Tractor Manuals Scotland

MELROE
HYDRAULIC
CONTROL
VALVE

COMPONENT REPAIR MANUAL

MELROE
INGERSOLL-RAND
© Melroe Company 1989
6570041 (6-89) Printed in U.S.A.
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INDEX

HYDRAULIC CONTROL VALVE INDEX

MODELS SIN TAB SECTION MANUFACTURER

443 All 1 A Melroe

540, 640 13001 & Above 1 A Melroe

740, 843 15001 & Above 1 A Melroe

I 750 Series

853
All

All
5

5
A

A
Melroe

Melroe

1213 All 4 A Melroe

1600 12001 & Above 1 A Melroe

2000 13001 & Above 1 A Melroe

2000 RTF All 1 A Melroe

2400 All 2 A Melroe

2400 Series Rear Aux. All 3 A Gresen

2410 All 5 A Melroe

Glossary of Terms TAB #6

Hydraulic Control Valve

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HYDRAULIC CONTROL VALVE

CONTROL VALVE
Centering Mechanism 10
Detent Assembly 6
Disassembly and Assembly 5
Inspection 11
Installation of the Centering Spring 12
Orifice 11
Valve Spool Stud 12

CONTROL VALVE IDENTIFICATION

Chart 2

IDENTIFICATION & INSTALLATION OF SPOOL SEAL

No Chamfer 13
Notch for Seal 14
Short Chamfer 15
Long Chamfer 16

TAB 1 Control Valve

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Revised Aug. 92
Component Repair Manual

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MELROE
INGERSOLL-RAND

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Gl
LIFT

TILT

AUX.
G4

OUTLET PORT

8-6283 8-6757

Fig. 1 Melroe Valve for Farmboy, 443, 540 and 640 Series Loaders Fig. 2 Melroe Valve for 740 and 843 Series Loaders

LIFT Gl
TILT
TILT
G2
LIFT G2
AUX. G3
AUX. G3

OUTLET PORT
OUTLET PORT

8-6758 8-6759

Fig. 3 Melroe Valve for 1600 Series Loaders * Fig. 4 Melroe Valve for 2000 Series Loaders

MR

LIFT

TILT

AUX.

8-5762

Fig. 5 Melroe Valve for 2000 RTF

Control Valve
* Revised
0134005
Oct. 87 -2- Component Repair Manual

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CONTROL VALVE IDENTIFICATION (Cont'd)

BOBCAT MODEL

farmboy 440 540, 640 740,843 1600 2000 2000 RTF

Item Fig. 4
Fig. 1 Fig. 1 Fig. 1 Fig. 2 Fig. 3 Fig. 5

Lift Cylinder Tilt Cylinder

A-1
Rod End Rod End

Tilt Cylinder Tilt Cylinder Tilt Cylinder Lift Cylinder

A-2
Base End Rod End Base End Rod End

Auxiliary
Auxiliary Rear Auxiliary Auxiliary
A-3 Hydraulics
Hydraulics Hydraulics Hydraulics
(Optional)

Front Auxiliary
A-4
Hydraulics

Lift Cylinder Tilt Cylinder

B-1
Base End Base End
W/Orifice W/Orifice

Tilt Cylinder Tilt Cylinder Tilt Cylinder Lift Cylinder

8-2
Rod End Base End Rod End Base End

Auxiliary
Auxiliary Rear Auxiliary Auxiliary
8-3 Hydraulics
Hydraulics Hydraulics Hydraulics
(Optional)

Front Auxiliary
8-4
Hydraulics

Load Check Valve Load Check Valve

C-1
Lift Function Tilt Function

Load Check Valve Load Check Valve

C-2
Tilt Function Lift Function

Load Check Loader Check Load Check

C-3 Valve Valve Valve
Auxiliary Function Rear Auxiliary Auxiliary Function

Load Check
C-4 Valve
Front Auxiliary

0-1 Lift Spool Tilt Spool

0-2 Tilt Spool Lift Spool

Auxiliary
Auxiliary Spool Rear Auxiliary Auxiliary Spool
0-3 Spool
Spool
(Optional)

Front Auxiliary
0-4
Spool

Control Valve
00
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TAB 1 -3- Component Repair Manual

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CONTROL VALVE IDENTIFICATION (Cont'd)

BOBCAT MODEL

farmboy 440 540, 640 740,843 1600 2000 2000 RTF

Item
Fig. 1 Fig. 1 Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5

Anti-Cavitation Port Relief

E-1
Valve Valve

Anti-Cavitation
E-2
Valve

E-3 Plug

E-4 Plug

MR Main Relief Valve

F-1 Plug Port Relief Valve

Anti-C avitation Port Relief

F-2
Valve Valve

F-3

F-4

Centering
Centering Spring
G-1 Spring Detent, Lift Spool
Tilt Spool
Lift Spool
Centering
Centering Spring Detent
G-2 Spring
Tilt Spool Lift Spool
Lift Spool
Centering Centering Centering
G-3 Spring Detent, Auxiliary Spool Spring Detent, Auxiliary Spool Spring
Aux. (Opt.) Auxiliary Spool Auxiliary Spool

Detent
G-4
Spool

Control Valve

0134005 Component Repair Manual

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CONTROL VALVE

Disassembly and Assembly

See the Service Manual for your Model loader for removal and
installation of the control valve.

The 3-spool and 4-spool valves are used in different Model

loaders. The port relief valves, anti-cavitation valves and plugs
are at different locations in the control valve. Lift and tilt spools
can also be in different bores. Refer to pages 2 and 3 for the
correct locations of the parts for each control valve.

NOTE: THE ILLUSTRATIONS MAY NOT SHOW THE EXACT

LOCATION FOR THE PART YOU ARE REMOVING OR 8-5833
INSTALLING ON THE CONTROL VALVE, BUT THE
PROCEDURE IS THE SAME.
1. Relief Valve
2. O-Ring
3. Back-Up Washer
4. O-Ring

2
When making repairs on hydrostatic and hydraulic
systems, clean the work area before disassembly and
keep all parts clean. Always use caps and plugs on Iii
hoses, tubellnes and ports to keep dirt out. Dirt can
quickly damage the system. 0-1-0
1-2003-0284

E-1509

Mark each valve section and spool so that the parts will be 1. Anti-Cavitation Valve
returned to its original bore during assembly. Use bolts to fasten 2. O-Ring
the control valve to a work bench for easier disassembly and 3. Back-Up Washer
assembly. 4. O-Ring

Remove the load check valves (Item 1) from the top of the valve
rJc"Ports) ~.

2 3 4
Remove the following parts from the detent and spool linkage
sides of the control valve (IIF" & "E" Ports):
I
I I
1. Port Relief Valve [[].
-0-0-0
2. Anti-Cavitation Valve ~. E-1509
3. Plug~.

Remove the O-rings and back-up washers. 1. Plug

2. O-Ring
Assembly: Always use NEW O-rings and back-up washers. 3. Back-Up Washer
Tighten to 35-40 ft.-Ibs. (47-54 Nm) torque. 4. O-Ring

2 3 4
I II
-0-0-0
E-1509

Control Valve
TAB 1
0134005 -5- Component Repair Manual

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CONTROL VALVE (Cont'd)

: 324 5
Remove the main relief valve from the control valve ~.

Assembly: Always use NEW O-rings and back-up washers.

Tighten to 35-40 ft.-Ibs. (47-54 Nm) torque.
_-~O-o-d-
E-1509

1. Plug
2. O-Ring
3. Back-Up Washer
4. O-Ring
5. Back-Up Washer

Remove the screws (Item 1),rubber boots (Item 2), boot retainer
(Item 3) and filter (Item 4) from each spool [!].

Assembly: Tighten the screws to 90-100 in.-Ibs. (10-11 Nm)

torque.

e
1. Screw
2. Rubber Boot
3. Retainer
4. Filter Washer
5. Back-Up Washer
(Later Models Only)
Detent Assembly 6. O-Ring
8-6889
The tool listed will be needed to do the following procedure:

MEL-1278 - Detent Tool

Use the following procedure to remove and disassemble the

detent assembly.

Remove the snap ring and washer [g.

Remove the screws for the detent cap ~.

Assembly: Tighten the screws to 90-100 in.-Ibs. (10-11 Nm)

torque.

Remove the detent cap.

The detent assembly has small springs and balls. Do

not loose these parts during disassembly and assembly.
1-2012-0284

Remove the detent sleeve, detent balls and springs.

Control Valve
-6-
TAB 1
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CONTROL VALVE (Cont'd)

Remove the centering spring bolt ~ .

NOTE: Carefully remove the centering spring bolt, because

there is spring pressure.

Remove the spool from the bore.

Assembly: For installation of the centering spring (See Page

12 for the correct procedure).

8-6450

Remove the front and rear quad rings [!].

Use the following procedure to assemble the detent assembly.

Install a NEW quad ring into the groove in the front of the control
valve [g.

I NOTE: SEE PAGES 13, 14, 15 or 16 for seal and valve

identification.

Install the valve spool into the control valve from the rear of
the control valve. Push the spool into the valve just far enough
so that the rear quad ring can be installed [Q].

TAB 1 Control Valve

0134005
Revised Aug. 92 -7- Component Repair Manual

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CONTROL VALVE (Cont'd)

Install a NEW quad ring in the rear of the control valve ~.

Push the valve spool back into the control valve until it is even
with the rear machined surface of the control valve.

Put the detent adapter into a vise.

Install the detent spring ~.

Put grease on the jaws of the detent tool. Put the detent balls
on the jaws of the detent tool ~.

Hold the detent balls in position. Install the spring end cap over
the detent adapter ~.

Remove the detent adapter and spring cap assembly from the
vise.

Install the centering spring and the other spring cap on the spool
and tighten the bolt to 90-100 in.-Ibs. (10-11 Nm) torque.

NOTE: To replace the valve spool stud (See Page 12 for the
correct procedure).

8-9293

Control Valve

0134001
TAB 1 -8- Component Repair Manual

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CONTROL VALVE (Cont'd)

NOTE: Lift and Auxiliary Detent Sleeves are different:

Lift Detent Sleeve Bore Depth is 1.160" (29,5 mm).
Auxiliary Detent Sleeve Bore Depth is 1.061" (26,9
mm).

Install the detent spring into the detent adapter ~.

Hold the detent balls in position with the detent tool and slide
the sleeve into position 00.

Install the detent cap. Tighten the screws to 90-100 in.-Ibs. (10-11
Nm) torque.

B-9297
Install the washer and snap ring ~.

Control Valve
TAB 1 -9- Component Repair Manual
0134005

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CONTROL VALVE (Cont'd)

Centering Mechanism

Use the following procedure to disassemble and assemble the

centering mechanism.

Remove the screws from the cap ~.

Assembly: Tighten the screws to 90-100 in.-Ibs. (10-11 Nm)

torque.

A WARNING
Wear safety glasses to prevent eye injury when any of
the following conditions exist:

• When fluids are under pressure.

• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

Remove the cap. Remove the centering spring bolt I!].

Assembly: Tighten the centering sprinq bolt to 90-100 in.-Ibs.

(10-11 Nm) torque.

NOTE: Carefully remove the centering spring bolt, because 1. a-ring 4. Centering Spring
there is spring pressure. 2. Bushing 5. Spring Cap
(Early Models) 6. Adapter
3. Spring Cap 7. Bolt

Remove the spring caps, spring and adapter [g.

