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    210 views23 pages

    HUSCO Split Spool Valve

    Uploaded by

    Andres Leal

    Copyright:

    © All Rights Reserved
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    HUSCO SPLIT SPOOL VALVE Service manual SECTION | HUSCO SPLIT SPOOL VALVE GENERAL INFORMATION ‘The Split Spool Valve is ideally suited for large oil ows at high pressure. Although the Split Spool Valve ean be incor Porated in many applications, the Front End Loader best ex: ‘emplifis its capability, The service instructions in this manual apply to this appliestion, CAUTION: LOAD MUST BECOMPLETELY REMOVED FROM ALL ACTUATORS BEFORE AT- TEMPTING TO WORK ON THE VALVES, PREPARATION FOR REMOVAL OF VALVE FROM, MACHINE ‘Thoroughly clean the outside of the valve. To facilitate and insure accurate plumbing for reassembling of 6.5510 on ff the valve, it Is recommended that all inlet, outlet, pilot and cylinder ports be denoted (tagged) prior to removing the valve from the machine. This includes all hoses and associated plumbing Due to the weight of this valve (several hundred pounds)it is advisable that preparations be made for handling this weight when removing it from the machine. Prepare x clean and adequate work area before disassembling. Remove valve from machine and position on mounting pads. is recommended that a current assembly valve print be avail- able for reference before disassembling the valve. NOTE: CARE MUST BE TAKEN TO PROTECT ALL MACHINED SURFACES INLET SECTION Husco Valve Model Designation Stamped In This Loestion Ex: Hotco Valve Model (4002-7 Is Stamped 2-7 ‘Note: The Inlet i save considered as section umber 1 In the valve asertly It is recommended that all O-Rings be replaced when a valve is reassembled. ‘When reassembling a valve lubricate new O-Rings lightly with multi-purpose-type grease. All O-Rings are made of special compounds and are to be approved by or purchased from Husco. DISASSEMBLY Note the position of parts during disassembly so they can be reassembled in the correct position. Mark both covers (2 & 9) in insure correct reassembly. Remove the elght socket screws (1) and inlet cover (2). Remove springs (3 &4) and tag for pro- per assembly. Remove low pressure relief valve sleeve (5) with subessembly (6) and main reliet valve subassembly (7). Remove the eight socket serews (8) blank poppet cover (9) springs (10) and poppets (11). Remove all external O-ings (12, 13, & 14) from inlet housing. INSPECTION Gleam all parts including subassemblies in solvent and dry with ‘compressed air. Inspect the hole and ball poppet of low pres sure subassembly (8) for foreign particles, clean with com- pressed air. : Examine all for breaks or distortion. Inspect all poppet seating surfaces for nicks or excessive wear. All eats must be sharp and free of nicks. All bores and surfaces of sliding parts, ust be free of nicks, scores or excessive wear, Insert the pop- pets (11) into their respective bore and test for fit. Poppeis should fit freely, without binding through # complete revolu. tion, Follow same procedure to check fit between the sleeve (5) and low pressure relief valve (6). Examine all O-rings and back-up rings for damage or deteri- oration. Replace defective pars. ASSEMBLY Coat all parts including housing bores with hydraulic oll Insert poppets (11) and springs (10) into their respective bore. POP- PETS MUST BE INSTALLED IN CORRECT POSITION. (See Figure 1), Place O-tings (12, 13, & 14) into their corresponding grooves. A light coating of grease will hold them in place. tach blank cover (9) with socket screws (8) and torque to 60 ft-Ibs. In a ‘exoss comer sequence, Mate low pressure relief (6) with sleeve (5). Insert this subas sembly along with relief valve (7) and spring (3 & 4) into their respective bore. Attach inlet cover (2) with socket serews (1) ‘and torque to 60 ft-tbs. ina cross corner sequence. SPECIAL BUCKET PLUNGER SECTION (FOR ADDED VOID PROTECTION) DISASSEMBLY Note the position of parts during disassembly so they can be reassembled in the correct position. Mark both covers (2 & 15) to insure correct reassembly. Remove the eight socket screws (), cover @), O-rings @-& 4), spacer (2A), springs (3) and washers (6.) IMPORTANT: The spools are a select fit. Mark each spool (7 & 8) with respect to their proper bore and position (top and bottom) before removing spools from plunger section. Reversing spools