Inspect component for wear or damage. Replace
as required.

196W969A

(1) Lock Nut (8) Seal Washer

(2) Spring Set (9) Roller
(3) Lever (10) Plug
(4) Cir-Clip (11) Stud
(5) Pin (12) Push Rod
(6) Ci-Clip (13) Spring
(7) Pin
15.When assembling push rod in body, adjust lock nut
until push rod extends 18 mm (0.709 in.) from spring
set.

196W970A

(1) Stop Rod (2) Spring Set

(A) 19 mm (0.748 in.)
S196-WOO Jul. 2003 9-45
CHAPTER 9 CK20(H)

16.Remove cir-clip retaining cap plate to shaft.

196W971A

(1) Shaft (2) Cir-Clip

17.Remove stopper screw.

196W972A

(1) Shaft (2) Stopper

18.Remove shaft (1) from outside of housing and lever

from inside of housing.

196W973A

(1) Shaft (2) Lever

9-46 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

19.Measure shaft (1) outside diameter and bore in

housing. Replace if not in specifications.

Shaft (1) Specifications:

O.D. 21.95 mm (0.864 in.)

Bore I.D. 22.00 mm (0.866 in.)

20.Inspect shaft (1), O-ring, stopper screw and lever

for damage or wear. Replace as required.

196W974A

(1) Shaft (3) Stopper

(2) O-Ring (4) Lever

21.Remove Cir-clip from pin.

22.Remove Cir-clip from end of stud on arm.
23.Unscrew pin long-from outside of body marking sure
that arm does not bind on shaft of pin during removal.
24.Slide link from stud end and remove link assembly
from body.

196W975A

(1) Cir-Clip (4) Stud

(2) Pin (5) Arm
(3) Cir-Clip

25.Separate links by removing small Cir-clip securing

link to arm. Remove small Cir-clip retaining washer
and roller on arm.
26.Inspect component for wear or damage. Replace
as required.

Installation:
• Installation is the reverse of removal. Be sure to
pay attention to orientation of components when
assembling.

IMPORTANT
• Do not force components during disassembly or 196W976A

assembly. Clearances are tight and components

must be free to move for depth control mecha- (1) Cir-Clip (6) Link
nism to function correctly. (2) Cir-Clip (7) Cir-Clip
(3) Support Pin (8) Roller
(4) Arm (9) Plain Washer
(5) Seal Washer
S196-WOO Jul. 2003 9-47
CHAPTER 9 CK20(H)

c. Rockshaft Removal.
1. Remove set screw securing arm to shaft.

IMPORTANT
• Rockshaft can only be removed from one side of
housing due to stepped bearing surfaces. Be sure
to determine correct orientation of rockshaft be-
fore attempting to remove rockshaft from housing.

2. Determine to which side of rockshaft splines are

cut(shallow taper in splines). This is direction rock-
shaft must move for removal.
3. Using a press remove rockshaft from housing. 196W977A

(1) Shallow Tapered Splines

(2) Arm
(3) Set Screw
(A) Direction of Shaft Movement

4. Measure shaft bearing surfaces. Replace shaft if

not within specifications.
5. Inspect component for wear or damage. Replace
as required.

196W978A

(1) Hydraulic Arm Shaft (5) Hydraulic Rod

(2) Hydraulic Arm (6) O-Ring
(3) Pin (7) Stopper Screw
(4) Spring Pin

6. Using a screwdriver remove shaft seals from

housing.
7. Measure bushings. Replace if not within specifications.

196W979A

(1) Shaft Seal

9-48 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

8. If bushing require replacement use appropriate

bushings driver to remove shaft bushings. Drive
busing out from inside of housing. Replace by driv-
ing in from outside of housing.

NOTE:
• THE FOLLOWING MESURMENTS ARE FOR NEW
COMPONENTS, AND DO NOT REFLECT WEAR
SPECIFICATIONS.

Rockshaft Specifications:

Factory specifi- Allowable

Item
cation limit
196W980A
Shaft to busing 0.075 ~ 0.114 mm 0.3 mm
clearance 0.0030 ~ 0.0045 in. 0.0118 in. (1) Rioted Bearing Driver
Shaft, right O.D 40.020 ~ 40.040 mm
-
1.5756 ~ 1.5763 in.

Shaft, left 35.020 ~ 35.040 mm

O.D -
1.3787 ~ 1.3795 in.

d. Control(MLS) Valve Removal And Installation

(A)Remove
1. Remove the snap ring (1) from the universal joint
(3) on the Hydraulic control shaft.
2. Remove the pin (2) from the universal Joint (3).

196W981A

(1) Snap Ring (3) Pin

(2) Universal Joint

3. Remove two cap screws (2) securing shaft control

valve (1) to housing.
4. Remove shaft control shaft control valve from hous-
ing taking care not to damage O-rings on valve body.
5. Disassemble and inspect shaft control valve.

196W982A

(1) Rockshaft Control Valve (2) Cap Screw

S196-WOO Jul. 2003 9-49

CHAPTER 9 CK20(H)

(B) When reassembling

NOTE:
• Installation is carried out in reverse order of removal.