Assembly: For correct installation of the centering spring (See

Page 12 for the correct procedure).

Remove the spool from the bore.

Remove the front and rear O-rings.

Install the front quad ring into the groove ~.

NOTE: See Pages 13, 14, 15 or 16 for seal and valve

I indentification.

TAB 1 Control Valve

Revised Aug. 92 -10- Component Repair Manual
0134005

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CONTROL VALVE (Cont'd)

Install the valve spool into the valve from the rear of the control
valve ~.

Push the spool into the valve just far enough so the rear quad
ring can be installed.

Install the rear quad ring ~.

Push the spool back into the control valve until it is even with
the rear machined surface of the valve.

Install the centering mechanism.

Orifice

Some Model loaders use an orifice in a top port. Use the

following procedure to remove and install the orifice (See Page
2 and 3 for the correct location).

Loosen the orifice hex nut ~.

Installation: Tighten the orifice hex nut to 90-100 in.-Ibs. (10-11

Nm) torque.

Remove the hex nut and orifice ~.

8-6442
Inspection

Check the spools for scratches or wear.

Check that the spools are not loose in their bores.

Check that the centering springs are not broken.

Check that the load check valve seats are not worn.

Check the load check poppets for damage.

Check the rubber boots, boot retainers and filters that they are
not worn or damage.

Replace the parts as needed.

8-6443

Control Valve
-11- Component Repair Manual
0134005
TAB 1

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CONTROL VALVE (Cont'd)

Installation of the Centering Spring

The tool listed will be needed to do the following procedure:

MEL-1285 - Valve Spring Holding Tool

Put the washer and collar in the ends of the spring.

Compress the spring assembly and install it into the holding tool
~.

8-9504

With the tool in position over the spring, assemble the spring
to the spool using an allen wrench lID.
When assembly is completed, remove the tool.

8-9503


Valve Spool Stud

Install the plastic plug (lift spool only).

Install the stud and leave about 0.60" (15,2 mm) of the stud
sticking out ~.

NOTE: DO NOT use loctite on the threads.

Plastic Plug
Assemble the centering spring and washers and install detent
adapter.

8-9973

Tighten the adapter to 90-100 in.-Ibs. (10-11 Nm) torque [Q].

Control Valve
TAB 1 -12-
0134556
Component Repair Manual

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IDENTIFICATION & INSTALLATION OF SPOOL SEAL

There are two types of seals for the control valve, a quad-ring
seal and a lip seal. First identify the control valve (See Page 13, CUT AWAY SIDE VIEW
14, 15 or 16) to find which seal is used. See the Parts Micro- OF VALVE BODY
Fiche for your model loader for the part number of the quad-
ring seal or the lip seal used. Use the following procedure to MC-1699

install the seals into the control valve. QUAD-RING SEAL

NO CHAMFER

1. Uses only quad-ring seal.

2. Check the seal surface area for rust, corrosion, scratches, NO CHAMFER
etc. Correct any irregularities before continuing. De-burr the
sharp edge at the seal area (both ends).

3. At the linkage end of the spool, de-burr the groove for the
rubber boot as needed.

NOTE: Lubricate with grease between the seal and retainer

before installation (both ends).

4. Put clean oil on the valve spool. Install the quad-ring seal
over the valve spool. Be Careful not to damage the quad-
ring seal on the valve spool edges. MC-1606

NOTE: An alternate method to protect the quad-ring seal by

putting plastic material (Example: Discarded micro-
fiche card) over the spool to protect the seal.

5. Install spool into the valve bore.

6. Slide the linkage end quad-ring seal over the rubber boot
groove. Be Careful not to damage the seal.

7. Install the quad-ring seal retainer.

8. Continue with assembling the control valve.

INSTALLING QUAD-RING
SEAL ON VALVE SPOOL

INSTALLING QUAD-RING
SEAL REATINER

Added Aug. 92 Control Valve

TAB 1
0134115 -13- Component Repair Manual

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IDENTIFICATION & INSTALLATION OF SPOOL SEAL (Cont'd)

NOTCH FOR SEAL CD

NOTE: This control valve (with the notch for seal) must be
removed from the loader for the quad-ring seal
installation. CUT AWAY SIDE VIEW MC-1699

OF VALVE BODY QUAD-RING SEAL

1. Uses only quad-ring seal.

2. Check the seal surface area for rust, corrosion, scratches,

etc. Correct any irreqularities before continuing.

3. The detent mechanism or centering spring must be removed

from the valve spool.

4. At the linkage end of the spool, de-burr the groove for the NOTCH FOR
rubber boot as needed.
SEAL
5. Install the quad-ring seal into the notch in the linkage end
of the control valve.

6. Put clean oil on the valve spool. Install the spool into the
valve from the rear end (centering spring or detent
mechanism side). Be Careful not to damage the quad-ring
seal, already installed, when going over the groove for the
rubber boot. Push the spool into the valve just far enough
so that the rear quad-ring seal can be installed.

7. Install the quad-ring seal in the rear groove of the valve.

8. Push the valve spool back into the control valve until it is
even with the rear machined surface of the valve.
DE-BURR EDGE ::x MC-1606


9. Continue with assembling the control valve.

INSTALLING FRONT
QUAD-RING SEAL

INSTALLING SPOOL

Added Aug. 92 Control Valve

TAB 1 -14- Component Repair Man~al
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IDENTIFICATION & INSTALLATION OF SPOOL SEAL (Cont'd)

SHORT CHAMFER CD
1. Uses only quad-ring seal. CUT AWAY SIDE VIEW
OF VALVE BODY
2. Check the seal surface area for rust, corrosion, scratches,
MC-1699
etc. Correct any irregularities before continuing. De-burr the
sharp edge at the seal area (both ends). QUAD-RING SEAL

3. At the linkage end of the spool, de-burr the groove for the
rubber boot as needed.
DE-BURR
NOTE: Lubricate with grease between the seal and retainer
SHARP EDGE
before installation (both ends).

4. Put clean oil on the valve spool. Install the quad-ring seal
over the valve spool. Be Careful not to damage the quad-
ring seal on the valve spool edges.

NOTE: An alternate method to protect the quad-ring seal by +-0.060" (1,5 mm)
putting plastic material (Example: Discarded micro-
fiche card) over the spool to protect the seal.

5. Install spool into the valve bore.

6. Slide the linkage end quad-ring seal over the rubber boot MC-1606
groove. Be Careful not to damage the seal.

7. Install the quad-ring seal retainer.

8. Continue with assembling the control valve.

INSTALLING QUAD-RING
SEAL ON VALVE SPOOL

Added Aug. 92 Control Valve

TAB 1
0134556 -15- Component Repair Manual

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IDENTIFICATION & INSTALLATION OF SPOOL SEAL (Cont'd) LIPS FACE

TOWARD
LONG CHAMFER
VALVE BODY

1. Uses only lip seal.

2. Check the seal surface area for rust, corrosion, scratches, CUT AWAY SIDE VIEW
etc. Correct any irregularities before continuing. OF VALVE BODY

3. Put clean oil on the valve spool. Install the lip seal over the
valve spool, Be Careful not to damage the lip seal on the
valve spool edges.

NOTE: An alternate method is to protect the lip seal by putting

plastic material (Example: Discarded micro-fiche
card) over the spool to protect the seal.

4. Install spool into the valve bore.

NOTE: Lubricate with grease between the seal and retainer

before installation (both ends).

5. Slide the linkage end lip seal over the rubber boot groove.
Be Careful not to damage the seal.

6. Install the seal retainer.

7. Continue with assembling the control valve.

INSTALLING LIP
SEAL ON VALVE
SPOOL

Added Aug. 92 Control Valve

0134556
TAB 1 -16- Component Repair Manual

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CONTROL VALVE INDEX 2400

CONTROL VALVE
Auxiliary Section 3
Disassembly and Assembly 2
Inspection 8
Installation of the Centering Spring 8
Lift Section Detent Disassembly and Assembly 5
Tilt Section 7
Valve Spool Stud 8

CONTROL VALVE IDENTIFICATION

Chart 1

1D~~:~I~~:I~~r~ .I~~~~~~~~I~.N. " ~~~~~ .~~~~~ 9

1 Long Chamfer 10

TAB 2 Control Valve

0134556
Revised Aug. 92 Component Repair Manual

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0134551

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2400
ITEM FUNCTION

A1 Tilt Cylinder Rod End

A2 Lift Cylinder Rod End

A3 Auxiliary Hydraulics

B1 Tilt Cylinder Base End

B2 Lift Cylinder Base End

B3 Auxiliary Hydraulics

C1 Load Check Valve - Tilt

C2 Load Check Valve - Lift

C3 Load Check Valve - Auxiliary

01 Tilt Spool

02 Lift Spool

03 Auxiliary Spool - Solenoid

E1 Port Relief - Tilt

E2 Port Relief - Lift

F1 Anti-Cavitation - Port Relief

F2 Port Relief

G1 Centering Spring - Tilt Spool

G2 Centering Spring - Lift Spool

G3 Centering Spring - Solenoid

MR Main Relief Valve

Control Valve
0134556
TAB 2 -1- Component Repair Manual

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CONTROL VALVE

Disassembly and Assembly

See the Service Manual for your Model loader for removal and
installation of the control valve.

The port relief valves, anti-cavitation valves and plugs are at

different locations in the control valve. Lift and tilt spools can
also be in different bores. Refer to Page 1 for the correct
locations of the parts for each control valve.

IMPORTANT
1. Relief Valve
2. a-Ring
When making repairs on hydrostatic and hydraulic
3. Back-Up Washer
systems, clean the work area before disassembly and
4. a-Ring
keep all parts clean. Always use caps and plugs on
hoses, tube lines and ports to keep dirt out. Dirt can
quickly damage the system.
1-2003-0284
2

Mark each valve, plug and spool location so that the parts will
be returned to its original bore during assembly. Use a vise or
I i
O-@-O
I
bolts to fasten the control valve to a work bench for easier
disassembly and assembly. E-1509

Remove the load check valves (Item 1) from the top of the valve
ric" Ports) [!]. 1. Anti-Cavitation Valve
2. a-Ring
3. Back-Up Washer
4. a-Ring
Remove the following parts from the detent and spool linkage
sides of the control valve r/F" & "E" Ports):

1. Port Relief Valve [ID.

2. Anti-Cavitation Valve ~.
2 3 4
3. Main Relief Valve [Q].

Remove the O-rings and back-up washers.

I I I
Assembly: Always use NEW O-rings and back-up washers.
-0-0-0
Tighten to 35-40 ft.-Ibs. (47-54 Nm) torque. E-1509

Control Valve
TAB 2
0134556 -2- Component Repair Manual

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CONTROL VALVE (Cont'd)

Auxiliary Section

Remove the jumper line from the solenoid block fitting I!].

NOTE: Be sure the restrictor (Item 1) is located at the fitting

(both solenoid blocks) I!].

Remove the solenoid from the block [ID.

Remove the restrictor fitting from the block [g.

Remove the solenoid block bolts (front and rear) ~.

Control Valve
0134556
TAB 2 -3- Component Repair Manual

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CONTROL VALVE (Cont'd)

Remove the solenoid blocks (front and rear) ~.

Remove the spool ~.

Install NEW quad rings at assembly.

INOTE: See Pages 9 & 10 for seal and valve identification.

