GROUP 4 MAIN CONTROL VALVE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
ż When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(3) Remove bolts and disconnect pipe.
(4) Disconnect pilot line hoses.
(5) Disconnect pilot piping.
(6) Sling the control valve assembly.and
remove the control valve mounting bolt.
ň weight : 104ָ
(7) Remove the control valve assembly.
ż 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.
‫ ڡ‬Cylinder (boom, arm, bucket)
‫ ڢ‬Swing motor
‫ ڣ‬Travel motor
ż See each item removal and install
(3) Confirmed the hydraulic oil level and
recheck the hydraulic oil leak or not.

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2. STRUCTURE (1/2)

1 O-ring 21 Cap 41 Over-load assy

2 Back-up ring 22 Plunger T assy 42 Cap
3 Cap 23 Plunger D assy 43 Cap
4 Check 24 Plunger A assy 44 Spring
5 Piston 25 Plunger M assy 45 Spring guide
6 Spring 26 Hex socket head bolt 46 Spool
7 Spring 27 Retainer 47 Sleeve
8 O-ring 28 O-ring 48 Piston
9 Cap 29 Spool 49 Spring
10 Piston 30 Spring 50 Check
11 Sleeve 31 O-ring 51 Poppet
12 Check 32 Spring guide 52 Sleeve
13 Spring 33 Hex nut 53 Spring
14 Cap 34 Cap 54 O-ring
15 O-ring 35 Cover 55 Shim
16 Main relief assy 36 Check 56 Shim
17 O-ring 37 Nylon chip 57 Spring guide
18 Cap 38 Spring 58 Cover
19 Housing 39 Check 59 Hex socket head bolt
20 Cap 40 O-ring 60 Cap

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STRUCTURE (2/2)

61 Cap 73 Spring washer 85 Poppet

62 Piston 74 Spring 86 O-ring
63 Spring 75 Check 87 Spring
64 O-ring 76 Spring 88 Check
65 Spool 77 Spool 89 Cap
66 Orifice 78 Cap 90 Cover assy
67 O-ring 79 Plunger C1 assy 91 O-ring
68 Back-up ring 80 Plunger B1 assy 92 Plug
69 Orifice 81 Housing 93 Back-up ring
70 Cap 82 O-ring 94 O-ring
71 O-ring 83 Spring
72 Hex socket head bolt 84 O-ring

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3. DISASSEMBLY AND ASSEMBLY

1) PRECAUTION
(1) Disassembly
‫ ڡ‬Handle the components carefully not to
drop them or bump them with each other
as they are made with precision.
‫ ڢ‬Do 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.
‫ ڣ‬When disassembled, tag the components
for identification so that they can be re-
assembled correctly.
‫ ڤ‬Once 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.)
‫ ڥ‬If 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
‫ ڡ‬Take the same precautions as for
disassembly.
‫ ڢ‬When 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.
‫ ڣ‬O-rings and backup rings are to be
replaced with new ones, as a rule.
‫ ڤ‬When installing O-rings and backup
rings, be careful not to damage them.
(Apply a little amount of grease for
smoothness.)
‫ ڥ‬Tighten the bolts and caps with
specified torque. (See "Disassembly
/Assembly".)

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2) MOUNTING AND DISMOUNTING VALVES

(1) Disassembly
3-plunger valve can be removed by 1
loosening socket bolts (1,2), while 4
plunger valve can be removed by
loosening socket bolt (3).

