INDEX The Lollowing pages centain information about the follwing hydraulic valves found in Caturpilar hydraulic systems: pad wo a 24 2 2 33 Subnet Spool Yatve Simple Relief Valve Pilot-Operaied Relief Valve Piston-Operated Helicf Valve kesteictiontype Relief valve Make-Up Valve ¥low Conteol Valve Flow Divider Valve Pressure Reducing Valve beessure Differential Valve Udi fied blo t-opersted Reliuf Valve Modulating Relief valve PAGE 35 7 ay 4a a 51 55. 57 59 el 63 65 sussecr Ovifice cheek Valve Siaple tlechanical Protective Device Uechantcal Protective hevice with Spool Valve Uydraulic vrotective Valve Combined with Reutralizer Funecten Uydraulic Protective Valve Combined with Sequence Valve Cosbination Valve Protective Reset Vaive Neutralizer valve Hydraulic Shift Governor Priority Valve Rotary Selector Soovl Nolulating Redueiag Valve (Shown in Valve StatLoa)INTRODUCTION ‘The illustrations in this book will help you to recognize the type of valve, its purpose, how it operates, and where it is used. At is suggested that yeu use 4 set of colored pencils te show oil flow through the valve diagrams. Keep this book ag a reference; it will help you review the function and use of hydraulic valves. Before commencing the review of hydraulic valves, consider the following points, which will allow you to selve most problem: 1. SPRINGS; - Their purpose in hydraulic circuits. A. Before pump commences oil flow, the springs will be fully expanded to the Limit of the housing or compartment where they are located. &, They can be compressed or expanded by oil pressure, but will retum to theit original length when the system 1s depressurized, 2. VALVES ~ Simply block or control ofl flow. (souetines at a predetermined rate) 3, PRESSURE: Comes only with resistance to ofl flow. 4, WYDRAULEK grecurrs ~ Read them like 2 map; the valves are sign posts for oil flow, A. Gat a clear picture of the problems write down factors concerned if it helps. B. Try to anderstand what must be done. A few minutes of thought eun ave hours of labor. Like any journey, start at the beginning and follow through to the source of the problen.S3A0049 ONI¥aLH3D PNOLLYDINANT Toods sL01S ONTTLLOWML JATWA 100dSSPOOL VALVE 1. PuReosi Block or direct the flow of oil to the desired circuit 2. Teees: Ke Iwo Position {1.e., Furvard, Reverse) Three Position (ive., Reise, Hold, Lower} © Your Position (1.e., Raise, wold, Lower, ¥loat) 3. CONSTRUCTION: 3B. Lands that can be noved to select a efrouit, (i.e., 1, 2 of 3) B. Throttling slots machined in leads te allow partial flow, (Le., close blade control) C. Machine grooves around the valve land to assist in lubricating, sealing and centering the spool in the bore 4. WHERE USED 4, Bulldozer hydraulic controle Track loader hydraulic controls ‘transmission hydraulic controls D. Implement hydraulic controls TROUBLESHOOTING HALFUNCTION POSSINLE CAUSE CORRECT LON Blade or bucket drift | A. Leakage between spool | Replacement of damaged land and valve body components B, Worn seals Replace Jamaing in bore A. Foreign material Clean Jamming spool, B. Valve body improperly | Refer to specification torqued at assembly for torque and ©, Mounting face not flat | tightening sequence NOTE: High pressure application epool is not available without a matched body. Low pressure application spool (such as power shift transmission spool) is many times individual ly available, Parts Rooks, in aone instances, 1st .020" oversize bore and spool. Reason -- to salvage body machined oversize in wanufacture.SIMPLE RELIEF VALVE TANK = =~ PUMP WORK seSIMPLE RELIEF VALVE 1, 7URFOSE: f To limit maxinum proccure 2. CONSTRUCTION Valve, seat and spring 3. OPRRATION Valve is initially held closed by spring force. Pressure oil acts upon the valve, Excessive pressure (always sensed on upstrean side of circuit) will overcome the spring force and open the valve to allow the oil to be bypassed. 4. WHERE Uso: 4, low pressure applications where exact pressure is not critical Booster and lubrication aystene €. Mhen noise from operation is not critical TROUBLESHOOTING HAL PURCT LOR BOSSISLE CAUSE Comair Low Pressure A. Broken or weak spring Replace B. Faulty seat Replace or recut C. Foreign material jammed Clean or replace under valve seat D. Incorrect shims adjust High pressure A. Poppet jammed Warped body: dirt in valve B. Incorrect shins Adjustaa ene: 2 OMIYdS oe VEN NAN Wes tee] a>141¥o ONIYdS LONd JAIWA 431158 031VY4d0-LO1dPILOT-OPERATED RELIEF VALVE PURPOS! K. To limit maximun pressure B. To protect the hydraulic system from pressure created by excessive Joad or blocked Line CONSTRUCTION Pilot velve, two springs and unloading valve with orifice OPERATTO! OT enters the relief valve housing and flows through the unloading valve orifice to contact the pilot valve. when oii pcessure rises to the relief valve setting, the pilot valve opens and dunps ail from the unloading valve spring chanber- Since mere of1 can flow past the pilot valve than through the unloading valve orifice, the pressure lessens in the unloading valve spring chamber The unloading valve then moves up, allowing full pump flow to be dumped into the tank. NOTE: Throttling holes in the base of the unloading valve allow for smooth dumping. WHERE USED AL ALL tractor hydraulic controls B. ALL track loader hydraulic controls €. ALL scraper hydraulic controls HY USED: A. Less flutter or hanmering 8. Large volune of oil can be passed quickly through a large dunp POEL, with use of only a small spring and small nechanical sonstruction, C. Maintains uniform pressure with widely different flow racesTROUBLESHOOTING MALFUNCTION POSSIBLE CAUSE CORRECTION Pressure setting high Pressure setting Low Erratic operation Excess number of shins Incorrect spring on pilot valve Pomp flow excessive Ineuffielent nunber of shins Foreign naterial jammed wador pilot valve coat Leakage fron unloading