Remove the centering spring bolts ~.

NOTE: Carefully remove the centering spring bolt which is

under spring tension.

Assembly: For correct installation of the centering spring (See

Page 8 for the procedure).

Remove the back-up washer, quad ring and a-ring from front
and rear of the control valve ~.

TAB 2 Control Valve

0134556
Revised Aug. 92 -4- Component Repair Manual

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CONTROL VALVE (Cont'd)

Lift Section Detent Disassembly and Assembly

The tool listed will be needed to do the following procedure:

MEL-1278 - Detent Tool

Use the following procedure to remove and disassemble the

detent assembly.

Remove the detent dust cap [!].

Remove the snap ring (Item 1) and washer (Item 2) ~.

Remove the screws for the detent cap.

Remove the cap ~.

IMPORTANT
The detent assembly has small springs and balls. Do
not loose these parts during disassembly and assembly.
1-2012-0284

Remove the detent sleeve, detent balls and spring ~.

Remove the spool from the bore.

Install NEW quad rings at assembly.

Control Valve

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CONTROL VALVE (Cont'd)

Remove the retainer screws and retainer I!].

Remove the back-up washer and quad rings from the front and
rear of the control valve [!].

A WARNING
Wear safety glasses to prevent eye injury when any of
the following conditions exist:

• When fluids are under pressure.

• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-20 19-1285

Clamp the spool yoke in a vise and remove the centering spring
bolt ~.

NOTE: Remove the bolt carefully, it is under spring tension.

IMPORTANT
The detent assembly has small springs and balls. Do
not loose these parts during disassembly and assembly.
1-2012-0284

Remove the adaptor, detent balls and spring from the centering
spring ~.

Remove the centering spring assembly from the spool.

Control Valve
TAB 2 0134556 -6- Component Repair Manual

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CONTROL VALVE (Contd)

Remove the centering spring assembly [!].

Remove the valve spool stud (Item 1) [!].

See Page 8 for the valve spool stud setting.

Tilt Section

Remove the cap from the centering spring [!].

IMPORTANT
The detent assembly has small springs and balls. Do
not loose these parts during disassembly and assembly.
1-2012-0284

Clamp the spool yoke in a vise and loosen the centering spring
bolt.

Remove the bolt, spring retainer and spring assembly ~.

Remove the screws and the retaining plate [QJ.

Control Valve
TAB 2
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CONTROL VALVE (Cont'd)

Remove the back-up washer and the quad ring ~.

Inspection

Check spools for scratches or wear.

Check that spools are not loose in their bores.

Check for broken centering springs.

Check that the load check valves seats are not worn.

Check the load check poppets for damage.

Check the seal retainers and back-up washers for damage.

Replace the parts as needed.

Installation of the Centering Spring

The tool listed will be needed to do the following procedure:

MEL-1285 - Valve Spring Holding Tool

Put the washer and collar into the ends of the spring.

Compress the spring assembly and install it into the holding tool
~. 8-9504

With the tool in position over the spring, assemble the spring
to the spool using an allen wrench.

When assembly is complete, remove the tool.

Valve Spool Stud

Install the plastic plug (lift spool only).

Install the stud and leave about 0.60" (15.2 mm) of the stud
sticking out ~.

NOTE: DO NOT use loctite on the threads.

8-9973
Assemble the centering spring and washer and install detent
adapter.

Tighten the adapter to 90-100 in.-Ibs. (10-11 Nm) torque [QJ.

Control Valve
TAB 2
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IDENTIFICATION & INSTALLATION OF SPOOL SEAL

There are two types of seals for the control valve, a quad-ring
seal and a lip seal. First identify the control valve (See Page 9
CD
or 10) to find which seal is used. See the Parts Micro-Fiche for CUT AWAY SIDE VIEW
your model loader for the part number of the quad-ring seal or OF VALVE BODY
the lip seal used. Use the following procedure to install the seals MC-1699
into the control valve.
QUAD-RING SEAL
SHORT CHAMFER

1. Uses only quad-ring seal.

DE-BURR
2. Check the seal surface area for rust, corrosion, scratches, SHARP EDGE
etc. Correct any irregularities before continuing. De-burr the
sharp edge at the seal area with a file or de-burring tool
(both ends).

3. At the linkage end of the spool, de-burr the rubber boot

groove as needed.

NOTE: Lubricate with grease between the seal and retainer

before installation (both ends).

4. Put clean oil on the valve spool. Install the quad-ring seal
over the valve spool. Be Careful not to damage the quad-
ring s,eal on the valve spool edges. MC-1606

NOTE: An alternate method to protect the quad-ring seal by

putting plastic material (Example: Discarded micro-
fiche card) over the spool to protect the seal.

5. Install spool into the valve bore.

6. Slide the linkage end quad-ring seal over the rubber boot
groove. Be Careful not to damage the seal.

7. Install the quad-ring seal retainer.

8. Continue with assembling the control valve.

INSTALLING QUAD-RING
SEAL ON VALVE SPOOL

P\-12861

Added Aug. 92 Control Valve

TAB 2
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IDENTIFICATION & INSTALLATION OF SPOOL SEAL (Cont'd) LIPS FACE

TOWARD
LONG CHAMFER VALVE BODY

1. Uses only lip seal.

2. Check the seal surface area for rust, corrosion, scratches, CUT AWAY SIDE VIEW
MC-1699
etc. Correct any irregularities before continuing. OF VALVE BODY

NOTE: Lubricate with grease between the seal and retainer

before installation (both ends).

3. Put clean oil on the valve spool. Install the lip seal over the
valve spool. Be Careful not to damage the lip seal on the
valve spool edges.

NOTE: An alternate method to protect the lip seal by putting

plastic material (Example: Discarded micro-fiche card)
over the spool to protect the seal.

4. Install spool into the valve bore.

5. Slide the linkage end lip seal over the rubber boot groove. ~ '-0.145" (3,7 mm)
Be Careful not to damage the seal.

6. Install the seal retainer.

7. Continue with assembling the control valve.

INSTALLING LIP
SEAL ON VALVE
SPOOL

Added Aug. 92 Control Valve

TAB 2
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REAR AUXILIARY CONTROL VALVE INDEX 2400

CONTROL VALVE
Auxiliary Detent Adjustment 9
Auxiliary Section 8
Disassembly and Assembly 2
Inlet Section 3
Lift Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Lock Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

CONTROL VALVE IDENTIFICATION

Chart 1

Control Valve
TAB 3 Component Repair Manual
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0134556

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2400 REAR AUXILIARY VALVE

03
ITEM FUNCTION 01 C2
C1
A1 Lock Pin Cylinder (Locked)

A2 Cylinder, Rod End

A3 Auxiliary Attachment

B1 Locking Cylinder

B2 Cylinder, Base End

B3 Auxiliary Attachment

C1 Port Relief (1500 PSI)

C2 Inlet Port

D1 Centering Spring Locking Spool

D2 Centering Spring Lift Spool

D3 Auxiliary Detent

E1 Port Relief (1 500 PSI)

E2 Port Relief (1500 PSI)

E3 Inlet Port

F1 Locking Cylinder Spool

E3
F2 Lift Cylinder Spool F3
MC-1187
F3 Auxiliary Spool

MR Main Relief (2700 PSI)

Control Valve

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CONTROL VALVE

Disassembly and Assembly

Mark each section of the control valve for assembly.

NOTE: Always use new o-rings during assembly of control

valve.

NOTE: The port relief valves are all set at 1500 PSI and have
the same function but different appearance. The
removal and installation procedure will be the same.

Loosen and remove the nuts on the thru bolts of the control
valve [!J.

Installation: Tighten the nuts to 32 ft.-Ibs. (43 Nm) torque.

Position the valve on it's end to remove the sections 00.

Remove the auxiliary section ~.

Remove the lift cylinder section [Q].

Control Valve
TAB 3 -2-
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CONTROL VALVE (Cont'd)

Remove the locking cylinder section ~.

Use a soft jaw vise or wood blocks in the vise to hold the
sections for repair.

Inlet Section

Remove the inlet and outlet fittings [!].

Loosen and remove the main relief valve ~.

Lock Section

Remove the screws from the centering spring cap.

Remove the cap [QJ.

Control Valve

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CONTROL VALVE (Cont'd)

Remove the fittings from the section ~.

Loosen and remove the port relief valve [!].

Remove the spring and poppet ~.

Remove the seal plate screws (Item 1), seal plates (Item 2),
seal (Item 2), retainer (Item 4) and back-up washer (Item 5) ~.

Control Valve
TAB 3 -4- Component Repair Manual
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CONTROL VALVE (Cont'd)

Remove the spool o-ring ~.

Remove the spool 00.

Hold the spool at the yoke end to remove the screw [g.

Remove the spring positioner assembly (Item 1) the back-up

washer and O-ring (Item 2) (See Inset) [g.

Lift Section

Remove the fittings from the section [Q].

Control Valve

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CONTROL VALVE (Cont'd)

Loosen the port relief valve [!J.

Remove the port relief valve, spring and poppet ~.

Loosen the anti-cavitation valve [g.

Remove the anti-cavitation valve, spring and poppet [Q].

Control Valve

00
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CONTROL VALVE (Cont'd)

Remove the seal plates (Item 1), seal (Item 2), back-up washer
(Item 3) and spacer (Item 4) I!J.

Remove the centering spring cap lID.

Remove the spool ~.

Put the spool yoke in a vise.

NOTE: The centering spring is under tension, hold spring when

removing snap ring.

Remove the external snap ring ~.

Control Valve

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CONTROL VALVE (Cont'd)

Remove the spring assembly (Item 1), detent cap (Item 2), balls
(Item 3), quad ring (Item 4), spacer (Item 5), poppet and spring
(Item 6) ~.

Installation: Grease the spring, poppet and balls. Push the

poppet against the spring when installing the detent cap over
the balls.

Auxiliary Section

Remove the plugs [!].

Remove the fitting ~.

Remove the screws and seal plate (Item 1), seal (Item 2), back-
up washer (Item 3) and washer (Item 4) IQJ.

Control Valve

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CONTROL VALVE (Cont'd)

Remove the spool, back-up washer and O-ring ~.

Remove the detent assembly first to remove the centering

spring assembly (See Page 10).

Remove the spool bolt (Item 1), spring assembly (Item 2), back-
up washer (Item 3)' washer (Item 4) and O-ring (Item 5) lID.

Remove the fitting ~.

Auxiliary Detent Adjustment

The auxiliary detent spring tension can be adjusted on the

control valve.

Turn the cap clockwise to increase tension and counter

clockwise to decrease tension ~.

Disassemble the detent as follows:

The cap is under spring tension, hold cap with one hand as cap
is removed.

Use a straight slotted tool to loosen the detent cap ~.

Control Valve

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CONTROL VALVE (Cont'd)

Remove the cap and spring ~.

NOTE: Grease spring before assembly.

Remove the detent ball positioner [ID.

NOTE: Grease the positioner before assembly.

NOTE: Be sure the positioner is installed with concave side

down.

Remove the twelve (12) detent balls [g.

NOTE: Grease the balls before assembly.

Remove the detent washer [Q].