(2) Assembly
ż Valves should be mounted after making
sure that all O-rings and check assy are
placed on the assembling faces of 4-
plunger valve and that check valve and
spring are placed on assembling faces of
3-plunger valve.
ň Place the valve assembly on plane
surface. 2 3
ň Tighten the socket bolts at specified
torque after making sure that the
Tools
assembly is leveled.
ňHexagon socket : 10֮
ň Tightening torque. ňTorque wrench
10kgfňm (72.3lbfňft)

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3) OPERATING SECTION OF HYDRAULIC PACK

(1) Disassembling
‫ ڡ‬Loosen socket bolt (1) to remove cover 2 1
(2).
‫ ڢ‬Pull the plunger out while holding the
spring.
ż Do not pull it out violently, but draw it
out gently while making sure of its 3 4 5
contact with HG hole.
‫ ڣ‬Place the plunger between holders and
loosen plunger cap (3) by using a vise.
‫ ڤ‬Remove plunger cap (3), guide (4) and Tools
spring (5) in this order. ňHexagon socket : 8֮
ňTorque wrench

(2) Assembling
‫ ڡ‬Place the plunger between holders and
clamp the holders with the vise.
‫ ڢ‬Mount guide (4), spring (5) and plunger
cap (3) to the plunger.
‫ ڣ‬Tighten plunger cap (3) at the specified
torque.
Tightening torque : 6kgfňm (43.4lbfňft)
‫ ڤ‬Restore the plunger to the valve
while holding the spring section.

ż Insert the plunger into the valve hole

while turning it slowly so that it is well
aligned with the HG hole. In particular,
be careful not to hit it against the first
round corner.
‫ ڥ‬Install cover (2) after making sure that
O-ring is placed on the edge of the
valve hole and tighten socket bolt (1)
with the specified torque.
Tightening torque : 3kgfňm (21.7lbfňft)

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4) ORIFICE ASSEMBLY
(1) Disassembling 1
‫ ڡ‬Remove cap (1)
(2) Assembling
‫ ڡ‬Tighten cap (1) with the specified
torque.
ż Be careful for the backup ring not
to protrude.
Tightening torque : 10kgfňm (72.3lbfňft)

Tools
ňHexagon socket : 12֮
ňTorque wrench

5) CHECK ASSEMBLY
1
(1) Disassembling
‫ ڡ‬Remove cap (1)
‫ ڢ‬Remove spring (2) and check valve (3). 3

(2) Assembling
‫ ڡ‬Mount check valve (3) and spring (2) to 2
the valve housing.
‫ ڢ‬Tighten cap (1) at the specified torque.
ż Be careful for the backup ring not
to protrude.
Tightening torque : 10kgfňm (72.3lbfňft) Tools
ňHexagon socket : 12֮
ňTorque wrench

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6) LOAD CHECK ASSEMBLY
1
(1) Disassembling
‫ ڡ‬Remove cap (1) 3
‫ ڢ‬Remove check valve (2), spring (3)
and check valve (4). 2
(2) Assembling 4
‫ ڡ‬Mount check valve (4), spring (3) and
check valve (2) to the valve housing.
‫ ڢ‬Tighten cap (1) at the specified torque.
ż Be careful for the backup ring not
to protrude. Tools
Tightening torque : 10kgfňm (72.3lbfňft) ňHexagon socket : 12֮
ňTorque wrench

7) MAIN RELIEF ASSEMBLY

Relief assy is assembled into a single
block as a cartridge. Do not disassemble 1
the relief assembly as a rule.
(1) Disassembling
Remove the cartridge as it is while
holding cap (1).
(2) Assembling
Install the cartridge and tighten cap (1) at
the specified torque.
Tightening torque : 10kgfňm (72.3lbfňft)
Tools
ňSocket : 30֮
ňTorque wrench

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8) FOOT RELIEF ASSEMBLY

(1) Disassembling 6 5 3 4 2 1
‫ ڡ‬Loosen socket bolt(1) and remove
cover(2).
‫ ڢ‬Remove spring seat(3) and spring(4).
‫ ڣ‬Remove sleeve(5) and poppet(6).