valve chamber Pilot valve seat wern Pilot valve spring retainer Loose Unioading valve janmed open Unloading valve sticking Worn pilot valve Remove and reset Replace Hatch valve to pump Add and reset Disnantie and clean Replace O-rings Replace Assemble correctly Free valve in bore check for bere distortion Check for foreign raterial in oit Replace 10aN NOTES WwNOusia gunssadd SOO, VE a ae f ae ANNA BATA LLP CLA i. 2 JATWA 43t1du GILVuadO-NOLSIdPISTON-OPERATED RELIEF VALVE PUREOSE &. Limit maximum pressure B. Protect the lines, cylinders and valve fron pressure created by an external force on the bucket 2, CONSTRUCTION Piston, valve, springs aud shins |. OPERATION: Gil trapped in the hydraulic Lines by the maia control valve can be pressurized by an external force on the track loader bucket or by blocked bucket Linkage, and is isolated from the main relief valve. The pressure oil will enter the valve and act on the piston. When sufficient force is available, the valve will move against the spring and dump sone o41 until overpressure is relieved. 4. aE Botk sides of the tilt circuit of both the wheel and track-type loaders. In some cases, two pistons are usel to sense pressures in different circuirs. The valve is then called “dud sensing.” TROUBLESHOOTING MALFUNCTION POSSIBLE CAUSE. comRecTION Hose, tilt or lift A. Relief valve inoperative Renove and repair cylinder failure or damage due to excessive pressure Relief valve A. Piston seized in Replace inoperative housing B. Hydraulic Lock in Glear drain passage apring chamber C. Dump valve seized Replace if damaged Bucket deift A. Leakage of O-ring Glean or replace seals, or past valve seat B, Relief valve opening Reset below pressure setting of main relief valve 13JAIWA Jala AdAL-NOILOISLSIYRESTRICTION-TYPE RELIEF VALVE 1. PURPOSE: Te anitially restrice pump Clow, and establish the system pressure 2. CONSTRUCT LO! Valve with an orifice and chanber open to pump pressure flow and spring. Sone have a piston (slug) in orifice chamber. 3. OPERATION Valve creates restriction to pump flow by blocking the outlet. As the system fills, pressure rises through the orifice into whe chamber aad moves the valve agadast the opring until the outlet is pena Oil can then flow past the valve to Limit pressure rise. A piston (or elug) seed in the orifice chamber vill allow a Light spring to control the action of the valve because the pressure oil will be acting on a reduced area. ‘A poppet may be used co dampen the action of the valve by slowing ite closing rate. 4, WHERE USED: Transmission hydraulic controls for some track-type tractors, track type loaders, small and large wheel loaders HALPUNCTION POSSIBLE CAUSE CORRECTION Low pressure A. Insufficient number of Add and reset shins B. Soft chima used and Replace with correct beaten out hardened shins €, Incerreet or broken Replace spring D. Slug (4£ used) missing Replace B, Deain passages behind Remove obstruction slug blocked High pressure A, Excess number of shims Remove and reset B. Pressure not entering Clear blocked orifice orifice ©. Valve seized in bore Replace if damaged D. Slug (if used) seized Clean or replace in valve E, Incorrect spring Drain aad flush syston Erratic condition A. Relief vatve land Determine source worn fron fine abrasives of abrasives in ofl Replace worn parts 4. Intermittent sticking Free valve in bore 15CHECK VALVE SSG TUE tS KARMA SSS fare [I HH Me J | ¢ WS BS sys — ¢CHECK VALVE 2. PURPOSE: To contrel ofl te flow in one direction only 2. CONSTRUCTION Spriag and valve with a tapered seats a round bell is sometines used instead of the valve shown here. In ether circuits, the check vaive is free floating (has no springs) or has en orifice in the valve. 3. OPERATION: The valve will Life off the seat and control the flow wen the slight spring force is exceeded. 4, WHERE USED: Tn dozer, ripper, tilt cylinder and track loader bucket citcuits to separate two cirouite. In steering clutch cireuita te provent prosoure loss during transmission range selection on power shift machines. HALEUNCTION POSSIBLE CAUSE CORRECTION Bucket or dozer drops | A. Worn seat Recut or replace slightly when raise positions selected B. Wore valve Replace ©. Broken spring Replace D. Dirt under valve Olean 17ONREES BATA JATVA dn-JVN «aaso70) 18MAKE-UP VALVE 1. PURPOS: Allows oil to bypass the pump and flow dircetly to the cylinder Lanes wheuever reservoir pressure is greater than Line pressure 2. CONSTRUCTION wheck valve and light spring. Valve vill always be located betow reservoir oil level. There will be one for each circuit. 3. OPERATION: When oil pressure in Lines is approximately 2 psi less than reservoir pressure, the make-up valve unseats, allowing oil to flow to Lines. (ixanple: quick dropping blade or bucket.) This prevents cavitation in cylinders and Lines. 4. WHERE USE Dozer, ripper and track loader hydraulic circuits TROUBLESHOOTING MALFUNCTION POSSTALE CAUSE CORRECT LON Blade or bucket drift | a, valve jammed open Clean or replace Blade will not Lift 3. Valve jamued open Clean ot replace Blade lacks down 6. Valve jamwed open Clean or replace pressure 19FLOW CONTROL VALVE ORIFICE Lilli DUMP VALVEhs FLOW CONTROL VALVE Pureo: Te provide 2 predetermined maximum flow rate to one cireuit and bypass excess flow to another circuit ‘CONSTRUCTION: An orifice designed te pass a certain flow at a specified pressure differential, ané a valve to bypass or restrict excess oil. The valve is loaded by a Light spring and sumetines the orifice is contained in the valve. OPERATION The Orifice, because of its size, creates a pressure drop across it du the direction of flow. The force from the higher pressure acts on the upstrean sida of the valve. ‘The force from the lower pressure plus the spring force act on the downstrean side of the valve. When the force differential between the two pressures rises above the