will result in the malfunction of this section, (Spools are chromed or black oxided). enttication of each poppet (9 & 10) with respect to its spool is mandatory. Remove spools (7 & 8) with the following: springs (5), washers (6) with O-rings (6A, and poppets , 10 & 11). Remove float poppet subassembly (12) a8 @ unit, Remove eight socket screws (16), and blank cover (15). Remove O-rings (20 & 21) and poppet (19). To complete disassembly remove plug (17) and O-ring (18), INSPECTION Clean all parts (including subassemblies) in solvent and dry with compressed ait. Inspect the ole and ball poppet of float poppet subassembly (12) for any foreign particles, clean with compressed air. Examine sll O-rings for damage or deterioration. Examine springs for breaks or distortion. Inspect all poppet faces and sorresponding seating surfaces in the spools. All seats must be sharp and free of nicks. Examine spools and bores for scratches for scoring. Test spools for fit in their respective bores. Spools should fit freely, without binding through a complete revolu- tion. Inspect the flow passages in spools, blank and. spool overs. These passages must be clean and free of foreign parti ‘les. Clean with compressed air, Replace defective parts, ASSEMBLY ‘Coat all parts, including housing bores, with hydraulic ol Insert poppets (9, 10 & 11) into spools (7 & 8). POPPETS MUST BE INSTALLED IN CORRECT POSITION. (See Figure 2. Install washers (6) with O-rings (6A), springs () and spacer (2A) imo spools (7 & 8). Slide spools into their respective bores. IT IS VERY IMPORTANT THAT SPOOLS ARE POSITIONED COR- RECTLY. ‘The “V" groove on the plunger should always be nearest the ‘cover (2) that the pilot lines connect to. Place O-rings (3, 4, 20 21) into their corresponding grooves. A light coating of grease will hold them in place. Install check valve poppet (19) and float poppet subassembly (12). Assemble (O-ring (18) to plug (17) and install in blank cover (15). Attach ‘cover (2) with socket serews (1) and torque to 60 ftelbs, Attach blank cover (15) with socket screw (16) and torque fo 60 ft-lbs. ‘Torque cover socket serews in a cross corner sequence, Note: The covers are marked to eottespond with the section they belong on. Esch plunger section as cast webs with an "A" and 2 "B" designation on it, The number of the section and the nearest web leter is stamped on the cover. The inlet section is always considered section number 1 When the valve is correctly assembled the stamped letter land number on the cover should match the web letter and section number ‘Truck and loader application incorporating float feature. I is recommended that all O-Rings be replaced when a valve is reassembled, When reassembling @ valve lubricate new O-Rings lightly with multi-purpose-type grease. All O-Rings are mate of special compounds and are to be approved by or purchased from Husco, Seetion Number & Web Designation Stamped on Cover car Fue 2 Spt Spool Valve — Bucket Plunger Section HOIST PLUNGER SECTION DISASSEMBLY Note the position of parts during disassembly so they can be reassembled in the correct position. Mark both covers (2 & 15) to insure correct reassembly. Remove the eight socket screws (2), cover (2), O-rings (3 & 4), springs (5) and washers (6). IMPORTANT: The spools are a select fit, Mark each spool(7 & 8) with respect to their proper bore and position (top and bottom) before removing spools from plunger section. Reversing spools will result in the maufunetion of this section. (Spools are chromed or black oxided). Identification of each poppet (9 & 10) with respect to its spool Ismandatory. Remove spools (7 & 8) with the following: springs (), washers (6) with O-rings (6A), and poppets (9, 10, & 11), Remove float poppet subassembly (12) as a unit. Remove eight socket serews (16), and blank cover (15). Remove O-rings (20 & 21) and poppet (19). To complete disassembly remove plug (27) and O-ring (18), INSPECTION lean all parts (including subassemblies) in solvent and dry ‘with compressed air. Inspect the hole and ball poppet of float poppet subassembly (12) for any foreign particles, clean with ‘compressed air. Examine all O-rings for damage or deterioration. Examine springs for breaks or distortion. Inspect all poppet faces and corresponding seating surfaces in the spools, All seats must be sharp and free of nicks. Examine spools and bores for seratches ‘or scoring. Test spools for fit in their