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Reelmaster 4000–D
Page 4 – 59
Hydraulic System
Disassembly of Lift Control Valve
1. Plug all ports and clean outside of valve thoroughly.
2. Remove cap assemblies (28). Do not remove retain-
ing rings (26) from spools unless spring (25) is broken.
3. Remove spools (13) from body (8).
NOTE: Spools and spool bores are matched sets. Be
sure each spool is identified with the correct body spool
bore.
4. Remove bushings (23) and O–rings (22) from spools.
5. Remove plugs (11).
6. Remove plugs (30), springs (31), poppets (33), seats
(35) and plungers (37, 29).
IMPORTANT: Check location and positioning of
plungers when removing from body to assure prop-
er assembly.
7. Remove plugs (6).
8. Remove plugs (1), discs (2), springs (3) and detent
plungers (4).
9. Remove locknut (34), washer (12), plug (14), wash-
ers (16, 17, 18), spring (19) and poppet (20).
10. Remove all O–rings and back–up rings from all
plugs and seats.
Inspection of Lift Control Valve
1. Remove all nicks and burns from parts and inspect for
excessive wear.
2. Inspect all plungers and poppet seats for burrs or
roughness.
3. Inspect spool springs (25), relief valve spring (19),
lockout springs (31), and detent springs (3) for break-
age.
4. If spools (13) have excessive wear, the valve be-
comes non–serviceable as the spools and spool bores
are matched and damaged spools cannot be replaced.
5. Inspect relief valve poppet (20) for breakage or wear.
Assembly of Lift Control Valve
1. Thoroughly clean and dry all parts. Apply a light coat-
ing of clean hydraulic oil to parts prior to assembly.
NOTE: All O–rings, back–up washers, wiper seals and
nylon poppets should be replaced as new items.
2. Install new O–rings (22) in proper grooves in spool
bores.
3. Install relief valve components (20, 19, 18, 17, 16)
with new O–ring (15) on plug (14).
4. Install plugs (11) with new back–up washers (10) and
O–rings (9).
5. Install plungers (37, 29).
IMPORTANT: Check location and positioning of
plungers during installation.
6. Install new O–rings (36) on seats (35). Install new
back–up washers (10) and O–rings (9) on plugs (30).
7. Install seats (35), new poppets (33), and plugs (30).
8. Install plugs (6) with new O–rings (7).
9. Install detent plungers (4), springs (3), discs (2), and
plugs (1) with new O–rings (5).
10. If retaining ring (27) has been removed to replace
spool spring (25), install washer (24), spring (25),
spacer (26), and secure with retaining ring (27).
11. Slide bushings (23) over spools. Slide new O–rings
(22) over spools and position next to bushings. Dip
spools in clean hydraulic oil and install spool assemblies
in proper location.
12. Install spool caps (28) and tighten to a torque of
20 – 25 ft–lb.
13. Install new wiper seals (38).
Hydraulic
System