desired level (when flow rises above designed axount), the valve will then move towards the low pressure side, overcoming spring force. This action will either bypass excess oil or restrict the flow of oil to the valve (depending on the construction of the valve). The flow throagh the orifice will then be maintained at a required value. WHBRE USED Transmission hydraulic controls, implement hydraulic controls TROUBLESHOOTING WALFONCTION POSSIBLE CAUSE CORRECTION Does not Limit Elow Valve seized in body Glean or replace incorrect spring 8. Full flow plug Replace with installed orifice plug Flow rate too low A. Valve spting broken Replace spring or weak B. Valve seized, partially Clean or replace closed C. Orifice plug installed Replace with higher flow rate plug 2=I WY N YW WA SZ, SMTAMIRAY 7 13TANG GaN LaTLAG LHOt 1437 JATWA Y3CIAIG MO1dFLOW DIVIDER VALVE PURPOSE equélly divide the oil flow frou a single punp, regardless of the diffecence in restriction on the outlets, allowing two separate circuits to be supplied simultaneously with oil frow a single pump CONSTRUCTION pool drilled to adnit oil to center, then cross-drilled te direct it to each separate outlet OPERATION: With both outlets providing equal restriction to the oil leaving the outlet passages in the body, the flow divider spool will be balanced in the center of the body. When the operator restricts one outlet by applying one brake or steering clutch and upsetting the balanced Flow, a pressure rise will cause the spool to move to the low pressure side. The spool itself will then restriet the oil flow from the pump and cause 2 pressure rise equal to the restriction caused by the action of the brake ot steering clutch. The oil flow from the two outlets vill then be equal. WHERE USED: Early model track loader steering clutch circuits and track-type tractor brake booster circuits TROUBLESHOOTING UALFUNCTION POSSIBLE CAUSE comaect ron Low 011 pressure when A. Valve seized in central Clean or replace one brake is applied, position correct oil pressure when both brakes are applied Pressure oil is A, Valve seized in one Clean or replace available to one brake end of bedy booster Brake pressure is low | A. Main relief valve set Remove and reset low B. Brake relief valve eet Replace spring low 23PRESSURE REDUCING VALVE Ve "OSS LD SS Oe A ae \\ YN i} t ae I, LLL IN ‘On aL) N A AY 1) basPRESSURE REDUCING VALVE Pyaros! Fo reduce punp pressure (established by the main relicf valve), to the requirenents of the systen STRUCTION Valve with slug compartment orifice open to dewnstrean pressure, The spring determines downstream systen pressure, OPERATION: K. Initially, the valve is held open to flow by the spring. B. Pressure must build up in the daynstreaw side and in the slug chamber. €, When pressure builds up sufficient force in chanber, the valve moves against the spring, reduciag the pump flow and maintaining the reduced pressure, 4, WIERE_ USED: Pranswisoion hydraulic controls ~ DbG, 600 Series, 769, 824 and 834. [ HALFUNCTLON POSSIALE CAUSE CORRECTION Reduced pressure not to Incorrect shimring Add or vemove shins specification B. Inlet pressure low Determine if tow proscure is due to rain rellef valve setting or lack of restriction on comstrean side of pressure reducing valve ©. Spring failed Replace spring D. Slug owitted during Heplace slug assembly Pressure uot reduced A. Orifice blocked Clear blockage by valve B. Valve jammed open Pree valve in bore C. Slug seized in valve Clean or replace No pressure sensed A, Valve jamned closed Free valve in bore on downstream side oknvalve B. Slug seized in valve Clean or replace holding valve closed ©. O41 drain passage behind | Determine reason for slug blocked hydraulic lock D. Orifice open to pump Determine reason, pressure flow, holding possibly caused by valve closed pressure surge fron downstream pushing valve orifice into pump flow chanber 2sARS AANDMID Javania Tee ala “sud JATWA TWILNJYSSdIC JYNSSIUdPRESSURE DIFFERENTIAL VALVE 1. PURPOSE: To supply o4} at a constant pressure differential to two circuits CoNSTRUCTIO Valve with passages leading to sprang conpartment and to the second circuit 3. OPERATION: Fhe differential valve initially blocks of1 flow until pressure rises, this prescure rise mover the valve againet tho spring and allove oil flow into the secondary circuit. As the pressure rises in the secondary circuit, oil will flow into the spring compartment and this will be at the same pressure as the ofl in the secondary circuit, ‘The pressure of the vil in the spring compartment combines with the action of the spring to move the valve back against the pressure of the oil in the primary circait. The valve will then find a position wiere the pressure in the prinary circuit equals the combined effect of the pressure in the secondary circuit ané the spring force. Regardicas of iatet pressure, the difference In pressure between the primary and secondary circuits is always equal to the equivalent pressure of the spring and is called the "pressure differential". It can only be altered by changing the spring rate. This can be done by changing the spring itseli. 