Control Valve
TAB 3
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 Tractor Manuals Scotland

CONTROL VALVE INDEX 1213

CONTROL VALVE
Anti-Cavitation Valve 8
By-Pass Valve 240 PSI 7
Centering Mechanism 6
Disassembly and Assembly 2
Lift Section Orifice 9
Load Check Valves 9
Port Relief Valve 8
Spool Electrical Solenoid 2

CONTROL VALVE IDENTIFICATION

Chart 1

IDENTIFICATION & INSTALLATION OF SPOOL SEAL

No Chamfer 10
Notch for Seal 11
Short Chamfer 12
Long Chamfer 13

TAB 4 Control Valve

0134556
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0134556

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CONTROL VALVE IDENTIFICATION

FRONT VALVE

I 1213
T
E
M FRONT VALVE REAR VALVE
Lift Cylinder- Accumulator-
A-1
Rod End Opens

Tilt Cylinder- Bogie Wheels-

A-2
Rod End Lowers

A-3 Shear-Opens Shear-Opens

Lift Cylinder- Accumulator-

B-1
Base End Closes

Tilt Cylinder- Bogie Wheels-

B-2
Base End Raises

B-3 Shear-Closes Shear-Closes

Load Check-Lift Load Check-Ace.

C-1
Function Function

Load Check- Tilt Load Check-Bogie

C-2
Function Wheels Function

Load Check-Shear Load Check-Shear

C-3
Function Function

Accumulator
0-1 Lift Spool
Solenoid
8-9243

Tilt Spool Bogie Wheels REAR VALVE

0-2
Solenoid

0-3 Shear Solenoid Shear Solenoid

E-1 Anti-Cavitation
Valve

Control Fluid
E-2
Passage Plug

Control Fluid
E-3
Passage Plug

F-1 Port Relief Valve

Anti-Cavitation
Valve Control Fluid
F-2
Passage Plug

Control Fluid
F-3
Passage Plug

Centering Spring- Accumulator-

G-1
Lift Spool Solenoid

Centering Spring- Bogie Wheels-

G-2
Tilt Spool Solenoid

G-3 Shear-Solenoid Shear-Solenoid

MR Main Relief Valve Main Relief Valve

8-6581

Control Valve

0134115
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CONTROL VALVE

Spool Electrical Solenoid

THE FRONT AND REAR CONTROL VALVE USE THE SAME

PROCEDURE FOR REMOVAL AND INSTALLATION OF THE
ELECTRICAL SOLENOID.

# * Remove the nut at the top of the solenoid I!].

#* Remove the cover and the solenoid coil.

#* Loosen the solenoid valve lID.

#* Remove the solenoid valve ~.

#* Remove the O-rings and back-up washers.

# * Installation: Always use NEW O-rings and back-up washers

when installing the solenoid valves.

8-8605

Disassembly and Assembly

NOTE: The procedure will list the difference between the front
and rear control valve.

# Disconnect the tubeline from the front and rear port block.
Remove the bolts from the port block ~.

# Installation: Tighten the bolts to 90-100 in.-Ibs. (10-11 Nm)

torque.

# Front Control Valve

* Rear Control Valve 8-8604

Control Valve
-2-
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CONTROL VALVE (Cont'd)

* 0 isconnect the tubeline between the front and rear port block
~.

* Remove the bolts from the port block [!].

* Installation: Tighten the bolts to 90-100 in.-Ibs. (10-11 Nm)

torque.

# Remove the front port block ~.

* Remove the front port block [Q].

\

# Front Control Valve

* Rear Control Valve 8-8569

Control Valve
TAB 4 -3- Component Repair Manual
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CONTROL VALVE (Cont'd)

# Remove the bolts and rear port block ~.

* Remove the bolts and rear port block 00.

# * Remove the orifice plug (g.

NOTE: In the rear control valve the orifice plug is located in

the center section of the control valve.

#* Remove the large O-ring ~.

# Front Control Valve

* Rear Control Valve

Control Valve
TAB 4
0134556 -4- Component Repair Manual

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 Tractor Manuals Scotland

CONTROL VALVE (Cont'd)

#* Remove the spool(s) from the control valve ~.

8-8598

#* Remove the quad ring(s) from the front side of the control
valve [!].

# * Remove the quad rings from the rear side of the control valve


[g.

# * Use the following steps for correct installation of the valve

spool(s) and quad rings:

1. Install the NEW quad ring into the groove in the front side
of the control valve [Q].

INOTE: See Pages 10, 11, 12 & 13 for seal and valve
identification.

# Front Control Valve

* Rear Control Valve

Control Valve
TAB 4
-5- Component Repair Manual
Revised Aug. 92
00
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CONTROL VALVE (Cont'd)

2. Install the valve spool into the control valve from the rear
side of the valve.

3. Push the spool into the control valve just far enough so that
the rear side quad ring can be installed ~.

4. Install a NEW quad ring [j].

INOTE: See Pages 10, 11, 12 & 13 for seal and valve
identification.
5. Push the valve spool back into the control valve until it is
even with the rear side machined surface of the valve.

6. Install the centering spring.

Rubber Boots and Retainer

The procedure is the same for the lift and tilt spool.

# Remove the screws (Item 1) and rubber boot retainer (Item

2
2) [g. 3
# Remove the rubber boot (Item 3), filter (Item 4) and O-ring I
(Item 5)

# Installation:
torque.
[g.

Tighten the screws to 90-100 in.-Ibs. (10-11 Nm) -til

8-9006

Centering Spring Mechanism

The tool listed will be needed to do the following procedure.

MEL-1285 - Spring Holding Tool

# Remove the cap screws [Q].

# Installation: Tighten the screws to 90-100 in.-Ibs. (10-11 Nm)

torque.

# Front Control Valve

* Rear Control Valve

TAB 4 Control Valve

Revised Aug. 92
0134551 -6- Component Repair Manual

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 Tractor Manuals Scotland

CONTROL VALVE (Cont'd)

# * Remove the center spring bolt.

NOTE: Carefully remove the bolt because there is spring

pressure.

# * Installation: Put the washer and collar into the ends of the
spring. Compress the spring assembly and install it into the hold
tool ~. Put Loctite on the bolt and tighten to 90-100 in.-Ibs.
(10-11 Nm) torque.

8-9005

#* Disassemble the centering spring mechanism as shown ~. 1. O-ring 5. Adapter

2. Spring Washer 6. Bolt
Check all the parts and replace the parts that are worn or broken. 3. Centering Spring 7. Centering Spring Cap
4. Spring End Cap 8. End Cap Screw
Always use NEW O-rings and back-up washers when
assembling the control valve.


E-1446

240 PSI By-Pass Valve

# Loosen the by-pass valve ~.

# Remove the housing, spring and poppet [Q].

Clean the parts. Inspect and replace -as needed.

# Front Control Valve

* Rear Control Valve

Control Valve
-7- Component Repair Manual
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CONTROL VALVE (Cont'd)

Anti-Cavitation Valve

# Remove the anti-cavitation valve from the lift section I!].

# Remove the anti-cavitation valve from the tilt section 00.

# Installation: Tighten the anti-cavitation valve to 35-40 ft.-Ibs.
(47-54 Nm) torque.

8-8593

Clean and inspect the valve. Install NEW O-rings and back-up 1. Anti-Cavitation Valve
washers before installation ~. 2. O-ring
3. Back-Up Washer
4. O-ring

E-1509

Port Relief Valve

# Remove the port relief valve from the control valve ~.

# Installation: Tighten the valve to 35-40 ft.-Ibs. (47-54 Nm)

torque.

Clean and inspect the valve. Install NEW O-rings and back-up 1.
washers before installation ~. 2. O-ring
3. Back-Up Washer
4. O-ring
234
I I I
#
*
Front Control
Rear Control
Valve
Valve
~-O-I-O- ,
1 E-1509 8-8594

Control Valve
TAB 4 0134556 -8- Component Repair Manual

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 Tractor Manuals Scotland

CONTROL VALVE (Cont'd)

Lift Section Orifice

# Use an allen wrench and remove the retaining nut.

# Remove the orifice [!J.

Clean and inspect the orifice.

Load Check Valves

# * Remove the load check plug (Item 1) at the top of the control
valve 00.
# * Remove the spring and poppet 00.
#* Remove the O-ring. Clean and inspect the poppet for wear.

#* Installation: Tighten the plug to 35-40 ft.-Ibs. (47-54 Nm)

torque.

8-9007

# Front Control Valve

* Rear Control Valve

Control Valve
TAB 4 0134556 -9- Component Repair Manual

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 Tractor Manuals Scotland

IDENTIFICATION & INSTALLATION OF SPOOL SEAL

There are two types of seals for the control valve, a quad-ring
seal and a lip seal. First identify the control valve (See Page 10, CUT AWAY SIDE VIEW
11, 12 & 13) to find which seal is used. See the Parts Micro- OF VALVE BODY
Fiche for your model loader for the part number of the quad-
ring seal or the lip seal used. Use the following procedure to MC-1699

install the seals into the control valve. QUAD-RING SEAL

NO CHAMFER

1. Uses only quad-ring seal.

2. Check the seal surface area for rust, corrosion, scratches,

etc. Correct any irregularities before continuing. De-burr the
sharp edge at the seal area with a file or de-burring tool
(both ends).

3. At the linkage end of the spool, de-burr the rubber boot

groove as needed.

NOTE: Lubricate with grease between the seal and retainer

before installation (both ends).

4. Put clean oil on the valve spool. Install the quad-ring seal
over the valve spool. Be Careful not to damage the quad- MC-1606
ring seal on the valve spool edges.

NOTE: An alternate method to protect the quad-ring seal by

putting plastic material (Example: Discarded micro-
fiche card) over the spool to protect the seal.

5. Install spool into the valve bore.

6. Slide the linkage end quad-ring seal over the rubber boot
groove. Be Careful not to damage the seal.

7. Install the quad-ring seal retainer.

8. Continue with assembling the control valve.

INSTALLING QUAD-RING
SEAL ON VALVE SPOOL

INSTALLING QUAD-RING
SEAL REATINER

Added Aug. 92 Control Valve

TAB 4
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IDENTIFICATION & INSTALLATION OF SPOOL SEAL (Cont'd)

NOTCH FOR SEAL CD

NOTE: This control valve (with the notch for seal) must be
removed from the loader for the quad-ring seal
installation. CUT AWAY SIDE VIEW MC-1699

OF VALVE BODY QUAD-RING SEAL

1. Uses only quad-ring seal.

2. Check the seal surface area for rust, corrosion, scratches,

etc. Correct any irregularities before continuing.

3. The detent mechanism or centering spring must be removed

from the valve spool.

4. At the linkage end of the spool, de-burr the rubber boot

NOTCH FOR
groove as needed.
SEAL
5. Install the quad-ring seal into the notch in the linkage end
of the control valve.

6. Put clean oil on the valve spool. Install the spool into the
valve from the rear end (centering spring or detent
mechanism side). Be Careful not to damage the quad-ring
seal, already installed, when going over the groove for the
rubber boot. Push the spool into the valve just far enough
so that the rear quad-ring seal can be installed.
CD
7.

8.
Install the quad-ring seal in the rear groove of the valve.

Push the valve spool back into the control valve until it is
even with the rear machined surface of the valve.
=HII ==n
DE-BURR EDGE ~MC-1606

9. Continue with assembling the control valve.

INSTALLING FRONT
QUAD-RING SEAL

INSTALLING SPOOL

Added Aug. 92 Control Valve

TAB 40134110 -11- Component Repair Manual

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 Tractor Manuals Scotland

IDENTIFICATION & INSTALLATION OF SPOOL SEAL

SHORT CHAMFER

1. Uses only quad-ring seal. CUT AWAY SIDE VIEW

OF VALVE BODY
2. Check the seal surface area for rust, corrosion, scratches,
MC-1699
etc. Correct any irregularities before continuing. De-burr the
sharp edge at the seal area with a file or de-burring tool QUAD-RING SEAL
(both ends).

