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.
Ɠ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(4) Remove bolts and disconnect pipe.
(5) Disconnect pilot line hoses.
(6) Disconnect pilot piping.
(7) Sling the control valve assembly and
remove the control valve mounting bolt.
şWeight : 193kg(426lb)
(8) Remove the control valve assembly.
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(1/3)

551
561
521
511

551
561
521
511

C1

C2

Cp2

603 167
553 155
602 203
561
201 102
551
611
974 561 159 601
971 159
201
209 556 203
165
201 602

971 975

209

165
202
165 103
561
153 602

561 603

553
252
201
602 556
602 101
602
561 561
153 153

561 602
551
611

101 Casing A 203 Cover 561 O-ring

102 Casing B 209 Flange 601 Relief valve
103 Block 252 Lock valve 602 Port relief valve
153 Plug 511 Poppet 603 Relief valve
155 Plug 521 Spring 611 Relief valve(Negative)
159 Plug 551 Plug 971 Screw
165 O-ring 553 Plug 974 Socket head screw
167 O-ring 556 Plug 975 Screw
201 Cover

8-30
STRUCTURE(2/3)

164

333

336 331
338
332 329
335
336 328
379
331
336 332 371 262
339 332
154 332 261
372
335
164 372 374
202 332
378 308
261
273 332
305
261
307
168

302 395
K
A
W
A
S
A
K
I
T
(L

392
)
S
B
2
A
1
B
C

515
521
561
516 551
523
561
552
518
521
561
264 168 551
261
264

273 561
202 551
332 204
561 511
551 339
204 376
371
332
336
273

164

154 Plug 328 Spring 378 Spring

164 O-ring 329 Spring 379 Spring
168 O-ring 331 Seat 392 Rod
202 Cover 332 Seat 395 Swing priority spool
204 Cover 333 Bolt 511 Poppet
261 O-ring 335 Stopper 515 Poppet
262 O-ring 336 Bolt 516 Poppet
264 O-ring 338 Stopper 518 Poppet
273 Socket head screw 339 Stopper 521 Spring
302 Arm1 spool 371 Spring 523 Spring
305 Swing spool 372 Spring 551 Plug
307 Boom2 spool 374 Spring 552 Plug
308 Travel spool 376 Spring 561 O-ring

8-31
STRUCTURE(3/3)

333

333 331
334
331 329
273 334
336 328
329
331
336 332 328 262
335 331
336 332 379 262
335
332 370
372
339 332
371 301
377 261
332
372 309
261
332
261
303

304
154
164
551 306
561
551 521
561 511
551 521
561 511
521
T

551
(R
)

561 511
O
P
T

521
154
B

517
1

164
B
K
A
2

166

168

273
264
202
202
204
204 165
204

154 Plug 303 Boom1 spool 339 Stopper

164 O-ring 304 Bucket spool 370 Spring
165 O-ring 306 Arm2 spool 371 Spring
166 O-ring 309 Option spool 372 Spring
168 O-ring 328 Spring 377 Spring
202 Cover 329 Spring 379 Spring
204 Cover 331 Seat 511 Poppet
261 O-ring 332 Seat 517 Poppet
262 O-ring 333 Bolt 521 Spring
264 O-ring 334 Stopper 551 Plug
273 Socket head screw 335 Stopper 561 O-ring
301 Spool 336 Bolt

8-32
1) MAIN RELIEF VALVE

123 124 125 561 562 611 663 621 163 614 661 613

512 521 541 121 122 103 104 664 673 652 671

103 Plug 512 Plunger 621 Spring

104 Adjusting plug 521 Spring 652 Adjusting screw
121 O-ring 541 Seat 661 O-ring
122 Spacer 561 O-ring 663 O-ring
123 O-ring 562 Back up ring 664 O-ring
124 Filter stopper 611 Poppet 671 Lock nut
125 Filter 613 Stopper 673 Lock nut
163 O-ring 614 Piston