respective bores. Spools should fit freely, without binding through a complete revolu- tion. Inspect the flow passages in spools, blank and spool covers. These passages must be clean and free of foreign patti ticles, Clean with compressed air. Replace defective parts. ASSEMBLY Coat all parts, including housing bores, with hydraulic oil Insert poppets (9, 10,& 11) into spools (7 & 8). POPPETS MUST BE INSTALLED IN CORRECT POSITION. (See Figure 3). Install washers (6) with O-rings (6A) and springs (5) into spools (7 & 8). Slide spools into their respective bores. IT IS VERY IMPORTANT THAT SPOOLS ARE POSITIONED CORRECT- Ly. ‘The “V" groove on the plunger should always be nearest the cover (2) that the pilot lines connect to. Place O-rings (3, 4, 20 & 21) into their correcponding grooves. A light coating of grease will hold them in place. Install check valve poppet (19) and float poppet subassembly (12). As semble O-ring (18) to plug (17) and instal in blank cover (15), Attach cover (2) with socket screws (1) and torque to 60 ft.-bs, ‘Attach blank cover (15) with socket screw (16) and torque to 60 ft -1bs.Torque eover socket serews in a cross comnersequence. Note: The covers are marked to correspond to with the seetion they belong on. Each plunger section has cast webs with an “A” and a “B” designation on it. The number of the section and the nearest web letter is stamped on the cover, The inlet section is always considered seetion num: ber 1. When the value is correctly assembled the stamped letter and number on the cover should match the web letter and section number. “Truck and loader application incorporating float feature. Section Number & Wed { Designation Stamped on Cover Desipiation Stamprd on Cover Figute 3. Split Spool Value ~ Heist Plunger Seton MAIN FLOW CONTROL POPPETS AND RELIEF VALVE SUBASSEMBLY Figure 4 Main Flow Control Poppet and Reliet Vato Subssambly DISASSEMBLY Remove reli valve Poppet (18) subassembly trom split spoo! inlet section. Begin disassembly by removing snap ring (1), lg (2) with esociaved parts intact, spring (3). poppet (4) and Piston (5). Remove Oxings (6, 7, 8, & 9) and back-up rings (10, 11, 12, & 13). Tassociated pars in the plog (2) are re rote, relief presse setting wil be altered. However, to in {eet the poppet (17) face and corresponding seating surface inthe plug (2) disassembly is necessary, Finish disassembly by removing lock nut (15) adjust screw (16), spring (14) and poppet (17). INSPECTION Clean all parts insolvent and dry with compresed ait Inspect Onring grooves for contamination. Check springs for breaks or distortion. Examine poppels (4 & 17) faces and coresponding seating surces in poppet (18) and plug (2) for scratches oF excessive wear. All seas must be shatp and free of niehs, With Oring and backup ving removed, insert poppet (4) into pop- pet sibassembly (18) ane test for fit. Poppet must ft smb ‘without binding through « compete revolution, Examine all Orrngs and back-up rings for damage ot deterioration, Replace any pars found tobe defective. ASSEMBLY ‘Con al parts with hydraulic ol. Insert poppet (17), spring (14) into plug (2) and thread in adjust serew (18) Refer to the chat fon reli valve pressure adjustments to obtain the coreet pret fre setting, (ote: After the adjust screw contacts the spring (14) the adjustment is made by following the chart and wil sive only an approximate pressureseiting. To obtain the correct Dresure setting the tlle valve must be adjusted in the main talve on the machine.) When the approximate pressure setting is obtained instal lock nut (15) and apply 30 ft-lbs. of torque Assemble O-rings (6, 7, 8, & 9) and beck-p rings (10, 11,12, & 18), note Figure 4 for positioning. Insert piston (8) spring (3) into poppet (4) and install as an assembly into poppet (18). Spring (3) in the 6400 valve main relief valve subassembly is fared on one end. When comely installed the flared end will contact plug (2) | Insert plug (2) with associated parts into poppet (18) and install snap ring (1), Assemble rele valve st sembly in inlet section. To function properly asa flow eon- ‘rol valve it must Git snugly without binding thru complete revolution, Note: When checking main relief valve subassembly for freeness ‘of poppet (4) do not be alarmed if the poppet does not spring back after being pushed towards plug (2). The hydraulic oil on the parts will prevent the poppet (4) ‘from returning. The