4. WHERE USED Some power shift transnission control circuits; 600 Wheel Tractor torque divider transmissions 5. WY USED: 3. Power shaft cransmissions - to ensure correct sequence of cluteh ongagenent b. 600 Series transmissions; part of the autonatic shift circuit TROUBLESHOOTING HALEUNCTION POSSIBLE CAUSE CORRECTION Pressure differential A. Incorrect or broken Replace spring less than specified spt ing B. Oil leaking from spring Determine cause of chamber leakage C. Insufficient restriction | Eliminate leakage on second circuit Pressure differential A, Incorrect spring Replace with correct greater than specified (weaker) spring B. Valve jaumed open Replace component if damaged Pressure not dropping A. Differential valve Ensure valve free in secondary circuit on not opening dump port in bore transmission vhen shift da made 2ontaas UY 10d 1 art lal A vay eres ar a ore BATVA LOd dis # 3GIND ONYES JATWA S3I13u O31VYad0-LOTd G3lsIdOW 28MODIFIED PILOT-OPERATED RELIEF VALVE PURPOS! A, fo set maximum system pressure for normal operating conditions B. Relieve pressure surges at a lower value ‘oonstueTION Toad Plston, load piston orifice, load piston chanber, two springs, pilot valve and unloading valve with orifice OPERATION: K7"Rormal Operating Condition Gil enters the relief valve housing and flows through che unloading valve orifice to the Face of the pilot valve and through a passage and orifice to the load pisten, As pressure rises end 1s sensed in the load piston chanber, the load piston moves to the right, compressing pilot valve springs this increases the pilot valve pressure setting. ‘The lead piston moves before the pilot valve because the area of the load piston is larger chan the face of the pilot valve, When the load piston {s hard against the stos, the pilot valve setting is at the nomal operating value. The remainder of the vperation {s identical co the operation of the pilot-operated relief valve. B. Pressure Surges Oil enters the relief valve housing and flows through the unloading valve orifice to the face of the pilot valve and to the orifice of the load pisten chamber. Because of the size of the orifice in the load piston chamber, flow is restricted, creating a delay in pressure to the load piston and resulting in a build-up of pressure along the passage tu the face of the pilot valve. Consequently, when a pressure surge exists, the pilot valve will always open first. The pilot valve opens and dumps ofl from the unloading valve spring chamber. The renainder of the operation is identical to the operation of the pilot operated relief valve. WHERE USED: A, 000 Series; scraper portion of hydraulics 3, 988 main pressure relief valve (loader portion) 23TROUBLESHOOTING MALFUNCTION POSSIBLE CAUSE CORRECTION Pressure setting low Pressure setting high Erratic operation A. Blocked load piston chamber orifice B. Foreign material jaamed uader pilot valve seat C. Leakage fron unloading valve chaaber D, Pilot valve seat worn E. Unloading valve jammed open F, Pilot valve spring broken A, Incorrect spring on pilot valve B. Pump flow excessive A, Unloading valve sticking 8. Yorn pilot valve Dismantle and clean Diomantle and clean Replace O-ring Replace Free valve in bore Replace Replace Match valve to a puop Cheek for bore distortion; check for foreign material in oil Replace 30NOTES 31JATWA J3I138 SNLLVINGOWMODULATING RELIEF VALVE 1. PURPOSE: To get 2 variable system pressure and, depending on the application, a delayed pressure buildup STRUCTION: Basically a relief valve with a load piston behind the spring 3. OPERATION As in the case of the normal relief valve, it creates restriction co punp flow by closing the outiet. If there is no pressure acting on the load piston it relieves at a lov pressure (usually called primary pressure). When the load piston is charged with oil, the relief pressure increases. ‘The maximus pressure is reached when the Load piston is against the stop. LF used in conjunction with an orifice check valve, the pressure buildup will be slow, yet the pressure drop will be rapid. 4. WHERE USE Power ehift tranomiccion hydraulic controls TROUBLESHOOTING MALPUNCT 108, FOSSIBLE CAUSE Pressure renains at initial setting A. Load piston sticking or seized B, No pressure buiidup beyond the load piston No nodulation A. Load piston sticking or seized Slow pressure buildup and slow, Load piston binding instead of rapid relief B. Orifice check valve binding nor! For further troubleshooting, see "Restriction-Type Relief Valve" (page 15). 3NOLSId OVO O1 Bovssvd Alddns TK JAIWA WOSH9 F9IdIHO£ 4, WHERE USE! ORIFICE CHECK VALVE Le PURPOS: To provide a different rate of Elow to and from a load piston CONSTRUCTION: Gheck valve without spring but with an orifice OPERATION Oil fron the supply vide moves the valve over and closes the draia port. Only a metered amount can pass through the orifice. When the flow reverses, the valve is moved to the left and uncovers the drain port, The discharge through the drain will be rapid. Power shift transmission hydraulic controls TROUBLESHOOTING MALFUNCT LON POSSIBLE CAUSE No pressure buildup Ay Cheek valve stuck, leaving drain open B. Orifice blocked Slow precsure relief A. Cheek valve stuck with the drain closed See aleo modulating volief valve (page 33). 36Newel YBONITAD AUNSS34d ONISNSS J9IAIO JAILOTLOWd TWOINVHOSW J1dWISSIMPLE MECHANICAL PROTECTIVE DEVICE 1, PURPOSE: Whenever pressure in a system drops below 4 minimum value for a length vf time, the selector is moved to a safe or neutral position. 2. BONSTHUETLON: Stationary piston with a spring-leaded cylinder 3. OPERATION: ie ofl that cones in through the red fills the space between the piston and the cylinder, As it compresses the spring, it allows free moverent of the selector spol valve. When the oi] pressure is Lost or the cngine 1s stopped, the spring moves the selector lever te neutral. A check valve in the piston allows quick charging during pressure inereases, but the oil in the cylinder can only Leak out ata controlled rate when the sensing pressure decreases. Therefore, the control doze not act vpon a short pressure drop (as could happen, tor instance when a gear is changed) « Power shift Cransmissions of soe early machines TROUBLESHOOTING MALRUNCTLOY POSSIBLE CAUSE ( Selector Lever cannet be moved into A. Linkage obstructed mechauically any gear B. Transwissien pump defect . Spring broken in modulating relief valve D. Piston and cylinder seized E. Passage for oft supply we protective device blocked ¥. Leaking protectice device Selector lever 1g not returned co feutral when the engine is stopped A. Tight Linkage