GROUP 4 MAIN CONTROL VALVE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury. 2
Ɠ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
1
(4) Remove bolts(2) and disconnect pipe.
(5) Disconnect pilot line hoses.
(6) Disconnect pilot piping.
3
(7) Sling the control valve assembly(1) and
remove the control valve mounting bolt(3).
ňWeight : 135kg(298lb)
(8) Remove the control valve assembly(1).
Ɠ When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL

(1) Carry out installation in the reverse order

to removal.
(2) Bleed the air from below items.
‫ ڸ‬Cylinder(Boom, arm, bucket).
‫ ڹ‬Swing motor.
‫ ں‬Travel motor.
Ɠ See each item removal and install.

(3) Confirm the hydraulic oil level and

check the hydraulic oil leak or not.

8-29
2. STRUCTURE(1/2)

40
8
9
42
31 32
16
33
15
34
76
58 64
77
36 78
15
35 6

25

27
28
26

15 25
83
82
9
4 8
15 3

57 67
6 66
25 56 57
74 6
56
57 65
2 6
39 1 56
38 80
37 26
79
66 81
67
6 57 21
25 89 6
56
24
23
75 73
86 44
12 45
24 2 43
13 23 29
19 30
87 15
6
9
85 68 8
14 58 31
70 29
17
18 30
69
15 31
16

1 Cap 14 Cap 27 O-ring

2 O-ring 15 O-ring 28 Housing
3 Socket bolt 16 Cap 29 O-ring
4 Spring washer 17 Spring 30 Retainer
5 Overload assy 18 Spring guide 31 Socket bolt
6 O-ring 19 Spring guide 32 Plunger assy(TS)
7 Orifice 20 Cap 33 Plunger assy(TL, TR)
8 Cap 21 Spring 34 Plunger assy(SW)
9 O-ring 22 Check 35 Plunger assy(BM2)
10 Cover 23 Cap 36 Plunger assy(AM1)
11 Socket bolt 24 O-ring 37 Cover assy
12 Sleeve 25 O-ring
13 Check 26 O-ring

8-30
STRUCTURE(2/2)

8 31
9

42
40 33 16
51 15
42 76
52 77 63
58 78
55 54 15
56 62
6 57 53 61
66 60
67 7
59
73
71 56 6 8
56 57 9
6 69
57 66 1
72
66 2
67
A
75 50
49
6
48 3
47 4
46
11 24
23
92
10 89
91
88
89
90
26 2
41 15
1
A
15 58 29
94
93 30 29
95 22 84 31 30
21 8
5 29
6 9
20 30 31

31

38 Spring 53 Plunger assy(BM1) 68 Spacer 83 Spool

39 Poppet 54 Plunger assy(AM2) 69 Cover 84 Stopper
40 Cover 55 Cap 70 Piston 85 Selector assy
41 Manifold 56 Back up ring 71 Cap 86 O-ring
42 O-ring 57 Nylon chip 72 Check 87 O-ring
43 Cap 58 Overload assy 73 Cap 88 Spring guide
44 Spring 59 Spring 74 Cap 89 Spring
45 Spool 60 Check 75 Foot relief assy 90 Poppet
46 Plug 61 O-ring 76 Plug 91 O-ring
47 O-ring 62 Back up ring 77 Back up ring 92 Back up ring
48 Retainer 63 Cap 78 O-ring 93 O-ring
49 Socket bolt 64 Main relief assy 79 Cap 94 Back up ring
50 Housing 65 Cap 80 Spacer 95 O-ring
51 Plunger assy(OPT) 66 Spring 81 Check
52 Plunger assy(BKT) 67 Check 82 Spring

8-31
3. DISASSEMBLY AND ASSEMBLY
1) PRECAUTION
(1) Disassembly
‫ ڸ‬Handle the components carefully not to
drop them or bump them with each other
as they are made with precision.
‫ ڹ‬Do not force the work by hitting or
twisting as burred or damaged
component may not be assembled or
result in oil leakaged or low performance.
‫ ں‬When disassembled, tag the
components for identification so that they
can be reassembled correctly.
‫ ڻ‬Once disassembled, O-rings and backup
rings are usually not to be used
again.(Remove them using a wire with its
end made like a shoehorn. Be careful
not to damaged the slot.)
‫ ڼ‬If the components are left disassembled
or half-disassembled, they may get rust
from moisture or dust. If the work has to
be interrupted, take measures to prevent
rust and dust.
(2) Assembly
‫ ڸ‬Take the same precautions as for
disassembly.
‫ ڹ‬When assembling the components,
remove any metal chips or foreign
objects and check them for any burrs or
dents. Remove burrs and dents with oil-
stone, if any.
‫ ں‬O-rings and backup rings are to be
replaced with new ones, as a rule.
‫ ڻ‬When installing O-rings and backup
rings, be careful not to damage
then.(Apply a little amount of grease for
smoothness.)
‫ ڼ‬Tighten the bolts and caps with specified
torque.(See Disassembly/Assembly.)

