SERVICE MANUAL- HYDRAULICS

CONTROL VALVE V91

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The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent, or incorrect
operation of the equipment or from misuse of the equipment.
Every effort has been made to ensure the accuracy the contents of this Manual, however the manufactures,
publishers and author accept no liability for any loss, damage or injury caused by any errors in or omissions
from the information contained within this document.
The contents of this Manual are believed to be correct at the time of printing. In the interests of a commitment
to a policy of continuous development and improvement , the manufacturer reserves the right to change the
specification of the products or their performance or the contents of this Manual, without notice.
All rights reserved. No part of this Manual may be stored, reproduced or transmitted in any form or by any
means, electronically or mechanically including photocopying, recording or by any information retrieval system,
without permission in writing from the publisher.

Copyright © HIAB AB February 2005

HIAB AB
SE-824 83
Hudiksvall
Sweden

Telephone +46 (0) 650 91000

FAX: +46 (0) 650 12174

Author: CLM

Date of Issue: February 2005

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Control Valve V91

CONTENTS
CONTROL VALVE 91 .................................................................. 4
Description ......................................................................... 4
Connections ....................................................................... 5
Spools ......................................................................................... 6
Description ......................................................................... 6
Dump valve (Closed) .................................................................. 7
Description ......................................................................... 7
Function ............................................................................. 7
Conclusion ......................................................................... 8
Dump valve (Open) ..................................................................... 9
Description ......................................................................... 9
Function ............................................................................. 9
Conclusion ......................................................................... 9
Idling ...........................................................................................11
Description ........................................................................11
Function ............................................................................11
1st and 4th function ................................................................. 13
Description ....................................................................... 13
Function ........................................................................... 13
Lifting ........................................................................................ 14
Description ....................................................................... 14
Function ........................................................................... 14
Conclusion ....................................................................... 15
Overload (Outer Boom) ............................................................ 16
Description ....................................................................... 16
Function ........................................................................... 16
Conclusion ....................................................................... 16
Overload (Extension) ............................................................... 17
Description ....................................................................... 17
Function ........................................................................... 17
Conclusion ....................................................................... 17

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CONTROL VALVE 91

fig.1

Description

Valve 91 is a load sensing pressure compensated control valve, a so-called closed-centre valve. This means
that each valve function delivers an oil flow directly proportional to control lever movement as long as pump
flow is sufficient. The flow is completely independent of load even when several valve functions are used
simultaneously. Valve 91 can be used together with a variable pump. However, we recommend a constant
displacement pump for HIAB cranes. Except 6 valve functions there is in the valve block, a shunt function, the
duty of which is to direct pump oil to tank and further to maintain a certain pressure in the pump line.
The valve block can be fitted with a solenoid valve, which controls the shunt function, e g when using remote
control. There are no separate port relief valves in valve 91. These relief valves have instead been moved out to
the load-holding valves for inner and outer boom cylinders, for the slew function to the crossover valve. For the
extension a special spool with built-in signal pressure relief for side A or B is available.
The load-holding valve LHV-91 has been specially developed to be used in the inner and outer boom functions
together with valve 91.

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Connections

P1 = Pressure connection from pump (R 3/4”)

P2 = Pressure outlet for pressure reduction filter (R 1/4”)

(CombiDrive)

P3 = Serial outlet to stabiliser valve. Serial connection plug necessary (R3/4”)

T1 = Tank connection (R 3/4”)

T2 = Return from pressure reduction filter (R 1/4”)

(CombiDrive)

T3 = Return from load-holding valve 91 (R 1/2”)

S1 = Gauge connection for signal pressure/ signal connection to variable pump (R 1/4”)
S2 = Signal pressure connection from following closed centre valve (R 3/8”)

There are also casting marks for side A and B, P-connections, T-connections, S-connections, and section
numbers.

Notes

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SPOOLS

fig.2

Description

The spools are adapted to suit crane size and function by means of shaping metering slits for a predetermined
and approved speed.

Each spool is coded. In this first case 14B which means 63-63-35-35. In more detail 63 1/mm to piston side
and 35 1/min out from rod side. From the other direction, 35 1/min into rod side and 63 1/mm out from piston
side.

It is about time to make acquaintance with the new valve symbol. Ports A and B are closed which is similar to
D-spools but we now have a “closed centre”, i e closed throughput in neutral position. Instead we find here
an S connected to T for tank. This S means signal line. Let’s take a closer look at the symbol figures when
describing the lifting and lowering functions.

The spool in the centre is a DM-spool, which as previously means motor spool. The code 84A means 50 L/min
out as well as in. As you can see from the symbol the DM-spool has ports A and B connected to tank in neutral
position.