or epoot valve B. Piston and cylinder of protective device seized C. Spring broken Selector lever jumps to lower A. TransniseLon punp has Low gear on deecleratiog the engine output , Suction sereca blocked Aeration in suction Line WwS3AWA TOULNOD SHNSS3¥d Woes ONIDYYHD NAHM 3DIAaa —_— dO LNSWZA0W BATWA “100dS gy TWNOLLOBHI wos BATWA 4D3HO NOILDANNOO HDLN 19 TWNOLLISMIT OL, JATVA 100dS HLIM J9IA50 SAILOILOUd TWOINVHOAWMECHANICAL PROTECTIVE DEVICE WITH SPOOL VALVE PURPOSE: When the oil pressure is low in the system, it prevents oil flow to the directional clutches. coustencrron: A simple mechanical protective device with spool valve OPERATION When there is no oil pressure, the piston is extended, making it impossible fer the speed selector to b= placed in any gear which also means that the passage (A) to (#) will be closed Mthen the device i charged, it compresses the spring vhich now gets shorter, so that a speed may be selected if desired, Should the engine be stopped with the selector lever in any gear, or the of1 pressure be Lost for any reason, the device pushes the spool valve to the left to Neutral position, which intercupts the passage (A) to (B). A check valve in the piston aliows quick charging during pressure imereaues, but the oil ia the cylinder cun only loak out at a controlled rate when the sensing pressure is lower. ‘Therefore, the control does not ect upon a short pressure drep (as could happen, for instance, when a gear is changed). WHERE _USEI over shift trauswissions of some early machines 39TROUBLESHOOTING MALFONCE LON POSSIBLE CAUSE Seluetor lever cannot be moved into any gear Selactor ig not returned to Neutral when the engine is stopped Selector Lever jumps to Lower gear on decelerating the engine A. Linkage obstructed wechanteally B. Transmission pump defect C. Spring broken in modulating relief valve D, Piston and cylinder seized Pagsage for oil supply te protective device blocked Leaking protective device A. Tight Linkage or spool vatve B. Liston and cylinder of protective device seized C. Spring brokea A. Transmission punp has low output Buction eereen blocked ; Aeration in suction line 40NOTES aTWangN NI AINO 3anssaud BATWA T00dS Wows ZENIT 4F71N9 To : a \ NOLLONNS Y3ZI1VHLNAN HLIM GANIGWO9 FATWA JAILOILOYd JITAVECAHRemsed 2/84 HYDRAULIC PROTECTIVE VALVE COMBINED WITH NEUTRALIZER FUNCTION PUROSE K. To pravent the nachine fron moving when the engine is started with the selector lever in a gear position 3. To neutralize the treasmission when the left brake pedal is depressed, in conjunction vith the neutralizer vaive cous rRUCT ro Spool valve with various lands; {a reset pusitioa, held by a spring to close the passage to the directicnal clutches a A. When the machine is started with the selector lever not in Keutral, ofl will not be able to get from passage (A) to (B) which eventually leads te the directional clutches. Placing the selector lever fa Neutral provides pressure from passage (©) which can reach cavity (2) through the orifice (1). In reaction, the valve Ls pushel to the left, opening the passage (A) to (8). If flow the selector lever is moved to Forward or Reverse, the increasing pressure at (A) can open the valve completely and wi have pressure at (@) and pressure in a directional elutch. BK, There is a connection fron the neutralizer valve to passage (D). In notwal operation, the valve closes this passage, but 1f the lett breke pedal is applied, (D) is connected to drain, wecause nore oil can drain out than gets inte cavity (E), the valve moves to che right Separating passages (A) and (B) but mot go far that the orifices (2) are covered by the land. This interrupts the power flow through the transmission. When the neutralizer valve 1s released, passage () will he blocked and the oil that entors the holes (2) shifts the valve open again. WHERE USEI Power SUIE£t transwission hydraulic contrels; for instance, 980 On scraper transmissions, a similar type of velve is used, but without the neutralizer function.TROUBLESHOOTING MALFUNe TION POSSIBLE CAUSE Machine moves vhen the engine is started with the selector lever in a gear position lachine dees not move vhen the selector is moved to Forward or Reverse a Direction clutch, linding Spool valve misad justed Combination valve sticking so that holes (2) communicate with (A) Spring of protective valve broken Linkage problem Weong spool valve adjustment Leak in the directional elaceb or in the line to it Protective valve sticking beutralizer valve icking Modulating relief valve spring broken Modulating relief valve stuck open Load piston of modulating relief valve stuek in the reset position ‘transmission pump failure Torque converter feilureNOTES 451 Ly VLE a Q \ N N N JATWA JONINDAS HLIM GINIGWOD SATIVA JAILISLOUd OFINVHGAHlL 4 HYDRAULIC PROTECTIVE VALVE COMBINED WITH SEQUENCE VALVE PURPOSE: K. To prevent the machine from moving vhen the engine is started with the selector lever ia a gear 8, To interrupt power flow chrough the transmission whea oil pressure ie toot CONSTRUCTION: ‘Two spring-loaded spool vatves. In reset position, the sequence valve closes the passage to the pressure control group and clutches. OPERATION A. When the engine is started with the selector lever in a gear, the reset Valve (not shown) does not allow punp pressure to enter at (A). ‘The protective valve remains at reset position aad the oil coming in at (2) goes to drain at the protective valve. There is not enough foree created in the slug cavity (1} to nove the sequence valve to the left. When the selector lever is muved to Neutral, the reset valve, which is mechanically connected to it, allows pressurized oil to enter passage (A). This moves the protective valve to the left and closes the drain port, The oil entering passage (B) builds up pressure and the reaction in slug cavity (1) moves the sequence valve to the left. The