GROUP 2 MAIN CONTROL VALVE

1. STRUCTURE
3 1 7 1 3

2
1 Plunger
2 Orifice
3 Load check valve 3
SW 6
4 Load check valve
5 Center bypass valve BM
3
6 Orifice AM
7 Foot relief valve BKT
4
8 Orifice OPT
9 Foot relief valve 4
TR
10 Over load relief valve
TL
11 Logic valve
12 Main relief valve 5 5
13 Arm summation check valve
14 Travel straight valve

9 9

10

12

11

13

14

2-21
 STRUCTURE

49
1
42
16
16 17 25
18 3
17 2 4 21
18 19
19 5 23
25 6
24 22
14 8
31 17
30 18
3230 19 13
26
33 34 25 24 7
36 35

29
30 55
20

10
7
9

11
12 24
25
8 19
18
17
15

1 Cover 14 Cap 27 Foot relief valve

2 O-ring 15 Cap 28 O-ring
3 O-ring 16 Cap 29 Cap
4 Spring 17 Back up ring 30 O-ring
5 Poppet 18 O-ring 31 Cap
6 Housing 19 Nylon chip 32 Cap
7 O-ring 20 Over load relief valve 33 Piston
8 Bolt 21 O-ring 34 Steel ball
9 Cover 22 Back up ring 35 Spring
10 Plunger 23 O-ring 36 Spool
11 Plunger 24 Check 42 Washer
12 Plunger 25 Spring 49 Bolt
13 Cover 26 Check

2-22
 STRUCTURE

45
21 39 37
38 18

38 15
37
39 19
21 40 18
40 25
24
21
44
42

39
47
48 40 21
43
24
40
25
26 42
41
19
18
54 17
53
52 46 40 21 40
43
30
31
51
50

15 Cap 37 Cap 47 O-ring

17 Back up ring 38 O-ring 48 Main relief
18 O-ring 39 O-ring 50 Cap
19 Nylon chip 40 O-ring 51 O-ring
21 O-ring 41 Bolt 52 Spring
24 Check 42 Washer 53 Spool
25 Spring 43 O-ring 54 Cap
26 Check 44 Bolt 55 Orifice
30 O-ring 45 Logic check
31 Cap 46 Manifold

2-23
 STRUCTURE

8
13
7 8
51
65 50

67 66
7
22
20
21
24 23
25 18
18 17
17 19
19 16
15
24 18
63 25 26 17
62 19
7 15
8
30
9 14
29
36 18
20 35 17
59 34 19
57 33
64 22 58 3032
61 12 56 60 30
30 31
37 29
28
27 42
49

7 O-ring 24 Check 49 Bolt

8 Bolt 25 Spring 50 Cap
9 Cover 26 Check 51 O-ring
12 Plunger 27 Foot relief valve 56 Plug
13 Cover 28 O-ring 57 O-ring
14 Cap 29 Cap 58 Plunger
15 Cap 30 O-ring 59 O-ring
16 Cap 31 Cap 60 Bolt
17 Back up ring 32 Cap 61 O-ring
18 O-ring 33 Piston 62 Plunger
19 Nylon chip 34 Steel ball 63 Plunger
20 Over road relief valve 35 Spring 64 Plunger
21 O-ring 36 Spool 65 Housing
22 Back up ring 37 Cap 66 Cover
23 O-ring 42 Washer 67 Piston

2-24
2. FUNCTION
1) HYDRAULIC CIRCUIT DIAGRAM

PY PL

Px PR

BR1
al1
bl1
Mu BL1
br1 AL1
d c
ar1
al2
AR1
bl2
a
ar2
BL2
b AL2
br2
BR2 al3
AR2
bl3
ar3
BL3
AL3
br3
BR3 al4
AR3
bl4
a BL4
AL4
b

c fr T3 Py Pi Px R fl d

2-25
2) BASIC OPERATION
(1) Travel straight circuit
This circuit keeps straight travel in case
of simultaneous operation of other P1 P2
actuators (SW, AM, BKT,BM) during a p

straight travel.
‫ ڸ‬During straight travel by operating
left/right travel plunger (TL, TR):
Operation of travel spool, the pilot Fr Fl
signal(PX) line inside the control valve is PL PR
blocked, but the pilot signal(PX) line is
connected to the tank by orifice
therefore, the travel straight select valve
is not operated ; oil from pump P1 is fed
into cylinder port AR3 only. SW
Oil from pump P2 is fed into cylinder
BM
port BL4 by the operation of TR plunger.
AM
Thus, straight travel is performed
separately with pump P 1 driving BKT

rightward travel(T L ) and pump P 2 OPT

driving leftward travel(TR). TR

TL
R

P2 P1

p
Pi

AL4 BL4 BR3 AR3 Py

P
Px
Py Px

TR al4 ar3

TL Travel - RH
Travel - LH Travel straight
select valve

PL Neutral(Except travel)