3. At the linkage end of the spool, de-burr the rubber boot

groove as needed.
DE-BUPR
SHARP EDGE
NOTE: Lubricate with grease between the seal and retainer
before installation (both ends).
~-- SHORT CHAMFER
4. Put clean oil on the valve spool. Install the quad-ring seal
over the valve spool. Be Careful not to damage the quad-
ring seal on the valve spool edges.

NOTE: An alternate method to protect the quad-ring seal by

putting plastic material (Example: Discarded micro-
fiche card) over the spool to protect the seal.

5. Install spool into the valve bore.

MC-1606
6. Slide the linkage end quad-ring seal over the rubber boot
groove. Be Careful not to damage the seal.

7. Install the quad-ring seal retainer.

8. Continue with assembling the control valve.

INSTALLING QUAD-RING
SEAL ON VALVE SPOOL

Added Aug. 92 Control Valve

TAB 4
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IDENTIFICATION & INSTALLATION OF SPOOL SEAL (Cont'd) LIPS FACE

TOWARD
LONG CHAMFER
VALVE BODY

1. Uses only lip seal.

2. Check the seal surface area for rust, corrosion, scratches, CUT AWAY SIDE VIEW
etc. Correct any irregularities before continuing. OF VALVE BODY

NOTE: Lubricate with grease between the seal and retainer

before installation (both ends).

3. Put clean oil on the valve spool. Install the lip seal over the
valve spool. Be Careful not to damage the lip seal on the
valve spool edges.

NOTE: An alternate method to protect the lip seal by putting

plastic material (Example: Discarded micro-fiche card)
over the spool to protect the seal.

4. Install spool into the valve bore.

5. Slide the linkage end lip seal over the rubber boot groove. __.. ~O.145" (3,7 mm)
Be Careful not to damage the seal.

6. Install the seal retainer.

7. Continue with assembling the control valve.

INSTALLING LIP
SEAL ON VALVE
SPOOL
INSTALLING LIP SEAL
RETAINER

Added Aug. 92 Control Valve

TAB 4 -13- Component Repair Manual
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HYDRAULIC CONTROL VALVE

CONTROL VALVE
Anti-Cavitation Valve 4
Auxiliary Electrical Solenoid 12
Auxiliary Spool 11
Disassembly and Assembly 2
Inspection 13
Lift Spool Detent 6
Load Check Valve 2
Main Relief Valve 3
Port Relief Valve 3
Rubber Boot 5
Tilt Centering Spring 10

CONTROL VALVE IDENTIFICATION

Chart 1

I ID~~:r~I~~:~f~r
Long Chamfer
~ .I~~~~~~~:I~.~ ~.F. ~~~~.L. ~~~~ 14
15

TAB 5 Control Valve

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CONTROL VALVE IDENTIFICATION

750 SERIES
Chart

MR
750 853 2410
Item Series Loader Loader
G1
A1 Lift Cyl. Base
End Restrictor Lift Cyl. - Rod End

A2 Tilt Cyl. G2
Base End Tilt Cyl. - Rod End

A3 Auxiliary Hydraulics
G3
B1 Lift Cyl.
Rod End Lift Cyl. - Base End Resitrictor

B2 Tilt Cyl.
Rod End Tilt Cyl. - Base End
H1 H3 MC-1423
B3 Auxiliary Hydraulics

C1 Load Check Valve/Lift Function

853 LOADER
C2 Load Check Valve/Tilt Function

C3 NO Load Check Valve Auxiliary Function

C4 Oil Cooler
By-Pass Outlet Fluid Flow
01
D1 Lift Spool
Detent Lift Spool

D2 Centering 02
Spring Tilt Spool Tilt Spool

D3 Auxiliary Spool
03
E1 Port Relief

E2 Anti-Cav. Valve

F1
H2
MC-1426
F2 Anti-Cav. Valve

G1 Lift Spool Lift Spool Detent

2410 LOADER
G2 Tilt Spool Tilt Spool Centering Spring

G3 Auxiliary Spool

H1 Auxiliary Auxiliary
Electric Plug Electric
Solenoid Solenoid 01

H2 Plug/Port Relief (Optional)

D2
H3 Auxiliary Auxiliary
Electric Plug Electric
Solenoid Solenoid D3
MR Main Relief Valve

H1 H3
MC-1425

TAB 5 Control Valve

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CONTROL VALVE

Disassembly and Assembly

See the Service Manual for your Model loader for removal and
installation of the control valve.

The anti-cavitation valve, port relief valves and plugs are at

different locations in the control valve. Refer to Page 1 (Control
Valve Identification Chart) for the correct location of the parts
for each Model control valve.

NOTE: THE PHOTO'S MAY NOT SHOW THE EXACT

LOCATION FOR THE PART BEING REMOVED OR
INSTALLED ON THE CONTROL VALVE, BUT THE
PROCEDURE IS THE SAME.

When making repairs on hydrostatic and hydraulic

systems, clean the work area before disassembly and
keep all parts clean. Always use caps and plugs on
hoses, tubelines and ports to keep dirt out. Dirt can
quickly damage the system.
1-2003-0284

Mark each valve section and spool so that the parts will be
returned to its original bore during assemble.

Use bolts to fasten the control valve to a work bench for easier
disassemble and assemble.

Load Check Valve

Loosen the load check plug ("C" port; Page 1) ~.

Assemble: Always use new O-ring. Tighten the plug to 35-40

ft.lbs. (47-54 Nm) torque.

Remove the load check plug [!I.

Remove the spring and poppet [g.

Control Valve
TAB 5
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CONTROL VALVE (Cont'd)

Main Relief Valve

Loosen the main relief valve ~ .

Assemble: Always use new O-rings and back-up washers.

Tighten to 35-40 ft.lbs. (47-54 Nm) torque.

Remove the main relief valve ~.

Remove the O-rings and back-up washers from the main relief
1 2 345
valve [g.

It"_-~U-J
E-1509

Relief Valve
2. Back-Up Washer
3. O-Ring
4. O-Ring
5. Back-Up Washer

PI-1079B

Port Relief Valve

Loosen the port relief valve [QJ.

Assemble: Always use new O-rings and back-up washers.

Tighten to 35-40 ft.lbs. (47-54 Nm) torque.

NOTE: The port relief valve can be located on either side of the
control valve ("E" or IIF" ports; Page 1).

TAB 5 Control Valve

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CONTROL VALVE (Cont'd)

Remove the port relief valve ~.

Remove the O-rings and back-up washer from the port relief
valve [j].
2 3 4
I I I
0-1-0
E-1509

1. Relief Valve
2. O-Ring
3. Back-Up Washer
4. O-Ring

PI-10801

Anti-Cavitation Valve

Loosen the anti-cavitation valve [g.

Assemble: Always use new O-rings and back-up washers.

Tighten to 35-40 ft.lbs. (47-54 Nm) torque.

NOTE: The anti-cavitation valve can be located on either side

of the control valve ("E" or "F" ports; Page 1).

Remove the anti-cavitation valve from the control valve ~.

TAB 5 Control Valve

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CONTROL VALVE (Cont'd)

124
Remove the O-rings and back-up washer from the anti-cavitation
valve ~. I I ~ I
~-O-O-O
E-1509

1. Anti-Cavitation Valve
2. O-Ring
3. Back-Up Washer
4. O-Ring

PI-10804

Rubber Boot

Loosen the two screws on the rubber boot retainer [iI.

Assemble: Tighten the screws to 90-100 in.lbs. (10,2-11,3 Nm)

torque.

Remove the screws ~.

Remove the rubber boot and retainer [Q] .

TAB 5 Control Valve

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CONTROL VALVE (Cont'd)

Remove the back-up washer ~ .

After the spool is removed, use a O-ring pick and remove the
spool seal from the spool bore [jJ.

INOTE: See Pages 14 & 15 for seal and valve identification.

Lift Spool Detent

The tool listed will be needed to do the following procedure:

MEL-1278 - Detent Tool

Remove the snap ring with a screwdriver [g.

Remove the snap ring and washer [Q].

TAB 5 Control Valve

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CONTROL VALVE (Cont'd)

Remove the screws from the detent cap ~.

Assemble: Tighten the screws to 90-100 in.lbs. (10,2-11,3 Nm)

torque.

Remove the detent cap ~.

IMPORTANT
The detent assembly has small springs and balls. Do
not loose these parts during disassembly and assembly.
1-2012-0284

Put a rag around the detent sleeve [g.

·Remove the detent sleeve, detent balls and spring ~.

TAB 5 Control Valve

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CONTROL VALVE (Cont'dl

Remove the spool, centering spring, back-up washer and spool

seal assembly from the control valve [!I.

Put the linkage end of the spool in a vise.

NOTE: BE CAREFUL when removing the detent adapter,

because there is spring pressure.

Loosen the detent adapter I!J.

Remove the detent adapter, end cap and centering spring [g.

Remove the back-up washer and spool seal [Q].

TAB 5 Control Valve

Revised Jan. 91 -8- Component Repair Manual

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CONTROL VALVE (Cont'd)

Lift Spool Only: Remove the stud from the end of the spool ~.

Removal of the plastic plug:

a. Make a center point in the plug using a 3/16" drill.

b. Drill a hole all the way through the plug using a 7/64" tap
drill.

c. Turn a 6-32 tap into the plug. Pull the tap and plug out of
the spool. BE CAREFUL, do not break the tap.

d. Clean all the debris from the inside of the spool bore.

Assemble: Install the new plastic plug. Install the stud and leave
about 0.60" (15,2 mm) sticking out [j].

NOTE: DO NOT USE LOCTITE ON THE STUD THREADS.

Plastic
Plug ., 0.60"
(15,2 mm

NOTE: Put grease on all detent components surfaces before

assembly.

Install the detent balls and spring into the detent adapter. Hold
the detent balls in position with the tool and install the detent
adapter into the end cap [g.

Install the spool seal, back-up washer, centering spring, end

cap/detent adapter on the valve spool. Tighten the detent
adapter to 90-100 in.lbs. (10,2-11,3 Nm) torque.

Install the detent balls and spring ~.

TAB 5
Revised Jan. 91 Control Valve
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CONTROL VALVE (Cont'd)

Hold the detent balls and spring in position with the tool [!].

Install the detent sleeve over the balls and into position ~.

Tilt Centering Spring

Remove the end cap screws [g.

Assemble: Tighten the screws to 90-100 in.lbs. (10,2-11,3Nm)

torque.

Remove the end cap [Q].

TAB 5 Control Valve

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CONTROL VALVE (Cont'd)

Remove the spool, centering spring, back-up washer and spool

seal ~.

Assemble: If the centering spring bolt is removed, tighten to

90-100 in.lbs. (10,2-11,3 Nm) torque. Put grease on all the
centering spring component parts. Always use new spool seal.

Auxiliary Spool

Remove the end plate screws [j].

Assemble: Tighten the screws to 90-100 in.lbs. (10,2-11,3 Nm)

torque.