of1 now has the passage open and eil can flow fron (B) to (C). &B. Lf the engine is stopped or if the ofl pressure drops below a safe level, the protective valve spring forces the valve spool over to the right, relieving the pressure in the slug cavity (1) to drain. The sequence valve is then forced to the right Ly ite epring and separates the passage (B) to (C). Whea the engine is started or the pressure regained, the selector lever must be moved to Neutral position first in order to reseu the protective valve and open the paesage (B) to (C) by the sequence valve. WHERE USED: Power shift transmission hydraulic controls (for instance, 988, 992, B24, 834) a7TROUBLESHOOTING MALPUNCTION PROBABLE CAUSE, Nachine moves when the engine is started with the selector Lover io gear Uachine deas not move hen the selector lever is moved to Forvard or Reverse from Neutral F, Directional clutch bindiag Reset valve misad justed Protective valve seized at the left position Protective valve spring broken Sequence valve stuck open Sequence valve spring broken Reuet valve misal jucted Spool valves misadjusted Leak tm the directional clutch or line to it Cluteh failere Protective valve sticking in reset position Sequence valve sticking in reset position Passage to slug cavity (1) blocked Modulating relief valve spring broken Hodulating relief valve stuck open Load piston of modulating relief valve stuck in reset position Neutralizer valve stuck in applied position ‘Teansmission pump failure Torque converter failure 48NOTES 49a | $891aIdO SHL 40 NOLLUSOd MOHS OL MIA S3HOLNT2 TWNOLLOZaI0 OL Nivaa Nive VE Mt a NS ONLLYINGON SHL JO NOLSI¢ GVO OL BOVSSVE Ll J I BATVA 100d ao1sNo TWNOLLOSIG OL JOvSSvd + SAQWA 4SNBZY ONILVTNAON WoHA TiO FATWA NOLLYNIGWODCOMBINATION VALVE PURPOS! Ay Protective valve B. Differential valve C, Flow control valve Dd. Check valve cous nevettow: Valve with metering orifices loaded by two springs of which only one 4S in contact in reset position. Passages to or from the modulating relief valve, the directional epool valve, the load piston of the directional spool valve, directional elutches and drains, OPERATION: A. Protective Valve When the engine is started with the transmission selector lever noi in the Neutral posiiion, system pressuce will now only eater passage (A), but, also, due Co che selector lever position, will enter passage (B) where it can pass through the holes (2). Having equal pressure on both sides of the spool, the spring will keep it in the reset position ond passage (C) cannot receive oil. The machine can’t move. loving the selector lever to Neuteai connects passage (B) to drain the selvetor valve group, O11 entering passage (A) now aoves the valve uatil it relieves into pessage (2). The load piston of the modulacing relief valve is connected to drain via (C) or (F) depending upon the application. This establishes the primary pressure in Neutral. B. Differential valve Tf the selector lever is taken out of the Neutral position, passage (B) is again connected to pump flow and system pressure. ‘This same pressure enters passage (A). Wow the valve can move to the right to sequence the clutch engagement. The difference between the speed and directional clutch pressures is controlled by the combined force of the tvo springs, Flow Control valve The size of the orifices (1) allows only a specific amount of vil to pass theough into the directional clutches during filling. D. Cheek Valve Passage (D) is blocked when the valve works, as explained under B. This allows pressure buildup behind the load piston of the wodulating relief valve, In Neutral position of the spool valve, and when gears are changed, passage (3) is connected to drain (C) or (#) (depending on the application) whieh quickly lowers the systen pressure. MMRE USED: Sone power shift transmission contrels (for instance, 12 & 14 Hotor Graders, 966C, 950, D4D, 941, 951B) Bo oil can pasa through orifices (1) ia the Neutral position, StTROUBLESHOOTING MALEUNCTION POSSIBLE CAUSE, Machine moves vhen engine is started with selector lover in a gear position Machine does not move when the selector is moved to forvard or reverse or from Neutral tc a speed Rough shifting Linkage problen Wrong epool valve adjustment Directional clutch binting Combination valve stuek in a position so that holes (2) are open to passage (Cc) Linkage problem Wrong spool valve aéjustnent Leak in the directional clutch or the passage to it Combination valve stuck in reget position Modulating relief valve spring broken Hodulating relief valve stuck open Load piston of modulating relief valve stuck in ceset position ‘Transmission pump failure Binding clutch plates Combination valve sticking 52NOTES 53BAWA JALLOaLOHd OL iii LZ YZ dWnd WOH JATWA 1494 JAILISLOUdPROTECTIVE RESET VALVE 1. PURPOSE, To prevent the machine fran moving when the engine is started with the selector lever in @ gear 2, cons TRUCTIO Normal spool valve; mechanically connected to the speed control spvol valve 3. OPERATION Only in Neutral position can pump oil enter the passage to the protective valve spool to reset it. 4. MERE seo: Power shift transmission hydraulic controls (for instance, 988, 992, 824, 834) TROUBLESHOOTING MALFUNCTION PROBABLE CAUSE, Machine meves shea the engine is Protective reset valve Started with the selector in a misad juoted gear position Machine does not move vhen the A, Protective reset valve selector lever is moved to misad justed Forward or Reverse out of Neutral Nore: For further troubleshooting hints, see Protective Valve combined with Sequence Valve (page 47)+ 55JATWA YAZIIWHLNANNEUTRALIZER VALVE 1. PURPOS! To cut off the o11 flow to the directional clutcnes in a power shift transmission when the left brake pedal is depressed 2. CONSTRUCTION. A spool valve is held by spring force in such a position that the oil going to the clutches has a direct