8-32
2) MOUNTING AND DISMOUNTING VALVES
(1) Disassembly
‫ ڸ‬Remove socket bolts and separate 4
spool valve and 5 spool valve.
(2) Assembly
Ɠ Valves should be mounted after making
sure that all O-rings and caps are placed
on the assembling faces of 4 plunger
valve.
‫ ڸ‬Carry out assembly in the reverse
manner of disassembly.
‫ ڹ‬Tighten the bolts to the specified torque.
ϦTightening torque : 10kgfϦm
(72.3lbfϦft)

Socket bolt
Tools
ϦHexagon socket : 10mm
ϦTorque wrench

8-33
3) PLUNGER
3 2 1
(1) Loosen socket bolt(1) and remove cover
(2).
ϦTightening torque : 3kgfϦm(21.7lbfϦft)
Ɠ Install cover (2) after making sure that O-
ring is placed on the edge of the valve
hole.
Tools
ϦHexagon socket : 6mm
ϦTorque wrench

(2) Pull the plunger out while holding the

spring.
Ɠ Do not pull it out violently, but draw it out
gently while making sure of its contact
with housing hole.

(3) Place the plunger between holders and

loosen plunger cap(3) by using a vise. Holder
ş Plunger cap
Hexagon socket : 8mm Spring guide
Tightening torque : 6kgfşm(43.4lbfşft)

(4) Remove plunger cap(3), spring guide(4)

and spring(5) in this order.

3 4 5 4

Tools
ϦHexagon socket : 8mm
ϦTorque wrench

8-34
 (5) Arm plunger only (Remove check).
Remove cap(6) and disassemble spring
(7) and check(8).
şTightening torque : 3kgfşm(21.7lbfşft)

8 7 6
Tools
ϦHexagon socket : 6mm
ϦTorque wrench

4) MAIN RELIEF ASSEMBLY

Relief assy is assembled into a single block
1 2 3 4
as a cartridge. Do not disassemble the
relief assembly as a rule.
(1) Loosen the hexagon nut(2) with a holding
adjust screw(1).
(2) Loosen the hexagon nut(3) with a holding
cap(4)
(3) Loosen the cap(4) and remove the
cartridge.

(4) Pull out the sleeve(6) and take off the

main poppet(7), spring(8) and orifice(9). 4 5
Ɠ Can't remove the pilot seat(5) from the
cap(4), because it was locked at the cap.

(5) Loosen each screw and remove.

Item No. Name Socket

1 Adjust screw 22mm
2 Hexagon nut 30mm
3 Hexagon nut 30mm
4 Cap 30mm

9 8 7 6

8-35
5) OVERLOAD RELIEF VALVE ASSEMBLY
Relief assembly is assembled into a single 1
block as a cartridge. Do not disassemble
the relief assembly as a rule.
(1) Loosen the relief sleeve (1) and remove
the cartridge.
ϦTightening torque : 4kgfşm(29lbfşft)
Tools
ϦHexagon socket : 27mm
ϦTorque wrench

(2) Loosen the relief seat (2) and remove the

subassembly.
ϦTightening torque : 6kgfşm(43.4lbfşft)

6 5 4 3 1 2

Tools
ϦHexagon socket : 24mm
ϦTorque wrench

(3) Pull out the poppet(3) and take off the

spring(4), piston(5) and main poppet(6).

3 6 2

5 4

8-36
6) FOOT RELIEF ASSEMBLY
(1) Loosen cap(1) and remove poppet (2).
ϦTightening torque : 6kgfşm(43.4lbfşft) 1

Tools
ϦHexagon socket : 30mm
ϦTorque wrench

(2) Remove cap (3) and take off shim (4) and
spring (5).
ϦTightening torque : 6kgfşm(43.4lbfşft) 3
Ɠ Make sure adjust shim quantity.

Tools
ϦHexagon socket : 30mm
ϦTorque wrench

8-37
7) BOOM HOLDING VALVE ASSEMBLY
(1) Loosen the socket bolt(1) and remove the
cover assy(2).
ϦTightening torque : 5kgfşm(36.2lbfşft) 2 1
Ɠ Install cover assy(2) after making sure
that O-ring is placed on the edge of the Overload
relief valve
valve hole.
(2) Remove the spring guide(3), spring(4)
and poppet(5).

3 4 5

Tools
ϦHexagon socket : 8mm
ϦTorque wrench

(3) Remove the cap(6), spring(7) and

spool(8).
ϦTightening torque : 3kgfşm(21.7lbfşft)

8 7 6

Tools
ϦHexagon socket : 6mm
ϦTorque wrench

8-38
8) CENTER BYPASS VALVE ASSEMBLY
(1) Remove cap (1). 1
ϦTightening torque : 8kgfşm(57.9lbfşft)

Tools
ϦHexagon socket : 36mm
ϦTorque wrench

(2) Remove spool (2) and spring (3).

8-39
9) ARM REGENERATION VALVE
1
(1) Remove cap(1) and take off spring(2),
spring guide(3), check(4) and sleeve(5).
ϦTightening torque : 10kgfşm(72.3lbfşft)

5 4 3 2
Tools
ϦHexagon socket : 27mm
ϦTorque wrench

(2) Remove cap(6) and spring guide(7).