relief valve should be checked in the main valve for proof of correct operation Relief Valve Pressure Adjustments Valve Model | Rated Flow [Change in Pressure (PSI) ve change| BPM | of position on adjust screw (16) "ium [storm] tum | 1 tum 6400 150 400 | 800 | 1200 | 1600 - 6500) 250 150 [ 300 | 450 | 600 1, When changing the relief valve pressure from a lower pres- sure to a higher pressure use the above chart, 1, When changing the relief valve pressure from a higher pres- sure toa lower pressure the correct pressure setting will be ‘obtained by doing the following: ) Determine how much the adjust screw (16) has to be tured, 'b) Turn the adjust screw (16) ' turn beyond the final po- sition. ©) Tur the adjust serew (16) back to the final position and Install lock aut (15). It is recommended that all O-Rings be replaced ‘when a valve is reassembled, When reassembling a valve lubricate new O-Rings lightly with mult-purpose-type grease, All O-Rings ate made of special compounds and are to be approved by or purchased from Husco. SECTION II PILOT CONTROL VALVE PILOT VALVE PLUNGER SECTION 28 DISASSEMBLY With the exception of the valve plunger and plunger housing, all cother paris are considered field serviceable. Should either plunger or housing require repair, itis ecormended to return the complete valve. However, if an emergency situation ne- ceessitales field repair of the plunger oF section housing see ‘emergency repaitinstmetions in this service manual ‘The internal parts of the plunger sections are similar theres Bs GENERAL INFORMATION ‘The Husco model 5000 sectional valve is used as the integral pilot operator for the split spool control valve. This pilot system provides precise control of large oil flows at high oper: ating pressure. PREPARATION FOR REMOVAL OF VALVE FROM. MACHINE, ‘Thoroughly clean the outside of the valve. To insure accurate plumbing for reassembly of the valve, it is recommended that all inlet, end eap and control ports be denoted (tagged) prior to removing the valve from the machine. Prepare a clean and adequate work area before disassembling. Remove valve from ‘machine and position on mounting pads. It isrecommended that a current assembly valve print be available for reference before disassembling the valve. 26 24 13 12 6 ie 19/18 19 \" fore the disassembly procedures pertain to both. Begin dis assembly by removing the cylinder port relief valve fr plunger sections. Instruetions for servicing them are providee in another seetion of this manual. Proceed to service the see- tion by removing machine screws (1), seal plate (2), wiper (3) and O-ring (4) from the tang end of plunger. Remove two socket screws (5) securing spacer (6) and plunger eap (7). Slide the plunger as a complete assembly from the section housing, With a firm grip on the plunger eap (7) unserew pilot plugs (8) and remove pin (9), spring (10), pistons (11), O-ring (12), back- up ring (24), and spacer (13), Place tang end of plunger (23) in a vise. To provent losing the detent balls (14) wrap @ cloth around the plunger eap (7) and with a swift jerk remove the plunger cap (7). Remove detent sleeve (15), balls (1:4), eam (26) and spring (17). Insert a rod through the cross hole in the detent pin (18) and unscrew it from the plunger. Slight pressure should be exerted against the detent pin (18) as it disengages and spring tension is released. Remove spring seats (19) plunger spring (20), eap spacer (6) and two O-rings (21 & 22) from the cap spacer. INSPECTION Clean all parts including housing in solvent and dry with com pressed alr. Inspect seal counter bores, they must be free of hicks and contamination. Examine all springs for breaks or dis- tortion. Inspect sliding surfaces of piston (11) and pilot plug (8) for nicks, scores or excessive wear. With O-ring (12) re- moved insert piston (11) in the pilot plug (8) and test for fit. Piston (11) must ft freely without binding through a complete revolution. O-ring grooves in piston (11) and cap spacer (6). "These surfaces must be free from nicks and contamination. Ex ‘amine all O-rings for damage or deterioration. Any parts found to be defective must he replaced. ‘Test plunger (28) for fit in its respective bore. The plunger must be free of longitudinal score marks and must fit freely without binding through a complete revolution. Inspect service port relief seats in section housing. They must bbe free of nicks or grooves. ASSEMBLY