(2) Assembling
Install in reverse order to removal.
Tightening torque : 5kgfňm (36.2lbfňft)

Tools
ňSocket : 8֮
ňTorque wrench

9) RELIEF ASSEMBLY
Relief assembly is assembled into a
single block as a cartridge. Do not 1
disassemble the relief assembly as a rule.
(1) Disassembling
Remove the cartridge as it is while
holding cap (1).
(2) Assembling
Install the cartridge and tighten cap (1) at
the specified torque.
Tightening torque : 4kgfňm (28.9lbfňft)
Tools
ňSocket : 27֮
ňTorque wrench

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10) SELECTOR VALVE ASSEMBLY
(1) Disassembling
‫ ڡ‬Remove cap (6) 1 2 3 4 5 6
‫ ڢ‬Pull the spool out while holding.
Torque wrench the spring.
‫ ڣ‬Take the spool with a holder and clamp
the latter with a vise.
‫ ڤ‬Remove hexagon nut (5), washer (4),
spring (3) and washer (2).

(2) Assembling
‫ ڡ‬Hold the spool with the holder and clamp
the latter on the vise. Tools
‫ ڢ‬Mount washer (2), spring (3) and washer ňHexagon socket : 36, 17֮
(4) to spool (1). ňTorque wrench
‫ ڣ‬Mount hexagonal nut (5) and tighten the
outer hexagon nut at the specified torque.
Tightening torque : 2.5kgfňm (18.1lbfňft)
‫ ڤ‬Restore the spool while holding the spring.
‫ ڥ‬Tighten cap (6) at the specified torque.
Tightening torque : 10kgfňm (72.3lbfňft)

11) CENTER BYPASS SPOOL ASSEMBLY

1
(1) Disassembling
‫ ڡ‬Remove cap (1) to take piston (2) off. 3
‫ ڢ‬Remove cap (3) to take spool assy (4) off. 2
(2) Assembling 4
‫ ڡ‬Insert spool assembly (4) into the valve
housing.
‫ ڢ‬Tighten cap (3) at the specified torque.
Tightening torque : 6kgfňm (43.4lbfňft)
‫ ڣ‬Insert piston (2) into cap (3).
Tighten cap (1) with the specified torque.
Tools
Tightening torque : 6kgfňm (43.4lbfňft)
ňSocket : 30֮
ňTorque wrench

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12) LOGIC CHECK ASSEMBLY
(1) Disassembling 7 6 5 4 3 2 1
‫ ڡ‬Remove cap (1) .
‫ ڢ‬Take off piston (2) and spring (3).
‫ ڣ‬Extract sleeve (4) with a magnet or the
like.
‫ ڤ‬Take off piston (5), spring (6) and check
valve (7).
(2) Assembling
‫ ڡ‬Mount check valve (7), spring (6) and
piston (5) into the valve housing. Tools
‫ ڢ‬Insert spring (3) and piston (2) into ňSocket : 36֮
sleeve (4). ňTorque wrench
‫ ڣ‬Mount sleeve (4) with spring (3) and
piston (2) to the valve housing.
‫ ڤ‬Tighten cap (1) at the specified torque.
Tightening torque : 10kgfňm (72.3lbfňft)

13) ARM REGENERATION

(1) Disassembling
9 8 7 6 5 4 3 2 1
‫ڡ‬ Remove cap (1) .
‫ڢ‬ Take off piston retainer (3) and spring (2).
‫ڣ‬ Remove cap (4).
‫ڤ‬ Take off spool (5), piston (6) and sleeve
(7).
‫ ڥ‬Take off spring (8) and check valve (9).
(2) Assembling
‫ ڡ‬Mount check valve (9) and spring (8) Tools
into the valve housing. ňHexagon socket : 10֮
‫ ڢ‬Insert piston (6) and spool (5) into ňSocket :27֮
sleeve (7). ňTorque wrench
‫ ڣ‬Mount sleeve (7) with piston (6) and
spool (5) to the valve housing.
‫ ڤ‬Tighten cap (4) at the specified torque.
Tightening torque : 6kgfňm (43.4lbfňft)
Mount spring (2) and spring retainer (3)
‫ ڥ‬to the assembly.
Tighten cap (1) at the specified torque.
‫ ڦ‬Tightening torque : 6kgfňm (43.4lbfňft)