ϦTightening torque : 6kgfşm(43.4lbfşft)

1 7 6

Tools
ϦHexagon socket : 10mm
ϦTorque wrench

8-40
10) ARM STROKE LIMIT ASSEMBLY
1 2
(1) Loosen the socket bolt(1) and remove
cover(2).
ϦTightening torque : 3kgfşm(21.7lbfşft)

Tools
ϦHexagon socket : 6mm
ϦTorque wrench

(2) Remove piston(3) and take off O-ring(4),

spacer(5) from the valve hole.
Ɠ Make sure inserting direction of the
spacer.

5 4 3

11) ARM LOAD HOLDING VALVE

(1) Basic unit
‫ ڸ‬Loosen socket bolt (1) and remove cover 2
assembly (2).
ϦTightening torque : 10kgfşm(72.3lbfşft)
Ɠ Install cover assembly (2) after making
sure that O-ring is placed on the edge of
1
the valve hole. Tools
ϦHexagon socket : 10mm
ϦTorque wrench

‫ ڹ‬Take off spring(3) and check valve(4).

8-41
(2) Selector unit
5
‫ ڸ‬Remove cap (5).
Take off piston(6) and spring(7). 6
ϦTightening torque : 3kgfşm(21.7lbfşft) 7

Tools
ϦHexagon socket : 6mm
ϦTorque wrench

(3) Cover assembly

8 9 10 11 12 13
‫ ڸ‬Remove cap(14).
Take off spring(15) and check valve(16).
ϦTightening torque : 5kgfşm(36.2lbfşft)

16
Tools 15
ϦHexagon socket : 8mm 14
ϦTorque wrench

‫ ڹ‬Remove cap (13) and take off piston (12).

ϦTightening torque : 6 kgfşm(43.4lbfşft)
‫ ں‬Push sleeve (11) out with a rod or the like
through the hole of cap (13).
Ɠ Be careful not to damage the guideway
(‫ٻ‬5) of the sleeve. 12 13

Tools
ϦHexagon socket : 10mm
ϦTorque wrench

‫ ڻ‬Remove cap (8).

Take off spring (9) and poppet (10).
8 9 10
ϦTightening torque : 5kgfşm(36.2lbfşft)

Tools
ϦHexagon socket : 8mm
ϦTorque wrench

8-42
12) BOOM FLOW SUMMATION CHECK
(1) Remove the cap(1) and take off spring(2)
and check(3).
ϦTightening torque : 10kgfϦm(72.3lbfϦft) BM1

Boom flow summation check

1 2 3
Tools
ϦHexagon socket : 12mm
ϦTorque wrench

13) BUCKET FLOW SUMMATION CHECK

(1) Remove the cap(1) and take off check(2)
and spring(3). BKT
ϦTightening torque : 6kgfϦm(43.4lbfϦft)

Bucket flow summation check

3 2 1

Tools
ϦHexagon socket : 30mm
ϦTorque wrench

8-43
14) CHECK ASSEMBLY(BOOM1, 2, BUCKET,
OPT, SWING, ARM-1)
(1) Remove cap(1).

Tools
ϦHexagon socket : 12mm
ϦTorque wrench

(2) Remove spring(2) and check(3).

ϦTightening torque : 10kgfϦm(72.3lbfϦft)

2 3

15) CHECK ASSEMBLY(ARM 2)

1 4 2 3
(1) Remove cap(1).

Tools
ϦHexagon socket : 12mm
ϦTorque wrench

(2) Remove spring(2) and check(3, 4).

ϦTightening torque : 10kgfϦm(72.3lbfϦft)

4 2 3

8-44
16) CHECK ASSEMBLY(TR)
(1) Remove cap(1).
ϦTightening torque : 10kgfϦm(72.3lbfϦft)

Tools
ϦHexagon socket : 12mm
ϦTorque wrench

(2) Take off spring(2) and check(3).

2 3

17) CHECK ASSEMBLY(P1)

(1) Remove cap(1).
ϦTightening torque : 10kgfϦm(72.3lbfϦft)

Tools
ϦHexagon socket : 12mm
ϦTorque wrench

(2) Remove spring(2) and check(3).

2 3

8-45
18) CHECK ASSEMBLY(TL)
1 2
(1) Remove cap(1) and spacer(2).
ϦTightening torque : 10kgfϦm(72.3lbfϦft)

Tools
ϦHexagon socket : 32mm
ϦTorque wrench

(2) Remove cap(3) and take off spring(4) and

check(5). 3 4 5
ϦTightening torque : 4kgfϦm(29lbfϦft)

Tools
ϦHexagon socket : 8mm
ϦTorque wrench

19) SELECTOR VALVE ASSEMBLY

(1) Remove cap(1) and take off spring(2) and
1 2
spool(3).
ϦTightening torque : 3kgfϦm(21.7lbfϦft)

Tools
ϦHexagon socket : 6mm
ϦTorque wrench

8-46