The exterior of the bottom spool looks like the topmost spool, but there is a in–built signal pressure relief
valve. This is set at a fixed pressure, in this case 140 bar above port A. A spool of this kind can be used for
an extension function, because the 91-valve has a common signal pressure relief for ports A and B and the
port relief (shock) valves are fitted in the load holding valves. Normally there are no load-holding valves on the
extension cylinder and therefore pressure limiting for extension out is solved in this fashion.

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DUMP VALVE (CLOSED)

fig.3

Description

This is a cross-section of the connection end of valve 91 showing both dump valve and shunt. The shunt
housing at SI with shunt spring and shunt piston. The dump valve consists of the vertical cartridge in the top left
corner. This version is used for manual operation. For remote control a solenoid valve (dotted line) is added.

Shown also is the pump connection P1, the CombiDrive oil supply P2 and the oil supply P3 to the stabiliser
valve e g. The blue field in a diagonal pattern is a chamber behind connecting all tank connections such as
T1 to tank. Other tank connections include T2 (return from CombiDrive), T3 (port relief oil from and reference
pressure to the load-holding valve).

Function
In this case the dump valve is closed. When used for manual operation this means that a plug closes
connection between top and bottom side of the dump piston. For remote control with a voltage over the
solenoid the connection channel is also closed. Pump pressure having been transmitted up through the dump
piston into the spring housing becomes locked in and gives hydraulic balance to the dump piston. The spring
keeps the piston closed against releasing pump pressure to tank. The pressure level 13 bar is determined by
the shunt spring.

continued on page 6

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Conclusion

When used for manual operation or remote control with voltage over the dump solenoid (emergency button
pulled out) the closed dump valve means full standby pressure 13 bar to the valve. Pressure is determined by
the shunt.
We can follow this in fig.3: The shunt to the left admits oil to tank while the dump valve to the right is closed.
The plug below T2 is the serial plug used for a separate stabiliser valve connected to P3. The plug below T3 is
the plug seen to the left in the cross-section

Notes

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DUMP VALVE (OPEN)

fig.4

Description
The open dump valve is seen here. For opening a solenoid valve the same as used for remote control is
necessary.

Function
Voltage over the solenoid valve is OV, i e the emergency button is pushed in. A poppet opens connection to
tank whereby the locked in pressure behind the dump piston is released. The piston moves up and is balanced
only by the weak spring corresponding to 3 bar. The shunt spring closes the shunt and circulation pressure is
reduced to 3 bar with the shunt open.

Conclusion
Pushing in the emergency button will reduce circulation pressure from 13 bar to 3 bar which means reduced
heat generation.The hydraulic diagram shows that the plug below T3 has been replaced by a two-position valve
open/closed. With the valve open counter pressure will be drained and pump oil dumped to tank.

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fig. 5

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IDLING

Description

This is the valve when idling, i.e. no lever has been moved. Fig.5 shows a valve cross-section at different
levels. Far left the ground floor is seen with shunt, pressure compensator, and signal system including signal
pressure relief valves. Further to the right at the 3rd up to the 5th function we are moving upward to the spool
floor. Of course there are pressure compensators and signal systems under the spools as well. At the 6th
function we have moved down to the bottom floor again. Pressure compensator and pressure relief belonging
to this function are seen. It is to be noted that the signal system is equipped with balls on every function except
the last one. The reason for this being that the pressure must be drained when the lever is released.

Function

The pump is supplying oil at 120 l/min. Since the valve is a so-called closed-centre valve there is no other exit
for the oil than passage through the shunt back to tank. Since signal pressure is 0 bar and the signal pressure
spring puts up a resistance corresponding to 13 bar, this will be the circulation pressure.
The colours also make clear that the pressure compensator of each function reduces pressure down to 8 bar
above signal pressure which in this case was 0 bar. Seen also is the pressure gauge connection on the shunt
cover. It will indicate pressure in the signal pressure system. When idling full flow goes to tank over the shunt.

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1ST AND 4TH FUNCTION

Description

Figure 6 shows the same basics figure as the previous one, but the 1st and 4th function are being operated.
Same pump flow, 120 1/mm.

Function

First, the system will sense which one of the functions needs the highest working pressure. It is seen that
slewing needs 50 bar, extension 100 bar. The slew spool is made for 18 l/min, the extension spoo1 for 75 1/
min. 100 bar being the highest pressure passes through the signal system to the shunt.
Attempting to follow the diagonal pattern signal pressure we find it begins at the A-port of the 5th function,
passes through the spool out into the centre channel down to the pressure compensator and signal pressure
relief below (not shown). From there, signal pressure passes via the shuttle valve out toward the shunt. We can
see it appearing at the 2nd function (inner boom) where it is compared to 0 bar before progressing further to
the slew function. There, the signal pressure 100 bar is compared to the signal pressure 50 bar (lighter colour)
before going to the shunt.
Since the shunt spring is sized for 13 bar the shunt piston will build up a pump pressure of 13 + 100 bar = 113
bar. Following the pump channel to the slew function we can see that the compensator reduces pump pressure
to 58 bar which is 8 bar above signal pressure for this function. The same thing happens in 2nd, 3rd, 5th,
and 6th function but down to 8 bar, signal pressure being 0 bar. In the 4th function (extension) the pressure
regulator has adapted pressure to 108 bar since signal pressure is 100 bar. Oil consumption is 75 + 18 1/mm =
93 1/min. The surplus 27 1/min is conducted at 113 bar to tank via the shunt.

