Service Manual

Workman HD SeriesPage 9 − 64Hydraulic System
Hydraulic Manifold (High Flow Hydraulics Kit)
Removal (Fig. 48)
1. Park vehicle on a level surface, raise and support bed
(if installed), shut engine off and engage the parking
brake. Remove key from the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
CAUTION
Before performing any service or repair on hy-
draulic system components, relieve system
pressure to avoid injury from pressurized hy-
draulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
3. Label and disconnect hydraulic hoses and tubes
from hydraulic manifold. Install caps or plugs in hoses,
tubes and fittings to prevent contamination and leakage
of hydraulic oil.
4. Remove manifold from vehicle.
5. If hydraulic fittings are to be removed from manifold,
mark fitting orientation to allow correct assembly. Re-
move fittings from manifold and discard O−rings.
Valve Cartridge Service (Fig. 49)
1. Make sure the entire outer surface of the manifold is
clean before removing the valve.
2. Remove nut securing solenoid coil to the cartridge
valve. Carefully slide solenoid off the valve.
IMPORTANT: Use care when handling the valve car-
tridge. Slight bending or distortion of the stem tube
can cause binding and malfunction.
3. Remove cartridge valve with a deep socket wrench.
Note correct location for O−rings, sealing rings and
backup rings on valve. Remove and discard seal com-
ponents.
4. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads or contamina-
tion.
1. Hydraulic manifold
2. Hydraulic tee fitting
3. Flange head screw
4. Flange nut
5. Frame bracket
6. Hydraulic hose
7. O−ring
8. Hydraulic tube
9. O−ring
10. Hydraulic hose
11. Hydraulic tube
Figure 48
FRONT
RIGHT
3
5
2
1
4
2
6
7
7
8
9
10
9
11
1. Nut
2. Solenoid coil
3. Solenoid cartridge valv
e
4. Manifold body
Figure 49
1
2
3
4
5 ft−lb
(6.8 N−m)
25 ft−lb
(34 N−m)