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14) BUCKET FLOW SUMMATION CHECK
(1) Disassembling
3 2 1
‫ ڡ‬Remove cap (1) .
‫ ڢ‬Take off spring (2) and check valve (3).
(2) Assembling
‫ ڡ‬Mount check valve (3) and spring (2) to the
valve housing.
‫ ڢ‬Tighten cap (1) at the specified torque.
Tightening torque : 10kgfňm (72.3lbfňft)

Tools
ňHexagon socket : 12֮
ňTorque wrench

15) CHECK ASSEMBLY(4-plunger valve assembling face)

(1) Disassembling
‫ ڡ‬Remove cap (1) . 1
‫ ڢ‬Take off spring (2) and check valve (3).
(2) Assembling
‫ ڡ‬Mount check valve (3) and spring (2) to
2
the valve housing.
‫ ڢ‬Tighten cap (1) at the specified torque.
Tightening torque : 4kgfňm (28.9lbfňft)

Tools
ňSocket : 22֮
ňTorque wrench

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16) INTERNAL PARALLEL CIRCUIT
1 2
(1) Disassembling
‫ ڡ‬Remove cap (1) for 4-plunger valve.
‫ ڢ‬Screw M5 thread in the end extracting.
Torque wrench tap of orifice (2) and
extract orifice (2).
‫ ڣ‬Remove cap (5) for 3-plunger valve.
‫ ڤ‬Take off spring (4) and check valve (3).
(2) Assembling
5 4 3
‫ ڡ‬Mount check valve (3) for 3-plunger
valve and spring (4). Tools
‫ ڢ‬Tighten cap (5) at the specified torque. ňHexagon socket : 6֮
Tightening torque : 3kgfňm (21.7lbfňft) ňTorque wrench
‫ ڣ‬Mount orifice (2) to 4-plunger valve.
‫ ڤ‬Tighten cap (1) at the specified torque.
Tightening torque : 3kgfňm (21.7lbfňft)

17) LOAD HOLDING VALVE

(1) Disassembling (basic unit) 1
‫ ڡ‬Loosen socket bolt (1) to remove cover 2
assembly (2).
‫ ڢ‬Take off spring (3) and check valve (4).
3
(2) Assembling (basic unit)
‫ ڡ‬Mount check valve (4) and spring (3) to
4
the valve housing.
‫ ڢ‬Mount cover assembly (2) to the valve
housing and tighten socket bolt (1) at the
specified torque.
Tools
Tightening torque : 10kgfňm (72.3lbfňft)
ňHexagon socket : 10֮
ňTorque wrench

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(3) Disassembling (cover assembly)
5 6 7
‫ڡ‬ Remove cap (5).
‫ڢ‬ Take off spring (6) and check valve (7).
‫ڣ‬ Remove cap (8).
‫ڤ‬ Take off piston (9). 9
‫ڥ‬ Remove cap (10). 10
‫ڦ‬ Extract spring (11) and check valve (12). 8 11
‫ڧ‬ Push sleeve (13) out with a rod or the like
12
through the hole of cap (8).
ż Be careful not to damage the guideway 13
of the sleeve.
(4) Assembling (cover assembly)
‫ ڡ‬Mount sleeve (13) to the cover.
Tools
‫ ڢ‬Mount spring (11) with check valve (12)
ňHexagon socket : 8,10֮
to the cover.
ňTorque wrench
‫ ڣ‬Tighten cap (10) at the specified torque.
Tightening torque : 5kgfňm (36.2lbfňft)
‫ ڤ‬Insert piston (9) into the cover.
‫ ڥ‬Tighten cap (8) at the specified torque.
Tightening torque : 6kgfňm (43.4lbfňft)
‫ ڦ‬Mount check valve (7) and spring (6).
‫ ڧ‬Tighten cap (5) at the specified torque.
Tightening torque : 5kgfňm (36.2lbfňft)

(5) Assembly/disassembly
Put the plunger between holders and
clamp them by a vise after degreasing
the plunger and holders as a special tool.

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