Remove the end plate, O-ring and spring [g.

Remove the end plate, O-ring and spring from the other side.

Remove the washer (both sides) [Q].

TAB 5 Control Valve

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CONTROL VALVE (Cont'd)

Remove the auxiliary section spool from the control valve ~.

Auxiliary Electric Solenoid

Remove the nut from the end of the solenoid ~.

Assemble: Tighten the nut to 9-12 in.lbs. (1,02-1,36 Nm) torque.

Remove the solenoid coil and end plate ~.

Loosen the electric solenoid valve ~.

Assemble: Tighten the electric solenoid valve to 96-144 in.lbs.

(10,8-16 Nm) torque.

TAB 5 Control Valve

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CONTROL VALVE (Cont'd)

Remove the electric solenoid valve from the control valve ~.

NOTE: Always use new O-rings and back-up washers when

assembling.

Remove the plug from the control valve ("H" port; Page 1) [1].

Replace the O-ring.


Depending on the application of the auxiliaries, the control valve
may be equipped with a port relief valve (IIH" port; Page 1) [g.

Remove the port relief valve and replace the O-rings and back-
up washers (Page 3).

Inspection

Check the spools for wear or scratches.

Check that the spools are not loose in their bore.

Check that the centering springs are not broken.

Check that the load check valve seats are not worn.

Check the load check poppets for damage.

Check the rubber boots and retainers that they are not worn
or damaged.

Replace the parts as needed.

TAB 5 Control Valve

-13- Component Repair Manual
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IDENTIFICATION & INSTALLATION OF SPOOL SEAL

There are two types of seals for the control valve, a quad-ring
seal and a lip seal. First identify the control valve (See Page 14
CD
or 15) to find which seal is used. See the Parts Micro-Fiche for CUT AWAY SIDE VIEW
your model loader for the part number of the quad-ring seal or OF VALVE BODY
the lip seal used. Use the following procedure to install the seals MC-1699
into the control valve.
QUAD-RING SEAL
SHORT CHAMFER

1. Uses only quad-ring seal.

2. Check the seal surface area for rust, corrosion, scratches,

etc. Correct any irregularities before continuing. De-burr the
sharp edge at the seal area with a file or de-burring tool
(both ends).

3. At the linkage end of the spool, de-burr the rubber boot

groove as needed.

NOTE: Lubricate with grease between the seal and retainer

before installation (both ends).

4. Put clean oil on the valve spool. Install the quad-ring seal
over the valve spool. Be Careful not to damage the quad-
ring seal on the valve spool edges. MC-1606

NOTE: An alternate method to protect the quad-ring seal by

putting plastic material (Example: Discarded micro-
fiche card) over the spool to protect the seal.

5. Install spool into the valve bore.

6. Slide the linkage end quad-ring seal over the rubber boot
groove. Be Careful not to damage the seal.

7. Install the quad-ring seal retainer.

8. Continue with assembling the control valve.

INSTALLlN~ QUAD-RING
SEAL ON VALVE SPOOL

Added Aug. 92 Control Valve

TAB 5
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IDENTIFICATION & INSTALLATION OF SPOOL SEAL (Cont'd) LIPS FACE

TOWARD
LONG CHAMFER VALVE BODY

1. Uses only lip seal.

2. Check the seal surface area for rust, corrosion, scratches, CUT AWAY SIDE VIEW
etc. Correct any irregularities before continuing. OF VALVE BODY

NOTE: Lubricate with grease between the seal and retainer

before installation (both ends).

3. Put clean oil on the valve spool. Install the lip seal over the
valve spool. Be Careful not to damage the lip seal on the
valve spool edges.

NOTE: An alternate method to protect the lip seal by putting

plastic material (Example: Discarded micro-fiche card)
over the spool to protect the seal.

4. Install spool into the valve bore.

5. Slide the linkage end lip seal over the rubber boot groove.
Be Careful not to damage the seal.

6. Install the seal retainer.

7. Continue with assembling the control valve.

INSTALLING LIP
SEAL ON VALVE
SPOOL
INSTALLING LIP SEAL
RETAINER

Added Aug. 92 Control Valve

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HYDRAULIC CONTROL VALVE

CONTROL VALVE
Anti-Cavitation Valve
Assembly 16
Disassembly 4

Auxiliary Electrical Solenoid

Assembly ~ . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly 4

Auxiliary Spool
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly 10

Lift Spool and Detent

Assembly 11
Disassembly 6

Load Check Valve

Assembly 18
Disassembly 2

Main Relief Valve

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly 3

Plug
Assembly 16
Disassembly 4

Port Relief Valve

Assembly 17
Disassembly 3

Rubber Boot
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly 5

Tilt Spool and Centering Spring

Assembly 11
Disassembly 10

SPOOL SEAL REPLACEMENT 19

CONTROL VALVE IDENTIFICATION

Chart 1

TAB 6 Control Valve

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CONTROL VALVE IDENTIFICATION

750 SERIES
Chart

750 853 2410

Item Series Series
I Loader

A1 Lift Cyl. Base

End (Restrictor) Lift Cyl. - Rod End

A2 Tilt Cyl.
Base End Tilt Cyl. - Rod End

A3 Auxiliary Hydraulics

B1 Lift Cyl.
Rod End
Lift Cy. Base
End (Resitrictor)
I Lift Cyl.
Base End

B2 Tilt Cyl.
Rod End Tilt Cyl. - Base End
6588142
B3 Auxiliary Hydraulics

C1 Load Check Valve/Lift Function

853 SERIES
C2 Load Check Valve/Tilt Function

C3 NO Load Check Valve Auxiliary Function

C4 Oil Cooler
By-Pass Outlet Fluid Flow

D1 Lift Spool
Detent Lift Spool

D2 Centering
Spring Tilt Spool Tilt Spool

D3 Auxiliary Spool

E1 Port Relief Anti-Cav. Valve Port Relief for A1

E2 Anti-Cav. Valve Plug

F1 Anti-Cav. Valve Port Relief for B1

6588236
F2 Plug Anti-Cav. Valve or Port Relief for B2

G1 Lift Spool Lift Spool Detent

2410 LOADER
G2 Tilt Spool Tilt Spool Centering Spring

G3 Auxiliary Spool

H1 Auxiliary
Electric
Solenoid

H2 Plug/Port Relief (Optional) for B3

H3 Auxiliary
Electric
Solenoid

MR Main Relief Valve

6588772

TAB 6 Control Valve

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CONTROL VALVE

The following tool is needed for reassembly of the Lift Spool

Detent:

MEL1278 - Detent Tool (See Page 13)

See the Service Manual for your Model loader for removal and
installation of the control valve.

The anti-cavitation valves, port relief valves and plugs are at

different locations in the control valve. Refer to Page 1 (Control
Valve Identification Chart) for the correct location of the parts
for each Model control valve.

NOTE: THE PHOTO'S MAY NOT SHOW THE EXACT

LOCATION FOR THE PART BEING REMOVED FROM OR
INSTALLED ON THE CONTROL VALVE, BUT THE
PROCEDURE IS THE SAME.

IMPORTANT
When making repairs on hydrostatic and hydraulic
systems, clean the work area before disassembly and
keep all parts clean. Always use caps and plugs on
hoses, tubelines and ports to keep dirt out. Dirt can
quickly damage the system.
1-2003-0284

Mark each valve section and spool so that the parts will be
returned to its original bore during assembly.

Load Check Valve Disassembly

Remove the load check plugs (Item 1) and plug (Item 2) ~.

Remove the O-ring from each plug.

Remove the spring and poppet from both load check valves 00.
Check the load check valve seats and load check poppets for
wear or damage. Replace the parts as needed.

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Main Relief Valve Disassembly

Remove the main relief valve ~.

Remove the glide ring (Item 1), two (2) O-rings (Items 2 & 3)
and back-up washer (Item 4) from the main relief valve [j].


Port Relief Valve Disassembly

Remove the port relief valve [g.

NOTE: The port relief valve can be located in the lIE", IIF"
or IIH2" (If equipped with optional auxiliary port relief
valve) ports depending on model. Refer to Page 1 for
the correct location and quantity.

CD-0012

Remove the two (2) O-rings (Items 1 & 3) and back-up washer
(Item 2) from the port relief valve ~.

CD-0013

TAB 6 Control Valve

-3- Component Repair Manual
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CONTROL VALVE (Cont'd)

Anti-Cavitation Valve Disassembly

Remove the anti-cavitation valve ~.

NOTE: Anti-cavitation valves can be located in "E" and "F"

ports depending on model. Refer to Page 1 for the
correct location and quantity.

CD-0014

Remove the two (2) O-rings (Items 1 & 3) and back-up washer
(Item 2) from the anti-cavitation valve 00.

Plug Disassembly

Remove the plug [g.

NOTE: The anti-cavitation valve can be located in the "E", "F"

and "H2" ports depending on model. Refer to Page
1 for the correct location and quantity.

CD-0016

Remove the two (2) O-ring (Items 1 & 3) and back-up washer
(Item 2) from the plug ~.

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Auxiliary Electric Solenoid Disassembly

Remove the nut (Item 1), solenoid coil (Item 2) and solenoid
valve (Item 3) from the valve body ~.

Remove the three (3) O-rings from the solenoid valve [@].

Rubber Boot Disassembly

Remove the two (2) screws from the rubber boot retainer [g.

Remove the rubber boot and retainer [Q].

Check the rubber boot for wear or damage. Replace as

necessary.

CD-0020

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Lift Spool and Detent Disassembly

Remove the back-up washer ~.

Remove the cap (Item 1), snap ring (Item 2) and washer (Item
3) 00.

CD-0022

Remove the two (2) screws and two (2) lock washers from the
detent cap ~.

While holding the detent sleeve in position with a punch, remove

the detent cap ~.

IMPORTANT
The detent assembly has small springs and balls. Do
not loose these parts during disassembly and assembly.
1-2012-0284

TAB 6 Control Valve

Added May 94 -6- Component Repair Manual
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CONTROL VALVE (Cont'd)

Lift Spool and Detent Disassembly (Cont'd)

Put a clean cloth around the detent sleeve and spring to catch
the detent balls. Remove the detent sleeve ~.

Remove the two (2) detent balls (Item 1) and spring (Item 2)
from the detent adapter [!].

Remove the spool assembly (Item 3) from the valve body [!].


Use an O-ring pick to remove the spool seal from the linkage
end of the spool bore [g.

CD-0029

Put the linkage end of the spool in a vise ~.

Loosen the detent adapter ~.

NOTE: The detent adapter is under spring pressure. BE

CAREFUL when removing the detent adapter.

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Lift Spool and Detent Disassembly (Cont'd)

Remove the detent adapter and spring centering collar assembly

(Item 1), spring (Item 2), spring centering washer (Item 3), back-
up washer (Item 4) and spool seal (Item 5) from the spool (Item
6) [!].

Hold a clean cloth around the detent adapter (Item 1)and spring
centering collar (Item 2) to catch the detent balls. Remove the
detent adapter 00.

IMPORTANT
The detent assembly has small springs and balls. Do
not loose these parts during disassembly and assembly.
1-2012-0284

Remove the two (2) detent balls (Item 3) and spring (Item 4)
from the detent adapter (Item 1) 00.

Remove the stud (Item 1) and plastic plug (Item 2) from the
spool ~.