2) PORT RELIEF VALVE

301 564 563 521 123 124 125 562 611 621 661 612

511 522 161 541 561 101 162 102 651 671

101 Body 511 Plunger 564 Back up ring

102 Plug 521 Spring 611 Poppet
123 O-ring 522 Spring 612 Spring seat
124 Filter stopper 541 Seat 621 Spring
125 Filter 561 O-ring 651 Adjusting screw
161 O-ring 562 Back up ring 661 O-ring
162 O-ring 563 O-ring 671 Lock nut
301 Piston

8-33
3) RELIEF VALVE BLOCK

561 551 521 511 561 551 521 511 156 601 B A

163
358

156

C SECTION C-C
974
C
SECTION A-A B A

159 513 159 357 156 163 103 166 165 166 169 165

156
155
357
158
166
512
159

SECTION B-B 167 167 165 169 165 169 167

103 Straight travel block 167 O-ring 391 Straight travel spool assy
154 RO plug 251 Plug 511 Poppet
156 RO plug 266 O-ring 521 Spring
159 Plug 308 Sequence sub 551 Plug
163 O-ring 324 Spring 561 O-ring
164 O-ring 325 Spring 601 Main relief valve
165 O-ring 338 Stopper 974 Hexagon socket bolt
166 O-ring 357 Orifice

8-34
4) ARM SPOOL

341 338 313 339 349 342 328 314 302 312 358 343 329 359 352

302 Spool 329 Spring A2 343 Spacer bolt

312 Sub spool 338 Spring 349 Stopper 1
313 Piston 339 C-ring 352 Plug
314 Sleeve 2 341 Plug 358 Spring seat
328 Spring A1 342 Sleeve 1 359 Spring seat

5) BOOM SPOOL

353 303

303 Spool 353 Plug

6) NEGATIVE CONTROL RELIEF VALVE

632 638 611 621 631

611 Poppet 631 Damping rod 638 Filter

621 Spring 632 Bushing

8-35
7) LOCK VALVE ASSEMBLY

301 164 101 162 171 541 511 161 512 201

163

101 Casing 164 O-ring 511 Spol

161 O-ring 171 Hexagon socket bolt 512 Spring
162 O-ring 201 Plug 541 Bushing
163 O-ring 301 Plug

8-36
3. TOOLS AND TIGHTENING TORQUES
1) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.

Tool name Remark

Vice bench -
27
Box wrench 30
32
4 B

5
6
Hex key wrench 8
10
12
14
Seal tape -
Loctite #262 -
Spanner 32

8-37
2) TIGHTENING TORQUE
Torque
Item No. Part name
kgfşm lbfşft
101 Body 7.0 ~ 8.0 50.6 ~ 57.8
102 Plug 7.0 ~ 8.0 50.6 ~ 57.8
103 Plug 7.0 ~ 8.0 50.6 ~ 57.8
155 Plug 0.85 ~ 1.15 6.1 ~ 8.3
156 Plug 3.5 ~ 4.0 25.3 ~ 28.9
158 Plug 1.0 ~ 1.26 7.2 ~ 9.1
159 Plug 0.75 ~ 1.0 5.4 ~ 7.2
201 Plug 7.5 54.2
301 Plug 3.5 ~ 4.0 25.3 ~ 28.9
341 Plug 6.0 ~ 7.0 43.4 ~ 50.6
343 Spacer bolt 1.0 ~ 1.2 7.2 ~ 8.7
352 Plug 6.0 ~ 7.0 43.4 ~ 50.6
353 Plug 6.0 ~ 7.0 43.4 ~ 50.6
357 Orifice 0.75 ~ 1.0 5.4 ~ 7.2
358 Plug 0.75 ~ 1.0 5.4 ~ 7.2
551 Plug 15.0 ~ 18.0 108 ~ 130
601 Main relief valve assy 7.0 ~ 8.0 50.6 ~ 57.8
671 Lock nut 2.8 ~ 3.2 20.3 ~ 23.1
673 Lock nut 2.8 ~ 3.2 20.3 ~ 23.1
974 Hexagon socket bolt 22.0 ~ 26.0 159 ~ 188