passage through to the dixectional clutches, 3, OPERATION Tn the reset position, the oil can pass straight through to the directions) clutches. when the left brake 4s applicd, oil or air pressure shifts the valve over and, in so doing, blocks the passage to the directional clutches and cpens the clutch to drain. This will interrupt the pover flow through the transmission, 4. MERE USE Power shift transnissions of wheel loaders TROUBLESHOOTING MALFUNCTION POSSIBLE CAUSE ‘Transmission does not neutralize A. leak in of! or air Line of brake system Neutralizer valve sticking ep Mechanical failure in transaiseion Transmission does noe transmit power 3. Torque converter failure Modulating xelief valve sticking D. Neutralizer valve sticking in applied position Srcken neutralizer valve spring 57S100dS BATWA ONIDNGSH (ONINOON|) BUNSS3IAd g BATWA ONISNGSa LaIHSNMOO YONYSACD LIIHS JNINVYCAH 58HYDRAULIC SHIFT GOVERNOR PURPOSE : Depending upon cransmissiea curput shaft rpm, varlable pressures are eveated -- working againet the reference prosoures. cousteuCtioN: Rotating Rousing with 3 reducing valve speols of different veights. Two of the valve spools coatain slugs which are different in size, OPERATION: Basically, each of the 3 reducing valve spools represents a normal reducing valve. Since the whole governor rotates, the reducing valve spools are subject to centrifugal force. The centrifugal force replaces the spring action ia a normal reducing valve because it is trying to open the incoaing pressure to the outlet side. The outlet pressure, as in a notmal reducing valve, 1s acting to close eff the inlet when it hus resched a certain valus. Due to the design of the reducing valve spools, there are various outlet pressures produced at any given speed. The pressures are not adjustable, These pressures work agelnse a fixed reference pressure in the selector valve spool group (not chon). WHERE USED: Hydrdulic controls of semiautomatic scraper transmissions TROUBLESHOOTING WALFUNCT ION POSSIBLE CAUSE ‘Transmission does not automatically A. One of the three reducing valve shift up at all or stops shifting up spools is stuck, closing off the at 4th or 6th speed incoming pressure Transmission selects 4th, Sth or Bth A. One of the 3 reducing valve speed as soon as the shift lever is spools is stuck in a position placed into the secend gear so that the inconing pressure goes directly to the ourlet side csPRIORITY VALVELe PURPOSE PRIORITY VALVE fo make sure thet oil is supplied to a particular circuit before it is permitted to flow to a second cirenit 2, QONSTRUCTIOT The most basic priority valve group has one inlet and two outlet passages. There are wevoral variations of this design, but the results of valve operation are the same for all types, 3. OPERATION. Supply Of1 eaters the inlet passage and flows to the primaxy circuit, At the same time, tho oil opens the poppet valve and fills the slug chamber. When the pressure of the oil in the primary circuit and in the slug chamber Increases to a specific value, the spool moves against the spring force and permits oil to flow to the secondary circuit. A peessure decrease (during a shift for example) will cause the valve to close and block flow te the secondary circuit. 4. MHRRE USED: Trans@ission hydraulic controls ~ L Series Tractors, 8-speed seniautanatic transmissions, and J-speed automtie transmissions 5. WHY USE a. Ls eres Tractor trausmissions —- to make sure that oil is available for operation of the steering clutches and brakes before any traneniesion clutches aze engaged B. G-speed seniautomatic and 7-speed automatic transmissions -- to nake sure that oil is available for opecation of the autonatic components (automatic pressure coatrol group, hydraulic governor, and autonatic sclector group) before any trensoission clutches are engaged TROUBLESHOOTING MaLYUNe TION POSSIBLE CAUSE CORRECTION Transaission clutches do not engage Transmission clutches slip during engagement Brakes release slowly or not at all (L Series) A. Valve stuck closed B. Opening pressure too nigh A. Valve stuck open B, Opening pressure too Low Restriction or blockage in primary circuit Free valve in bore Adjust pressure setting (renove shins) or replace spring Free valve in bore Adjust pressure setting (add shins) or roplace spring Determine cause of restriction or blockage and remove 61Wo 1N3130—~ (anoig jonuog aunssaig OL) $LYOd LATLNO ATEWAaSSY N3a¥OS pue Sd 100d$ HOLOITIS AYVLOU Joos 62ROTARY SELECTOR SPOOL PuRPOS' Directs the flow of pilot oil to initiate cluten engagement; provides drain ports to initiate clutch decay and prevent clutch engagement 2. CONSTRUCTION The rotary selector spool is basically a rotating shaft with a hollow center. A plug and screen assenbly divides the centet cavity into two seperate chambers, Adetent cam 15 installed in one end of the spool. 3. QPERATION The center chamber which houses the screen is normally filled vith pilot ofl. the chamber which does mot contain the screen is always open to drain, when the spool is rotated to a gear position, pilot oil from the outlet ports is directed to a pressure control valve group to initiate engagement of the appropriate clutches. At the sane tine, the drain ports cause the clutches which were engaged in the preceding gear ange to decay. The detent cam helps to locate each gear position of the spool. 