Removal of the plastic plug:

1. Make a center point in the plug using a 3/16" drill.

2. Drill a hole all the way through the plug using a 7/64" drill.

3. Turn a 6-32 UNC tap into the plug. Pull the tap and plug
out of the spool. BE CAREFUL not to break the tap.
8-9973
4. Clean all the debris from the inside of the spool bore.

Clean and dry all lift spool and detent parts. Check the parts
and valve body bore for wear or damage. Replace parts as
needed.

TAB 6 Control Valve

Added May 94
0134556 -8- Component Repair Manual

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CONTROL VALVE (Cont'd)

Tilt Spool and Centering Spring

Remove the back-up washer [!] .

CD-0030

Remove the screws from the end cap 00.

Remove the end cap (Item 1) and spool assembly (Item 2) from
the valve body [g.

CD-0033

Use an O-ring pick to remove the spool seal from the linkage
end of the spool bore [Q].

CD-0034

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Tilt Spool and Centering Spring (Cont'd)

Put the linkage end of the spool in a vise ~.

Loosen the screw ~.

NOTE: BE CAREFUL when removing the screw. The screw is

under spring pressure.

Remove the screw and lock washer (Item 1), adapter (Item 2),
spring centering collar (Item 3)' spring (Item 4), spring centering
washer (Item 5), back-up washer (Item 6) and spool seal (Item
7) from the spool (Item 8) 00.

Clean and dry all tilt spool and centering spring parts. Check
the parts and valve body bore for wear or damage. Replace parts
as needed.

Auxiliary Spool Disassembly

Remove the two (2) screws from both end plates [g.

CD-0035

Remove the end plate (Item 1) O-ring (Item 2), spring (Item 3)
and spring centering washer (Item 4) from both ends of the valve
body [Q].

Remove the spool (Item 5) from the valve body [Q].

Clean and dry all auxiliary spool parts. Check the parts and valve
body bore for wear or damage. Replace parts as needed.

TAB 6 Control Valve

Added May 94 -10- Component Repair Manual
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CONTROL VALVE (Cont'd)

All parts must be clean before assembly. Clean parts in solvent

as needed and allow to air dry.

The anti-cavitation valves, port relief valves and plugs are at

different locations in the control valve. Refer to Page 1 (Control
Valve Identification Chart) for the correct location of the parts
for each Model control valve.

NOTE: THE PHOTO'S MAY NOT SHOW THE EXACT

LOCATION FOR THE PART BEING INSTALLED ON THE
CONTROL VALVE, BUT THE PROCEDURE IS THE
SAME.
CD-0036
Auxiliary Spool Assembly

Apply oil to the spool (Item 5) and install the spool into the valve
body ~.

Apply a light coating of petroleum jelly to the two (2) new 0-

rings (Item 2). Install the O-rings into the end plates (Item 1)
~.

Install a spring centering washer (Item 4), spring (Item 3) and

end plate (Item 1) on each end of the valve body ~.

Install two (2) new screws into each end plate [!].

Tighten the screws to 90-100 in.-Ibs. (10,0-11,5 Nm) torque. CD-0035

Tilt Spool and Centering Spring Assembly

Apply a light coating of petroleum jelly to a new spool seal (Item

7). Install the spool seal with lips toward the valve body, over
the spool (Item 8) [g.

Apply a light coating of grease to the centering spring parts

(Items 2-6). Install the back-up washer (Item 6), spring centering
washer (Item 5), spring (Item 4), spring centering collar (Item
3) and adapter (Item 2) onto the spool (Item 8) [g.

With the linkage end of the spool in a vise, install a screw and
lock washer into the adapter [Q] .

Tighten the screw to 90-100 in.-Ibs. (10,0-11,5 Nm) torque.

TAB 6 Control Valve

0134556
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CONTROL VALVE (Cont'd)

Tilt Spool and Centering Spring Assembly (Cont'd)

Apply oil to the spool assembly. Install spool assembly (Item

1) into the valve body. Install the end' cap (Item 2) (!J.

CD-0033

Install two (2) screws in the end cap [j].

Tighten the screws to 90-100 in.-Ibs. (1O,0-11,5Nm) torque.

Apply a light coating of petroleum jelly to a new spool seal (Item

1). Install the spool seal, with lips toward the valve body over
the spool [g.

Apply a light coating of grease to the back-up washer (Item 2).

Install the back-up washer on the spool [g.

Carefully push the back-up washer and spool seal into the valve
body.

CD-0031

Lift Spool and Detent Assembly

Install a new plastic plug (Item 2) and the stud (Item 1) into the
lift spool [Q].

Turn the stud in until approximately 0.50" (12,7 mm) can be

seen.

., 0.50"
(12,7 mm)

8-9973

TAB 6 Control Valve

-12- Component Repair Manual
0134551
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CONTROL VALVE (Cont'd)

Lift Spool and Detent Assembly (Cont'd)

Apply a light coating of grease to all of the detent components

before assembly.

Put the spring centering collar (Item 1) into a vise ~.

Install a spring and two (2) detent balls into the detent adapter
(Item 2).

Holding the detent balls in position with the detent tool

(MEL-1278), install the detent adapter (Item 2) into the spring
centering collar (Item 1) ~.

Apply a light coating of petroleum jelly to a new spool seal (Item

5). Install the spool seal, with lips toward the valve body, over
the spool (Item 6) I!l.

Apply a light coating of grease and install the back-up washer

(Item 4), spring centering washer (Item 3), spring (Item 2) and
detent adapter assembly (Item 1) onto the spool (Item 6) [j].

With the linkage end of the spool in a vise, tighten the detent
adapter to 90-100 in.-Ibs. (10,0-11,5 Nm) torque [g.

Apply a light coating of grease to the detent balls, spring and

detent sleeve before assembly.

Install a spring and two (2) detent balls into the detent adapter
(Item 1).

Holding the detent balls in position with the detent tool

(MEL-1278), install the detent sleeve (Item 2) over the detent
adapter (Item 1) ~.

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Lift Spool and Detent Assembly (Cont'd)

Apply oil to the spool assembly. Install the spool assembly into
the valve body ~.

CD-0026

Install the detent cap (Item 1) over the detent sleeve 00.
Install two (2) screws and lock washers to retain the detent cap
[00.

Tighten the screws to 90-100 in.-Ibs. (10,0-11,5 Nm) torque.

Install the washer (Item 1) snap ring (Item 2) and cap (Item 3)
[g.

CD-0022

Apply a light coating of petroleum jelly on a new spool seal (Item

1). Install the spool seal, with lips toward the valve body, over
the spool [Q].

Apply a light coating of grease to the back-up washer (Item 2).

Install the back-up washer on the spool [Q].

Carefully push the back-up washer and spool seal into the valve
body.

TAB 6 Control Valve

0134556
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CONTROL VALVE (Cont'd)

Rubber Boot Assembly

Install a new rubber boot in the retainer. Install the rubber boot
and retainer onto the valve body I!J.

Push the rubber boot toward the valve body to seat the rubber
boot in the spool groove ~ .

CD-0020

Install the two (2) screws through the rubber boot retainer II].

Tighten the screws to 90-100 in.-Ibs. (10,0-11,5 Nm) torque.

Auxiliary Electric Solenoid Assembly

Apply a light coating of petroleum jelly to three (3) new O-rings.

Install the O-rings on the solenoid valve ~.

Install the solenoid valve (Item 3) into the valve body ~.

Tighten the solenoid valve to 8-12 ft.-Ibs. (11-16 Nm) torque.

Install the solenoid coil (Item 2) and nut (Item 1)on the solenoid
valve ~.

Tighten the nut to 9-12 in.-Ibs. (1,0-1,4 Nm) torque.

TAB 6 Control Valve

Added May 94 -15- Component Repair Manual
00
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CONTROL VALVE (Cont'd)

Plug Assembly

Apply a light coating of petroleum jelly to two (2) new O-rings

and a new back-up washer. Install the new back-up washer
(Item 2) and two (2) O-rings (Items 1 & 3) on the plug ~.

Install the plug into the valve body 00.

Tighten the plug to 35-40 ft.-Ibs. (47-54 Nm) torque.

NOTE: Plugs can be located in the lIE", "F" and "H2" ports
depending on model. Refer to Page 1 for the correct
location and quantity.

CD-0016

Anti-Cavitation Valve Assembly

Apply a light coating of petroleum jelly to two (2) new O-rings

and a new back-up washer. Install the new back-up washer
(Item 2) and two (2) O-rings (Items 1 & 3) on the anti-cavitation
valve [g.

Install the anti-cavitation valve into the valve body [g.

Tighten the anti-cavitation valve to 35-40 ft.-Ibs. (47-54 Nm)

torque.

NOTE: Anti-cavitation valves can be located in "E" and "F"

ports depending on model. Refer to Page 1 for the
correct location and quantity.

CD-0014

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Port Relief Valve Assembly

Apply a light coating of petroleum jelly to two (2) new a-rings

and a new back-up washer. Install the new back-up washer
(Item 2) and two (2) new a-rings (Items 1 & 3) on the port relief
valve ~.

CD-0013

Install the port relief valve into the valve body 00.
Tighten the plug to 35-40 ft.-Ibs. (47-54 Nm) torque.

NOTE: The port relief valve can be located in the "E", "F"
and "H2" (If equipped with optional auxiliary port relief
valve) ports depending on model. Refer to Page 1 for
the correct location and quantity.

CD-0012

Main Relief Valve Assembly

Apply a light coating of petroleum jelly to a new glide ring, two

(2) new a-rings and a new back-up washer. Install the two (2)
new a-rings (Items 2 & 4), back-up washer (Item 3) and glide
ring (Item 1) on the main relief valve [g.

Install the main relief valve into the valve body ~.

Tighten the main relief valve to 35-40 ft.-Ibs. (47-54 Nm) torque.

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Load Check Valve Assembly

Apply oil to each spring and poppet. Install a poppet and spring
into ports 1 and 2.

Apply a light coating of petroleum jelly to three (3) new O-rings.

Install a new O-ring on both load check plugs and the plug.
Install the load check plugs (Item 1) and plug (Item 2) [jJ.

Tighten each plug to 35-40 ft.-Ibs. (47-54 Nm) torque.

Spool Seal Replacement Assembly

IMPORTANT
When making repairs on hydrostatic and hydraulic
systems, clean the work area before disassembly and
keep all parts clean. Always use caps and plugs on
hoses, tubelines and ports to keep dirt out. Dirt can
quickly damage the system
1-2003-0284

Remove the two (2) screws (Item 1), rubber boot (Item 2) and
back-up washer (Item 3) [g.

Remove the two (2) screws [Q].

TAB 6 Control Valve

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CONTROL VALVE (Cont'd)

Spool Seal Replacement Assembly (Cont'd)

Remove the spool assembly from the bore by pushing on the

linkage end of the spool ~.

NOTE: When servicing the lift spool, the detent end cap must
not be removed from the spool or reassembly of the
detent will be required. When servicing the tilt spool,
the end cap can be removed.

Remove the spool seal (Item 1) over the spool ~.

CO-0003

Remove the spool seal from the spool bore 00.

CO-0004

Apply a light coating of petroleum jelly to a new spool seal.

Install the spool seal, with lips toward the valve body, over the
spool [g.

NOTE: To protect the spool seal from damage during

installation, put plastic material (example: discarded
microfiche card) over the spool while installing the
spool seal.