Coat all parts including housing bores with hydraulic oil, Begin OVERLOAD RELIEF VALVE GENERAL INFORMATION ‘The above Cartridge Relief Valve is of the poppet type. Pres: sure is set by means of an external adjustment serew. Relief Yalve failure is usually the result of foreign particles lodging bet ween the poppet and poppet seat. To perform service, lean the surrounding ares and remove the complete relie valve car. ‘ridge from the main valve housing. Provide clean area for re: lief valve parte DISASSEMBLY NOTE: IT IS RECOMMENDED THAT ITEMS 1, 2,3, & 4 RE- MAIN ASSEMBLED TO ITEM 7, AS THEIR REMOVAL WILL, ALTER PRESSURE SETTING. ‘With the relief valve removed from the plunger section, begin disassembly by separating cap (7), with adjust serew and as sociated parts intact from sleeve (11). Remove spring guide (5), ‘O-ring (6), spring (10), poppet (12), and O-ring (9). INSPECTION {lean all pais in solvent and dry with compressed alr. Examine poppet face (12) for nicks or seratches. Inspect poppets’ cor responding seating surface located in the sleeve (11). This seat ‘must be sharp and fre from any nicks or grooves. Examine the Orrngs (6 & 9) for indications of damage or deterioration. Tn spect the spring (10) and replace if found to be broken or ds- tered. Any paris found tobe defective must be replaced. ASSEMBLY Coat all parts with hydraulic cil, Assemble O-ring (9)to steve (21) and Oring (5) to spring guide (6). Insert poppet (22) spring (10) and spring guide (8) into sleeve (11). Thread eap (7) With adjust serew and associated parts intact onto sleve (11) Prior to installation, the nut (8) should be backed off ane com- plete turn, The relief valve i then installed as an assembly Into reassembly of the valve with plunger sections. Since the internal parts are similar, the assembly procedure pertains to both Install O-rings (21) in cap spacer (6) and slide over plunger. Piace tang end of plunger in vise. Assemble one spring seat (219) over plunger end. Install plunger spring (20) second spring seat (19) and thread detent pin (18) in the plunger. Slight pres sure wil be required to compress the plunger spring. Apply grease to cross holes of detent pin (18) to hold balls (14) inplace. Insert detent spring (17) in cam (16). Slide detent sleeve (15) into plunger eap (7) and place as an as- sembly over a drive pin or punch. Using this punch or drive pin depeess eam (16) with detent spring (17) and insert balls (14) into detent pin (18) eross holes. Guide detent sleeve (15) and plunger cap (7) a8 an assembly over the detent pin (18). Con- tinue to insert detent sleve (15) until it contacts spring seat (29). Secure assembly with cap serew (5) torqued to 6 ftbs. Assemble Oring (12), back-up ring (24), pin (9), spring (10) and insert as an assembly into pilot plug (8). Install spacer (13) in plunger cap (7) and thread pilot plug (8) assembly into plunger eap (7) Assemble O-ring (4), wiper (8), seal plate (2) and secure with machine screws (1). It is recommended that all O-Rings be replaced ‘when valve is reassembled When reassembling a valve lubricate new O-Rings Tightly with multi-purpose-type grease All O-Rings are made of special compounds and plunger section. Tt should be tightened until the face of sleeve (11) Js in firm contact with corresponding housing seat. Apply 2 FL, Pounds of torque to cap (7). Torque lock nut (8) to 10 Ft, Pounds, PRESSURE SETTING PROCEDURE Mount the relief valve in a Husco Relief Valve Block (Part Number 6756-2):Conneet the inlet of the block to a jerk pump with a Oto 5000 psi gage teed into the line. The pressure setting is to be made at cracking or approx. .5 G.P.M, (Note: % tur of adjust. screw (4) will change the pressure setting approx- imately 250 Pl.) After the desired pressure setting is ob- tained jam nut (3) and acorn nut (1) should be torqued to 15 ft-lbs. The pressure setting should be rechecked after torquing the nuts, gute 6 Overload Ralef Vale SAE 10W Hyérauli oi! to test and Set overload relief valve assemblies. SECTION Ill TROUBLESHOOTING GENERAL ‘The following suggested procedures should be followed in ‘checking @ machine incorporating the split spool valve, The Ihydraulic ofl must be at operating temperature, 2 minimum of 150 Deg. F., and an accurate 4000 P.S.1. pressure gauge must be installed in the line from pump to inlet side of main con: trol valve. Check oll in reservoir for proper level 1. Main valve inlet