4. WHERE USED: ALL S-speed semiautomatic transmissions with Indiyidial clutch nodulation (Tet) MALFUNCTION POSSIBLE CAUS CORRECTION Transuission remains | A. Spool stuck in one Free valve in bore ina particular geat position ‘Trangeiccion clutches | A. Seraen in pilot Disassenble valve group do not engage chamber plugged and ¢lean screen B. Pilot chamber outlet | Disassemble vaive group ports plugged and clean ports More than two clutehes | A, One or more drain Disassenble valve group try to engage ports plugged and clean ports 63ONtHds HOLD, SWINIVLAY, Ataans 3014140 Niwa Avoad aHINO NIVHO NOLSid d¥OT \ \ SA f \, S x ‘ X 5-9,0,0,0, tas NOASId ae ae e wososnas A oar eas E a vanoo_-—" J uB1No wa pm Noasld aATWA avo7 401s WOH TIVE nig Wa SONIUdS aoe Nivea NOISIED¥OT Angus anda JATWA 9NIONGSY {joods 10120105 M$ Lrroy wo) To Loud (NOILVLS JATWA NI NMOHS) JAVA SNIONGSY ONILYINGOW dOLS ONIudS waNNI 64MODULATING REDUCING VALVE (SHOWN IN VALVE STATION) puRves! Controls the pressure rise, maximum pressure, and rate of decay for a specific transmission clutch cons TRUC TION: Tho wodulating reducing valve congists of a spool, a ball check valve, a slug, a load piston, two load piston springs, and a load piston orifice. In the application shova, the modulating reducing valve is part of a "valve station." The additional components in a valve stetion include: an outer cover, a selector piston, and a decay orifice, Soue modulating redueing vaives are equipped as shown with a pin in the center of the load piston springs; other valve groups do not have the pin, OPERATION: Kftor start-up, supply oil ie aluaye available at the reducing valve spool. Valve movement and clutch engagenent cannot begin, however, until pilot oi1 fron the rotary selector spool moves the selector piston to the left. ‘oveaent of the selector piston accomplishes two purposes: (1) the drain passage at the decay orifice 1s blocked, and (2) the load piston springs are compressed. Conpressiny the lead piston springs moves the relucing valve spool te the left against the force of the inacr spring. This opens the supply passage (from the pump) and permits pressure oil to flow to the clutch. As the clutch Fills, presoure o1f opens the bsll chuck valve and fills the slug chanber at the left end of the reducing valve spool. At the same tine, oil flows through the load piston orifice and fills the chamber between the end of the load piston and the selector piston. The load piston orifice previles a pressure drop and tine delay in the flow of of] £0 the Load piston chamber. This helps control the rate of modulation. Filling the load piston chavber is nade possible when the selector piston covers the drain passage at the decay orifice. The clutch preosure ané the pressure in the slug chamber increase at the sane tate. Just #fter the clutch is filled, the pressure in the slug chamber moves the reducing valve spool to the right. This movement restricts the flow of pressure oil to the clutch and briefly linits the increase of clutch pressure, The pressure in the load piston chamber then aoves the load piston further to the left. This increases the spring foree and reopens the supply passage perwitting the clutch pressure to again increase. This cycle continues until the load piston has moved completely to the left (agains: the stop). The clutch pressure is then at its maximum setting. Durdug modulation, the reducing valve spool moves left and right witle tne load piston noves sneothly to the left. As the clutch pressure imercases to maximum, the operation of valve statins that are equipped with a pin in the center of their load piston springs is slightly different than te operation of stations that do net bave pins. Wear the ond of the modulation cycle, the pin contacts the reducing valve epeol, twoves the spool completely to the left, and opens the clutch passage to supply oil, At this point, modulation ends and the clutch pressure —Inaediately increases to the mexinum, During the time that che clutch is engaged, the reducing valve spool remains completely to the left (as shown) and the clutch pressure is equal to the system pressure. valve stations that do not have pins in the center of their load piston springs control cluteh pressure settings that are lower than the systen pressure, At the end of the modulation cycle, the pressure in the slug chamber moves che reducing valve spool a small distance co the eight co restrict the flow of supply oil to the clutch. This is the Yactering position” of the reducing valve spool. In this position, the valve maintains precise control of the clutch pressure. Durtug @ shift, che pressure of a clutch being disengaged does not immediately drop to zero. Instead, the clutch pressure decreases at a controlled rate. Clutch release (decay) is initiated when the pilot oil chamber at the right end of the selector piston is dcained. This pemits the selector piston and the load piston to move to the right. Clutch pressure starts to decrease, but cansot drop to zere until the chamber betwoea the load piston and the selector piston is drained. The only way that of] can flow out of this chamber is through the decay orifice which was uncovered when the selector piston moved to the right. As the load piston springs force the oil from the load piston chamber, the clutch pressuxe graluslly decreeses. When the loed piston has noved completely to the right, the clutch pressure is zero. WMERE US ALL S-speed semiautomatic transmissions with Individual clutch modulation (rat)TROUBLESHOOTING MALFUKCTION POSSIBLE CAUSE comREG TION Clutch slips during engagenent One er more cluzches do not engage ‘Tranamission shifts harshly Ey Low clutch pressure setting Partially restricted load piston orifice Pilot pressure low or at zero Restricted Joad piston orifice Reducing valve spool stuck closed Selector piston stuck in bore Load piston stuck in selector piston igh eluteh pressure setting Reducing valve spool atuck open Adjust prossure setting (add shims) or replace springs Glean or replace load piston orifice Check operation of priority reducing valve and neutralizer valve; Check for partial restriction of pilot oil supply port and passage Gleaa or replace Load pistan orifice Free spool in valve body Free selector piston in outer cover Free load piston Adjust pressure setting (remove shins) or replace springs Free spool in valve botyNOTES