1. Install new O-rings on body of shaft control valve if.

2. Orient shaft control valve so that the mounting holes
line up with the appropriate holes in the housing
with the shaft control shaft located towards the bot-
tom of the housing (See removal story step)
3. Lubricate shaft control valve bore in housing with
hydraulic oil and being careful not to damage O-
rings, slide shaft control valve into housing. Secure
with two capscrews.
4. Install bracket and secure with two capscrews.
5. Install shaft control shaft and U-joint securing with
two pins and Cir-Clips.
6. Replace tunnel cover.

e . Control (MLS) Valve Disassembly, Assembly

And Inspection
1. Remove the control valve from shaft housing.
2. Remove O-rings from outside of body.

196W983A

(1) O-Ring

3. Remove rubber boot from speed control shaft

4. Remove three socket head cap screws securing
head to body of rockshaft control valve.

196W984A

(1) Body
(2) Socket Head Cap Screws
(3) Rubber Boot
(4) Speed Control Shaft
(5) Head
9-50 S196-WOO Jul. 2003
 HYDRAULIC SYSTEM

5. Remove spool valve from head end of body.

6. Remove speed control valve from head end of body.

196W985A

(1) Spool Valve (3) Body

(2) Speed Control Valve

NOTE:
• Valves are composed of matched components
(spools, springs, body, etc.) If any component shows
wear entire valve must be replaced.

NOTE:
• Orientation of balancing passage in one end of spool
is very important. This balancing passage must be
assembled facing towards cap of spool valve.

7. Inspect components for wear. Replace as required.

196W986A

(1) Pilot Spool (7) Pin

(2) Spring (8) Valve
(3) Valve (9) Seat Valve
(4) O-Rings (10) Spring
(5) Plug (11) Valve
(6) Lever Ass’y

8. Screw a bolt into valve located under speed control

valve and remove valve.
9. Remove spring and ball under valve.
10.Inspect components for wear paying special atten-
tion to ball and seats. Replace as required.

IMPORTANT
• End plate is under tension from valve springs. DO
NOT remove socket head cap screws securing
end plate to body without retaining head as indi-
cated in story.
DO NOT disturb set screw with lock nut! Remov-
ing this screw will change internal relief 196W987A

pressures. (1) Valve (4) Valve

(2) Spring (5) Body
(3) Spool
S196-WOO Jul. 2003 9-51
CHAPTER 9 CK20(H)

11. Remove center socket head cap screw. Use one of

the socket head cap screw that were used to se-
cure head to body (longer than plate screw) in cen-
ter hole.
12.Place valve, head end down, on a level surface to
reduce chance of loosing internal components.
13.Back off all three screws evenly until two outside
screws disengage from threads in body. At this point
spring tension will be relieved to a safe level. Un-
screw center screw and remove.

196W988A

(1) End Plate

(2) Socket Head Cap Screws
(3) Set Screw Lock Nut (4) Body

14.Remove end plate, spring and valve spool as a unit.

15.Note location of spacers, piston, and spring followers.

196W989A

(1) Spring (5) Spring Followers

(2) End Plate (6) Relief Valve
(3) Piston (7) Valve Spool
(4) Spacers

16.Compress spring until it is free of spring pocket

and remove spring and valve spool from end plate.

196W990A

(1) End Plate (3) Spring

(2) Spring Pocket (4) Valve Spool

9-52 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

17.Remove spacers.
18.Remove spring follower and spring from body.

196W991A

(1) Spring Follower (3) Spring

(2) Spacers

19.Use magnet to remove ball from body. Also remove

ball seat if it did not come out with spring.

196W992A

20.Remove relief valve from body.

196W993A

(1) O-Ring (2) Relief Valve

S196-WOO Jul. 2003 9-53

CHAPTER 9 CK20(H)

21.Remove relief valve from body.

196W994A

(1) Relief Valve

22.Remove piston and piston spring from body.

23.Inspect O-ring on piston. Replace if damaged.

196W995A

(1) Piston (3) Spring

(2) O-Ring

196W996A

(1) Spring

9-54 S196-WOO Jul. 2003

 HYDRAULIC SYSTEM

24.Remove spool from body.

196W997A

(1) Spool

25.Remove orifice screw from side of body.

26.Make sure hole in orifice screw is not plugged or
damaged.

IMPORTANT
• DO NOT attempt to remove balls used to black
drill passages in body.

27.Clean body and components in suitable solvent.

Carefully blow out all passages in body with com-
pressed air.
28.Inspect body and all components for wear of
damage. Pay special attention to be sure that ports 196W998A

and small passages are clean and open. Replace

(1) Orifice Screw
as required.

NOTE:
• Individual components of speed control valve are
not serviceable. If body and/or components are
worn or damaged the entire speed control valve must
be replaced as a unit.

Assembly:

NOTE:
• Assembly is carried out in reverse order of
disassembly.

• Lubricate all components liberally with hydraulic

fluid during assembly.
• Always install new O-rings when reassembling
components.

S196-WOO Jul. 2003 9-55

CHAPTER 9 CK20(H)

• Make sure that balancing passage in spool is fac-

ing cap of spool valve.

196W999A

(1) Spool (3) Body

(2) Balancing Passage (4) Cap

• Make sure that flat on speed control valve lines up

with flat on the inside of the cover when installing
head cover.

196W9A1A

(1) Cover (3) Flat

(2) Flat

• Secure head to body with socket head cap screws.

• Replace rubber boot on speed control shaft.

196W9A2A

(1) Socket Head Cap Screws

(2) Body
(3) Head
(4) Speed Control Shaft
(5) Rubber Boot

9-56 S196-WOO Jul. 2003