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LIFTING

fig.7

Description

We will now look at what happens in a cross-section of the valve when lifting. The spool at the top floor,
pressure compensator and signal pressure relief valve at the bottom. The spool has been moved. It has an
effective control stroke of 8 - 2 = 6 mm. Pressure requirement is 100 bar

Function

First thing to happen is signal pressure 100 bar being sensed at the B-port. The pressure is transmitted
to the right along the spool and out into the centre channel. From there signal pressure goes down to the
bottom floor, lifts the shuttle valve ball and goes further toward the shunt where it is added to the shunt spring
corresponding 13 bar. Out comes a pump pressure of 113 bar. At the same time the pressure compensator
adapts oil pressure for this function to 108 bar (signal pressure 100 bar + spring pressure equivalent to 8 bar).
Oil at 108 bar is conveyed up to the spool and is reduced in the metering spool slits to 100 bar as required. On
the return side the spool has opened to the tank channel.

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Conclusion

Pressure drop across the spool is always 8 bar, independent of load. This gives controlled, similar and
proportional flow regulation over the full effective spool stroke of 6 mm

Valve 91 with load sensing and pressure compensation makes it necessary to learn a new symbol figure.
The diagram to the right shows from bottom: The shuttle in the signal pressure system, pressure regulator,
signal pressure relief valve 265 bar and the moved spool.
The restriction shown below the spool is physically the restriction found inside the signal channel of the spool
at the outlet to the centre port (in practice two restrictions but only one at a time can function). More about this
restriction in the next figure on overload.
The restrictions inside the spool symbol are physically the metering slits in the spool.
When the spool is moved the centre signal channel is pressurized. The pressure will open the shuttle, (and pre-
pressurize the shunt, not shown), it will pre-pressurize the pressure regulator as well and apply pressure on the
signal pressure relief valve. Pump oil at a determined pressure is conducted out in port B, return oil goes to tank
via port A.

Notes

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OVERLOAD (OUTER BOOM)

fig.8

Description

Same basic figure as before but now there is an overload situation shown by the opened signal pressure relief
valve.

Function

Pressure level after compensating is always 8 bar above signal pressure. In this case at maximum level 265
bar + 8 bar = 273 bar. This pressure is found all the way to the cylinder since the cylinder is at standstill. Oil
at overpressure is led into the spool channel where it is restricted down to 265 bar before entering the centre
channel and further to open the signal pressure relief. Only 3 1/mm at 265 bar passes out via the signal pres-
sure relief valve. The remaining surplus oil at 278 bar goes to tank via the shunt.

Conclusion

When measuring the pressure at the shunt cover it will be the max pressure 265 bar. If measuring at the
cylinder it will be 8 bar higher, i e 273 bar. The overload 273 bar from the cylinder is led via the spool through a
8 bar restriction down to pressure regulator, signal pressure relief valve and shuttle valve. The signal pressure
relief opens at preset maximum pressure.

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OVERLOAD (EXTENSION)

fig.9

Description

Overload as shown in the previous figure but in this case a spool with built-in signal pressure relief valve. It
could be the extension function.
From the hydraulic diagram we find that maximum working pressure for port A is 140 bar.

Function

As always, the pressure level after compensation is 8 bar above signal pressure. Here 140 bar + 8 bar = 148
bar. Since an overload situation exists this pressure is found all the way up to the cylinder. Oil at 148 bar is
directed into the spool signal channel but is restricted at the entrance to 140 bar. Signal pressure travels as
before down in the centre channel but it acts upon and opens the signal pressure relief of the spool as well.
In this way signal pressure is limited to 140 bar for port A. The regular signal pressure relief at 265 bar is valid
for port B only. Also in this case only a small amount of oil at a signal pressure of 140 bar is going to tank.
Remaining surplus oil exits at 153 bar via the shunt (unless another function at a higher pressure is operated at
the same time).

Conclusion

The valve function is normally equipped with 1 signal pressure relief valve, valid for both ports. If separate
settings are needed a spool with built-in signal pressure relief is to be used. The symbol for a spool with built-
in signal pressure relief is much simplified and is expressed in our hydraulic diagrams only by noting a max
pressure inside the spool symbol. The function in the diagram is otherwise similar to the previous case, the only
difference being that the regular signal pressure relief has not opened.

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