2-26
‫ ڹ‬In case of a swing operation during
straight travel for instance :
At the beginning of swing plunger stroke the
pilot signal(PX) line inside the control valve
P1 P2
is blocked and the signal pressure makes
p
the connection between the feed passages
of right and left travel plungers(TL, TR) by
switching spool (B) of travel straight select
valve. When the swing plunger is
completely switched, oil discharged from Fr Fl
PL PR
pump P1 preferentially flows into swing Orifice assy
motor which is positioned upstream.
Thus, simultaneous operation of swing and
straight travel is made possible as oil from
pump P2 is fed to swing and oil from pump
P 1 is fed to right travel(T R ) and left SW

travel(TL). BM
The orifice(A) at the upstream of the parallel AM
feed passage sends surplus oil of swing to
BKT
right and left travel(TL, TR) to avoid abrupt
OPT
change of the vehicle speed.
The basic operation is same with swing TR
even in the case of other actuators on upper TL
frame of machine during straight travel. R

P2 P1

AL1 BL1
p
SW
Pi

BR3 AR3 Py
P
Py Px al1 Px

Swing
TR
ar3

AL4 BL4
TL
Travel - RH Travel straight
select valve

al4 Spool B

Travel - LH
Swing spool opration

2-27
(2) Arm flow summation circuit
ş Arm out operation
Oil from pump P2 is fed into cylinder port
BL2 by adding pressure to arm plunger
pilot port bl2.
P1 P2
Oil from pump P1 flows into the center p
bypass valve assembly via the center
bypass passage. Since the same pilot
pressure of the arm plunger pilot port is
applied to the pilot signal port of the Fr Fl
center bypass valve assembly (C), the PL PR
center bypass spool is switched;pushing
up the arm flow summation check valve
in the manifold through center bypass
passage of RH travel section. Oil flows
into the high pressure feed passage, SW
and joins to the flow from the pump P2.
ş Arm in operation is same as above, BM
AM
summing the flow of the P2 pump.(Pilot
signal pressure is applied a port.) BKT
OPT

Center TR
TL bypass
valve
R
a

Spool C

P2 P1

AL2 BL2

AM
p
bl2

Arm Travel - RH

2-28
(3) Boom up flow summation circuit

Oil from pump P1 is fed into cylinder port

BR1 by adding pressure to boom plunger
pilot port br1.
Oil from pump P2 flows into spool(D) of
P1 P2
the center bypass valve assembly via
p
the center bypass passage. Since the
same pilot pressure of the boom plunger
pilot port is applied to the pilot port(b),
the center bypass spool assembly
closes. At the same time, boom(up) Fr Fl
PL PR
signal works on the logic check valve
and the valve(E) opens; oil flows from
the center bypass passage of swing
section through the logic check
assembly into the boom high pressure
feed passage and joins to the flow from SW

the pump P1. BM

AM

BKT
OPT

TR
TL Center
bypass
valve R

Spool D
P2 P1

BM

BR1 AR1

br1

Swing Boom
Logic valve

Spool E

2-29
3) OPERATIONAL DESCRIPTION OF CONTROL VALVE
(1) Plunger operation
‫ ڸ‬Neutral position of plunger

Parallel feed passage

Cylinder port B Load check valve Cylinder port A
Port relief Port relief
valve assy valve assy

C2
C1
Pilot port a

Pilot port b

Spring
Tank passage Center bypass Tank passage
High pressure
feed passage

In neutral, spring sets the plunger at the neutral position; the high pressure feed passage is shut
off by the plunger; oil from the pump flows through the center bypass.