pressures with valve In neutral posi tion are to be ehecked and recorded at: (2) Hoist up position (6) Bucket roll-up positon 2, Main system relief valve pressure with following cylinders bottomed and engine at high idle: (@) Engine low idle (6) Engine high idle 3. Main valve inlet working pressures taken from exter. nal pressure gauge with empty bucket and engine at high idle performing following functions (refer to jeations contained in machine operator's (2) Host up (©) Hoist down (6) Hoist down in float position (@) Rolling bucket up (€) Dumping bucket 4. Time in seconds for th following operations with empty bucket and engine at high idle (refer to specifications contained in machine operator's manual): (2) Hoist up () Hoist down (©) Hoist dove in float position (@) Rolling bucket up (©) Domping bucket NOTE: DO NOT ATTEMPT TO ADJUST ANY OF THE RE- LIEF VALVES BEFORE READING THE RECOMMENDA. ‘TIONS IN THE TROUBLESHOOTING SECTION. If pressures and time eyeles do not correspond to specifica- tons contained in machine operstor's manual, the machine ‘will not perform properly and lack hydraulic power. Check recommendations in the trouble shooting section, 1 is recommended that all O-Rings be replaced when a valve is reassembled, When reassembling a valve lubricate new O-Rings lightly with rwulti-purpose-type grease. All O-Rings are made of special compounds and are to be approved by or purchased from Huseo. TROUBLESHOOTING INLET SECTION in| Flush out line. Replace if necessary. 10 ‘Trouble Probable Cause Remedy High operating temperature. (contin- | 2, Malfunctioning overload reliefs. Replace or see service instructions ued) covering main relief. 8, Excessive leakage in main contro! | Check spools and bores for excessive valve or pilot valve. ‘wear or scoring. Replace damaged parts. 4, Oplinder leaking. Replace cylinder packing. 5. Defective pump. Replace pump. Loss of power or delay in reaction | 1. Restriction in the main flow con- | Free hole of foreign material, time. trol body pilot hole. 2 Antivoid poppet in inlet section | Remove foreign material from poppet, stuck open. poppet seat, and bore, Make sure pop: Det seats properly and moves freely. Replace return spring if fatigued or distorted. 3. Ruptured supply line to pilot valve. | Replace supply line, 4, Pilot valve spool not positioned | Free and clean binding linkage. properly, (Check spool and detent balls. Replace if scored or damaged. 5, Malfunctioning main relief valve 6. Cylinder teaking Replace or see service instructions covering overload reliefs. Replace cylinder packing 1. Defective pump. Replace pump. 8. Excessive leakage in main control | Check spools and bores for excessive valve or pilot valve wear or scoring Replace damaged parts 9. Voir. See void remedy in following section. Noticeable voids in bucket and hoist | 1, Main flow control relief valve pop- | Replace or see service instructions ‘when lowering. pet stuck open. covering rin relief valve 2, Low pressure relief in inlet section | Remove foreign material from poppet, stuck open. poppet seat, end bore. Make sure pop: pet seats properly and moves freely. Replace return spring if fatiqued or | > distorted. 3. Anthvold poppet in inlet seetion | stuck closed. Remove foreign material from poppet, poppet seat, and bore. Make sure pop: pet seats properly and moves freely. Replace retum spring if fatigued oF distorted. TROUBLESHOOTING SPECIAL BUCKET SECTION {EvLINDER ROD) (evUNDER Base) fevtimoen woo) — | (eVLINDER Basey Figure 8. Bucket Section ‘Trouble Probable Cause Remedy [Bucket does not move or moves stowly. | 1. Spools binding in main control | Clean all foreign material until spool valve moves freely. Replace damaged or sworn parts 2, Restriction in pilot pressure Hine. | Flush out line oF replace as required. 3. Broken springs in either spool Replace springs in pais. 4, Ruptured plot pressure line. Replace pilot pressure line 5, Flot valve spool not positioned | Free and clean binding linkage. properly. Check spool and detent balls. Replace if scored or damaged. 6, Main relief valve malfunctioning. | Replace or see service instructions covering main relief valve. 7, Malfunetioning overload reliefs Replace or see. service instructions ‘covering overiond reliefs. 