Apply oil to the spool. Install the spool into the valve body ~.

CO-0003

TAB 6 Control Valve

-19- Component Repair Manual
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CONTROL VALVE (Cont'd)

Spool Seal Replacement Assembly (Cont'd)

Install! the two (2) screws to retain the end cap ~.

Tighten the screws to 90-100 in.-Ibs. (10,0-11,5 Nm) torque.

Apply a light coating of petroleum jelly to a new spool seal (Item

1). Install the spool seal, with lips toward the valve body, over
the spool ~.

Apply a light coating of grease to the back-up washer (Item 2).

Install the back-up washer on the spool 00.

Carefully push the back-up washer and spool seal into the valve
body.

Install the rubber boot onto the valve body [g.

Push the rubber boot toward the valve body to seat the rubber
boot in the spool groove.

CD-0006

Install the two (2) screws through the rubber boot retainer [Q].

Tighten the screws to 90-100 in.-Ibs. (10,0-11,5 Nm) torque.

TAB 6 Control Valve

01245006
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GLOSSARY OF TERMS AND COMPONENTS

NOTES __
For Hydraulic and Hydrostatic Systems

AUXILIARY HYDRAULICS - A set of hydraulic lines, couplers and valve used to

operate an attachment.

CAVITATION - A gaseous condition within oil which is caused by a pressure drop

due to a restriction.

CYLINDER, HYDRAULIC - A device which converts fluid power into linear mechanical
force and motion.

Cylinder, Lift - Used to raise the lift arms and attachment.

Cylinder, Tilt - Used to operate the bucket or attachment.

Base End - The fixed end of the hydraulic cylinder. This end has the larger
displacement area.

Rod End - The end of a hydraulic cylinder which has the moveable rod. This end has
a smaller displacement due to the area of the rod.

DETENT - A device used to hold the spool of a hydraulic valve engaged for continuous
flow of fluid.

DRIFT - Motion due to internal leakage past internal components in the hydraulic
system.

FLOW METER - A testing device which gauges the flow rate at a given pressure and
temperature.

FLOW RATE - The volume of fluid passing a point in a given time, under specific
pressure and temperature.

LEAKAGE - Fluid which escaped past seals, gears, pistons, etc.

MICRON - The size of openings in a hydraulic filter. One micron equals 0.00004 inch.

MOTOR, HYDROSTATIC - A device for converting fluid energy into mechanical force
and motion - usually rotary motion. Basic design types are
piston and geroller.

ORIFICE - A restricted passage in a hydraulic circuit. Usually a small hole limiting

flow which creates a pressure differential in a circuit.

PISTON DISPLACEMENT - The volume of air or fluid moved or displaced by moving

the piston from one end of its stroke to the other.

PRESSURE - Force per unit area, usually given in PSI.

Back Pressure - The pressure encountered on the return side of the system, due to
restrictions (tubelines, coolers, filter, etc.).

Charge Pressure - A regulated pressure used to force fluid into the hydrostatic
system.

Cracking Pressure - The pressure at which a relief valve, etc. begins to open and
pass hydraulic fluid.

Differential Pressure - The difference in pressure between any two points in a

system or a component (Also called pressure drop).

Operating Pressure - The pressure at which a system is normally operated.

Rated Pressure - The operating pressure which is recommended for a component

or a system by a manufacturer.

System Relief Pressure - The pressure at which the system relief valve is set and
will return oil back to tank.

TAB 7 Control Valve

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GLOSSARY OF TERMS AND COMPONENTS (Cont'd)

For Hydraulic and Hydrostatic Systems NOTES __

PUMP, HYDRAULIC - A device which converts mechanical force and motion into
hydraulic fluid power.

PUMP, HYDROSTATIC - A hydraulic pump, usually a piston type, operating at high

pressure (3000 to 5000 PSI) and can pump to either port
as directed.

RESTRICTOR - A device place in a line or passage which normally causes a pressure

drop in one direction (Example: floating orifice).

ROTATING GROUP - A cylindrical block with a series of holes and pistons. The
rotating group is usually connected to the splined pump shaft
and runs at or near engine speed.

VALVE - A device which controls fluid flow direction and pressure.

Anti-Cavitation Valve - A valve used to supplement fluid flow from a return passage
in the control valve to a cylinder port.

By-Pass Valve - A valve used to direct the normal flow of fluid to another route at
a given pressure.

Closed Center Valve - A valve that does not allow fluid flow when it is in neutral.

Load Check Valve - A valve used to hold a load when the spool is initially moved
to cause fluid flow to a pressure port.

Directional Control Valve - A valve used to direct fluid flow from a pump to
actuators.

Flow Control Valve - A valve used to supply a specific volume of fluid for a specific
function.

Open Center Valve - A valve that allows fluid flow when it is in neutral.

Pilot Operated Valve - A two-stage relief valve. A pilot senses system load and
opens to allow a larger relief port to open.

Poppet Valve - A spring loaded valve which prevents fluid flow when it is closed
against a seat.

Pressure Control Valve - A valve which directs fluid flow into a given passage
according to the amount of pressure it senses.

Priority Flow Divider Valve - A valve that divides the flow by first satisfying the
needs of one circuit and the remainder of the flow
is directed to another circuit.

Relief Valve - A pressure limiting valve.

Replenishing Valve - A valve used to add fluid to maintain a full hydraulic or

hydrostatic system.

Shuttle Valve - A valve moved by high pressure to open the return (low pressure)
side of the hydrostatic drive loop for fluid to be returned to the
system for cooling.

Shut-Off Valve - A valve used to allow fluid flow or block fluid flow.

Spool Directional Valve - A valve used to direct fluid flow from a pump to a working
circuit.

Volume Control Valve - A valve used to regulate the amount of fluid that goes to
a circuit.

VANES - Any plate, blade or similiar device attached to an axis and moved by air
or liquid.
TAB 7 Control Valve
Added Jan. 91 Component Repair Manual
01245002

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 Tractor Manuals Scotland

GLOSSARY OF TERMS AND COMPONENTS (Cont'd)

For Hydraulic and Hydrostatic Systems NOTES __

VISCOSITY - The internal resistance of a fluid, caused by molecular attraction,

which makes it resist flow.

TAB 7 Control Valve

01245006
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01245006

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M'ELROECOMPANY
___
Ml _ Jg 001
.. bobcat Revision Number

14 October 1987
HYDRAULIC CONTROL VALVE Date

COMPONENT REPAIR
MANUAL REVISION ROUTE TO
AFFECTING: ATTENTION
Product BOBCAT LOADER PARTS MANAGER D
SERVICE MANAGER [B'
Model AS LISTED IN MANUAL INDEX SALES MANAGER D
D
Manual No. 6570041 (4-86)

This is an update for the Component Repair Manual for the Melroe Hydraulic Control
Valve (PIN 6570941).

Remove the Hydraulic Control Valve Index Page & 2 and put in the revised page.

01245006
A BUSINESS UNIT OF CL'~RK EQUIPMENT COMPANY

Tractor Manuals Scotland - Please Do Not Copy

 Tractor Manuals Scotland

00134005

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 Tractor Manuals Scotland

M'E~ROECOMPANY 002
___fM _ ~ Revision Number
• bobcat 31 January 1991
Date
COMPONENT REPAIR MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product BOBCAT LOADER PARTS MANAGER D
SERVICE MANAGER ffi'
Model AS LISTED IN MANUAL INDEX SALES MANAGER D
D
ManuaI No. 6570041 (6-89) ___

This is an up-date to the Component Repair Manual for the Melroe Hydraulic Control
Valve (PIN 6570041).

Take out and put in the pages as listed below:

TAKE OUT PUT IN

INDEX INDEX (Revised Jan. 91)

AFTER TAB 5
GLOSSARY OF TERMS AND COMPONENTS HYDRAULIC CONTROL VALVE
TAB 5 (For Models 750 Series, 853 & 2410 Loaders)
(Added Jan. 91)

TAB 6 PAGE

GLOSSARY OF TERMS AND COMPONENTS

A BUSINESS UNIT OF CIRRK EQUIPMENT COMPANY Printed in U.S.A.

000
23
004

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00134005

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M'ELROECOMPANY
___fM _ ~
003
Revision Number
• bobcat 31 August 1992
Date
COMPONENT REPAIR MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product BOBCAT LOADER PARTS MANAGER D
SERVICE MANAGER []1"
Model AS LISTED IN MANUAL INDEX SALES MANAGER D
SERVICE TECHNICIAN []1"
Manual No. 6570041 (6-89)

This is an up-date to the Component Repair Manual for the Melroe Hydraulic Control
Valve (PIN 6570041).

TAKE OUT PUT IN

TAB 1
HYDRAULIC CONTROL VALVE-INDEX PAGE HYDRAULIC CONTROL VALVE-INDEX PAGE
(Rev. Aug. 92)
7,8 7 (Rev. Aug. 92), 8
9, 10 9, 10 (Rev. Aug. 92)
13 (Added Aug. 92), 14 (Added Aug. 92)
15 (Added Aug. 92), 16 (Added Aug. 92)

TAB 2
CONTROL VALVE INDEX 2400 CONTROL VALVE INDEX 2400
(Rev. Aug. 92)
3,4 3, 4 (Rev. Aug. 92)
9 (Added Aug. 92), 10 (Added Aug. 92)

TAB 4
CONTROL VALVE INDEX 1213 CONTROL VALVE INDEX 1213
(Rev. Aug. 92)
5,6 5 (Rev. Aug. 92), 6 (Rev. Aug. 92)
9 9, 10 (Added Aug. 92)
11 (Added Aug. 92), 12 (Added Aug. 92)
13 (Added Aug. 92)
TAB 5
HYDRAULIC CONTROL VALVE-INDEX PAGE HYDRAULIC CONTROL VALVE-INDEX PAGE
(Rev. Aug. 92)
5 (Rev. Jan. 91), 6 (Rev. Jan.91) 5 (Rev. Jan. 91), 6 (Rev. Aug. 92)
13 (Rev. Jan. 91) 13 (Rev. Jan. 91), 14 (Added Aug. 92)
15 (Added Aug. 92)

00134005
A BUSINESS UNIT OF ClARK EQUIPMENT COMPANY Printed in U.S.A.

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 Tractor Manuals Scotland

00134005

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M'E~ROEC()MPANY
-------
004

-bobcaf Revision Number

26 May 1994
Date
COMPONENT REPAIR MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product BOBCAT LOADER PARTS MANAGER D
SERVICE MANAGER [}?'
Model AS LISTED IN MANUAL INDEX SALES MANAGER D
Manual No. 6570041 (6-89)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

This is an up-date to the Component Repair Manual for the Melroe Hydraulic Control
Valve (PIN 6570041).
Take out the pages shown and put in the revised pages as follows:

TAKE OUT PUT IN

INDEX (Revised Jan. 91) INDEX (Revised May 94)

TAB 6
GLOSSARY OF TERMS AND COMPONENTS HYDRAULIC CONTROL VALVE
(Added Jan. 91) TAB 6 (For Models 750 Series, 853 & 2410 Loaders)
Pages 1 Thru 20 (Added May 94)

TAB 7

GLOSSARY OF TERMS AND COMPONENTS

(Added Jan. 91)

A BUSINESS UNIT OF ClARK EQUIPMENT COMPANY Printed in U.S.A.

00134005

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00134001

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