2-30
 ‫ ڹ‬Operation of plunger

Parallel feed passage

Cylinder port B Load check valve Cylinder port A

Port relief valve assy Port relief valve assy

C2
C1
Pilot port a

Pilot port b

Spring
Tank passage Center bypass Tank
High pressure passage
feed passage

When actuated(pressure is applied to pilot port a), the plunger moves to the left; the center
bypass is shut off; oil from the center bypass pushes up the check valve C1 and flows into
cylinder port A via the high pressure feed passage. Meanwhile, oil from the parallel feed
passage pushes down check valve C2 and flows into cylinder port A via the high pressure feed
passage.
The return oil from cylinder port B flows into the tank via the tank passage.
Ɠ Reversed when pressure is applied to pilot port b.

2-31
(2) Foot relief valve operation
‫ ڸ‬fp is lower than spring force

Spring B Orifice C

Poppet A

(fp) From center

bypass passage

Pressure signal
sent out to pump

Tank passage

Hydraulic oil from the center bypass passage flows into the tank via orifice(C) of poppet(A).
Pressure fp generated by orifice(C) is led to the pump, to control the pump delivery flow.

‫ ڹ‬fp is higher than spring force

Spring B

Poppet A

If a large amount flows due to delayed pump response, etc., and pressure fp reaches the preset
spring(B) force, then the poppet(A) is lifted and functions as a relief valve.

2-32
(3) Logic check valve operation
‫ ڸ‬Boom down or neutral
When boom up pilot pressure is not supplied.

Check C

Boom (up) Check B Orifice D

pilot signal

From 4 spool
side valve(Pa)

b d2
Z d1

To 3 spool side boom high

Piston A 1 pressure feed passage(Pb)

Tank passage

Spring force sets piston (A) in the shown position;

Pressure in the passage a (Pa) enters chamber (Z) via passage (1) and passage(2).
Pressure in the passage b (Pb) enters chamber (Z) via orifice(D).

If Pa > Pb
Check valve (C) is seated by area d1 > d2 and passage from a to b is blocked.

If Pa < Pb
Passage from b to a is blocked by the check valve (C).

2-33
‫ ڹ‬Boom up
When boom up pilot pressure is supplied.
Piston (A) moves to right; passage (1) is shut off from passage (2).

Check C

Boom (up) Check B Orifice D

pilot signal

From 4 spool
side valve(Pa)

b d2
Z d1

To 3 spool side boom high

Piston A 1 pressure feed passage(Pb)

Tank passage

When Pa > Pb

When Pa > Pb
Check valve (C) is lifted as the shown position; oil flows through from a to b.

When Pa < Pb
Passage from b to a is blocked by the check valve (C), because d1 > d2 .

2-34
(4) Main relief valve operation
‫ ڸ‬High pressure setting pilot signal : OFF
Piston (D) is seated to the right by spring (C) force.

Pilot poppet B
Main poppet A
Spring C
Piston D
d1
d2

From pump port

(Py)

1
Pilot signal : OFF

Tank passage 2 3 5 4

This relief valve is built-in between the pump port side (1) and tank passage.
Hydraulic oil from the pump port side enters chamber (3) via orifice (2) of poppet (A). Because
d1 >d2, poppets (A) is securely seated.

Pilot poppet B
Main poppet A
Spring C
Piston D

From pump port

To tank passage
2 3 5 4

When hydraulic oil reaches the pressure preset by spring (C), pilot poppet (B) opens; oil flows
around pilot poppet (B) and into the tank passage via side hole (4) and passage (5).

2-35
 Main poppet A

d1
d2

From pump port

To tank passage
2 3

When the above oil flow is formed, pressure drops before and behind orifice (2); when pressure
of chamber (1) x area d2 is larger than pressure of chamber (3) x area d1, main poppet (A) is
lifted and hydraulic oil flows into the tank passage.

Spring C
Piston D

From pump port

(Py)

Pilot signal : ON

To tank passage

‫ ڹ‬High pressure setting pilot signal : ON

Piston (d) moves to left; set pressure of spring (C) rises, making high pressure setting.

2-36
(5) Overload relief valve operation
‫ ڸ‬Overload working operation

Poppet B
Piston A Cylinder port
Pilot poppet C
(Front end orifice) (Front end orifice)

d2 d1

Spring D

1 Tank passage 2 Passage E

Hydraulic oil from cylinder port enters chamber (2) via orifice of piston (A). Because d1 >d2,
main poppet (A) is securely seated.

Poppet B
Piston A Cylinder port
(Front end orifice) Pilot poppet C
(Front end orifice)

Spring D

1 To tank passage 2 Passage E

When hydraulic pressure reaches the preset force of spring (D), pilot poppet (C) opens; oil flows
around poppet (C) and into the tank passage via side hole and passage (E).