8. Cylinder leaking, Replace eylinder packing 9. Defective pump. Replace pump. 410. Restrictor poppet incorrect or out | Check assembly print for correct pop: of place. | pet location. Consult list at end of | troubleshooting section of this manual for correct orifice size if color code has wom off. 2 ‘Trouble Probable Cause Remedy Load drops with handle in neutral position, 1. Malfunctioning overload reliefs, 2. Spool in pilot control valve not positioned properly. Broken or weak spool return spring in main control valve. 4, Holes in either spool or restrictor oppets plugged. Replace or see service instructions covering overload reiets Free and clean binding linkage. Check spool spring and detent balls. Replace if scored or damaged. Replace springs in pairs. Free holes of foreign material. Replace ‘worn or damaged parts Bucket drifts with engine shut off. 1. Cylinder leaking. 2, Spool binding in main control valve 3, Malfunctioning overload reliefs 4, Exeessive leakage in valves. 5. Broken springs in either spool. Replace eylinder packing. Gean all foreign material until spool moves freely. Replace damaged or ‘worn parts. Replace or see service instruetions covering overload reliefs, Check spool and bores for excessive ‘wear or scoring, Replace if necessary. Replace broken springs in palrs, Noticeable void or chattering when dumping bucket. 1. See Probable Cause and Remedy ‘under Inlet Section. 2. Restriction in pilot pressure lin. 43, Holes in spool plugged. 4, Restrictor poppet in spools not seating properly. 5, Malfunetioning overload reliefs. 6, External restrictors (if used) mal functioning. Flush out line or replace as required. Free holes of foreign material. Replace ‘wor or damaged parts Lap to mating seat or replace. Replace or see service instruetions covering overload reliefs Check restrictor for dirt or damaged parts. Replace if necessat Bucket drifts when engine is running. 1. See Probable Cause and Remedy under bucket drifts with engine shut off. 2. Pilot valve spool for bucket not centering. 4, Free up spool in pilot valve by mak- ing sure end mechanism is cor. rectly centered, . Replace pilot valve, Noticeable void or chattering when rolling bucket back. 1. Void In Hoist Poppet in hoist rod not seating cor- rectly or out of place — Reseat pop- pet or replace poppet in bore. TROUBLESHOOTING HOIST SECTION (EVLINDER ROD) Figure 9. Heist Seton —— (CYLINDER Basey ‘Trouble Probable Cause Remedy Hoist does not raise or moves slowly. 1, 12, . Spools binding in main control valve. Restriction in pilot pressure line. Broken springs in either spool. Ruptured pilot pressure line, Pilot valve spool not positioned properly. Main relief valve malfunctioning. Malfunctioning overload reliefs Void in Hoist Void in Bucket, Cylinder leaking. Defective pump. Restrictor poppet incorrect or out of place, lean all foreign material until spool moves freely. Replace damaged or, ‘wor parts, Flush out line or replace as required, Replace springs in pairs. Replace pilot pressure ine. Free and clean binding linkage. Check spool and detent balls. Replace if scored or damaged. Replace or soe service instructions ‘covering main relief valve. Replace or see service instructions ‘covering overload reliefs. Check restrictor poppet in hoist rod spool and seats inthe spool. ‘See Probable Cause and Remedy under Bucket Section. Replace cylinder packing. Replace pump. Check assembly print for correct pop- pet location. Consult list at end of trouble shooting section of this manusl for correct orifice size if color eode has worn off. ‘Trouble Probable Cause Remedy Load drops with handle in nevtral position, 1. Malfunctioning overload reliefs 2. Spool! in pilot control valve not positioned properly. 3. Broken ot weak spool return spring in main control valve. 4. Holes in either spool or restrictor oppets plugged Replace or see service instructions covering overload reliefs. Bree and clean binding linkage. Check spool spring and detent balls. Replace if scored or damaged. Replace springs in pais. Free holes of foreign material. Replace worn or damaged parts Load drops with handle in raise position and working bucket. 1. Holes in hoist base spool or restrictor poppet plugged. 2. Broken springs in spool. 3. Spool binding. Free holes of foreign material. Replace worn or damaged parts Replace broken springs in pars. Glean all foreign material until spool moves freely. Replace damaged or ‘worn parts, Check trouble and prob. able causes listed under "Hoist does not raise or moves slowly” and “Load

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