2-37
 Poppet B
Piston A Cylinder port
(Front end orifice) Pilot poppet C
(Front end orifice)

Spring D

1 To tank passage 2 Passage E

Oil flow is formed; pressure drops before and behind orifice of piston (A); piston (A) moves to
right and seats at the tip of pilot poppet (C).
Hydraulic oil from chamber (1) flows into the tank passage via orifice of piston (A) and pilot
poppet (C), side hole and passage (E).

Poppet B
Piston A Cylinder port
(Front end orifice) Pilot poppet C
(Front end orifice)

Spring D

1 To tank passage 2 Passage E

Pressure drops before and behind orifice of pilot poppet (C), making pressure of chamber
(1)>pressure of chamber (2); poppet (B) is lifted and hydraulic oil flows into the tank passage.

2-38
‫ ڹ‬Make up operation

Poppet B
To cylinder port

d2 d1

Fron tank passage

Poppet (B) is securely seated because the cylinder port pressure is normally higher than the
tank pressure and d1 > d2.
When the cylinder port pressure drops(closer to negative pressure) until the cylinder port
pressure is lower than the tank pressure, poppet (B) opens receiving the tank pressure for the
difference in area between d1 and d2; oil flows from the tank passage to the cylinder port in order
to prevent cavitation.

2-39
 (6) Arm regeneration circuit
‫ ڸ‬Arm in operation

Cp
Parallel passage
(PA) (PB)

AL2 BL2

C1
Around passage

Pilot
port a Pilot port b

C2
High pressure feed passage Tank passage
Center bypass passage

When pressure is applied to pilot port a of the arm plunger, the plunger moves to right as shown;
the center bypass passage is shut off; oil from the center bypass pushes up check valve (C1)
and flows into cylinder bottom port via the high pressure feed passage.

‫ ڹ‬PA is lower than PB

(PA) (PB)

AL2 BL2

C2
High pressure feed passage Tank passage

Return oil from cylinder rod side pushes up check valve (C2) in the plunger; it flows into cylinder
bottom side after returning to the high pressure feed passage.

2-40
‫ ں‬PA is higher than PB

(PA) (PB)

AL2 BL2

C2
Tank passage

The check (C2) is seated by the pressure (PA) of cylinder bottom side, the return oil from cylinder
rod side flows into the tank passage.

2-41
(7) Load holding valve operation
‫ ڸ‬When the plunger is in neutral (Px pilot signal : OFF)

5 Z

Check C

Check D 1
6
d1
To boom
bottom

d2 2(Pc) 7

3(Pv)
(Px)
Poppet B
Piston A

Pilot signal : OFF

VIEW Z
4 High pressure
Tank passage feed passage

Piston (A) and poppet (B) are in the status as shown; passages (5) and (6) are shut off by
poppet (B).
Therefore, the pressure of chamber (1) becomes PC as it is connected with chamber (2) via
orifice (4). Since d1 >d2, check (C) is seated, chambers (2) and (3) are completely blocked.

2-42
 ‫ ڹ‬When the plunger is operated (Px pilot signal : ON)
A. When PC is lower than PV (in the case of Boom UP)

5 Z

Check C

Check D 1
6

To boom
bottom

2(Pc) 7

3(Pv)
(Px)
Poppet B
Piston A

Pilot signal : ON

VIEW Z
4 High pressure
Tank passage feed passage

Because check valve (C) is seated, passages (6) and (7) are shut off. Therefore, the pressure
of chamber (1) becomes PC as it is connected to chamber (2) via orifice (4); poppet (D) is
pushed up; oil from high pressure feed passage flows into the cylinder port.

2-43
 B. When PC is higher than PV (In case of Boom down)

5 Z

Check C

Check D 1
6
d1
From boom
bottom

d2 2(Pc) 7

3(Pv)
VIEW Z

To tank passage

Piston (A) moves to right; poppet (B) opens; passages (5) and (6) are connected.
If pressure PC of cylinder port chamber (2) is higher than pressure PV of chamber (3), oil from
chamber (1) pushes up check valve (C) via passages (5) and (6) and enters chamber (3)
through passage (7). Chamber (3) is connected with the tank passage because the boom
plunger is moved to left. Therefore, pressure PC is applied to (area d1 - area d2), pushing up
check (D), and oil from the cylinder port flows into the tank passage.

2-44