8-38
4. DISASSEMBLY AND ASSEMBLY
1) PRECAUTION
(1) All hydraulic components are worked with precision working. Then, before disassembling and
assembling them, it is essential to select an especially clean place.
(2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
(3) When a control valve is to be removed from the machine, apply caps to all ports.
Before disassembling the valve, recheck that these caps are fitted completely, and then clean the
outside of the assembly. Use a proper bench for working, spread a paper or rubber mat on the
bench, and disassemble the valve on it.
(4) Support the body section carefully in carrying, transferring and so on of the control valve. Do not
support the lever, exposed spool, end cover section or so on without fail.
(5) After disassembling and assembling of the component it is desired to carry out various tests(For
the relief characteristics, leakage, flow resistance, etc.), but the hydraulic test equipment is
necessary to these tests.
Therefore, even when its disassembling can be carried out technically, do not disassemble such
component that cannot be tested, adjusted, and so on.
Besides, prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.

8-39
2) DISASSEMBLING
The figure in ( ) shown after the part name
in the explanation sentence shows its
number in the structure figures at page 8-31
to 8-38.
(1) Place control valve on working bench.
Ɠ Disassemble it in clean place and pay
attention not to damage flange face.
(2) Removal of relief valve block
Ɨ Removal
Loosen hexagon socket head bolts to
remove relief valve block (103) in its
assembled stated.

Ɨ Disassembling
‫ ڸ‬Hold casing(103) with vice.
‫ ڹ‬Remove plug(251) and pull out
poppet(511) and spring(521).
‫ ں‬Remove main relief valve(601).
(Disassemble main relief valve as shown
in the following.)

(3) Disassembling of main relief valve

‫ ڸ‬Since plug(103) and seat(541) are fixed
123 124 125 561 562 611 663 621 163 614 661 613
with C-ring(121), pull them out to remove
them.
‫ ڹ‬Take out spring(521) and plunger(512) P
from inside of seat(541).
‫ ں‬Remove lock nut(671) and adjusting R

screw(652) of adjusting plug(104) and 512 521 541 121 122 103 104 664 673 652 671
take out stopper(613), piston(614), spring
(621) and poppet(611).
‫ ڻ‬Loosen lock nut(673) of plug(103) and
remove adjusting plug (104).
‫ ڼ‬Remove C-ring(121) and spacer(122)
from plug(103).
Ɠ Since filter(125) and filter stopper(124)
are assembled to plug(103) with C-ring
(123), do not disassemble them more
than these conditions.

8-40
(4) Disassembling of travel spool
‫ ڸ‬Loosen hexagon socket head bolts(273)
and remove spring cover(203).

‫ ڹ‬Remove travel spool(308), springs(328,

329), spring seat(331), stopper(338) and
spacer bolt(333) in spool assembly
condition from casing.
Ɠ When pulling out spool assembly from
casing, pay attention not to damage
casing.

‫ ں‬Hold travel spool(308) in mouthpiece-

attached vise.
Remove spacer bolt(333) and
disassemble springs(328, 329), spring
seat(331) and stopper(338).

(5) Disassembling of arm spool

‫ ڸ‬Loosen hexagon socket head bolts(273)
and remove spring cover(201).

8-41
‫ ڹ‬Remove arm spool(302), springs(378,
372), spring seat(332), stopper(335) and
spacer bolt(336) in spool assembly
condition from casing.

‫ ں‬Hold arm spool(302) in mouthpiece-

attached vise. Remove spacer bolt(336)
and disassemble springs(378, 372),
spring seat(332) and stopper(335).

‫ ڻ‬Except when there is any problem

specially, do not disassemble arm spool
(302) more than these conditions. If this
is necessary at any cost, disassemble it
in the following procedures.
ş Hold middle section of arm spool(302) in
mouthpiece-attached vise and remove
plugs(352, 341) from its both ends.
ş Remove plugs(352, 341) and pull out
sub-spool(312) in assembly condition.
Remove piston(313) being fitted to plug
(341).
ş Hold sub-spool(312) in mouthpiece-
attached vise, remove space bolt(343)
and take out spring(329) and spring
seats(358, 359).
Ɠ Pay attention not to damage sub-spool
(312).
ş Since sub-spool(312), sleeve 2(314),
spring(328), sleeve 1(342), stopper(349)
and C-ring(339) are assembled in one,
do not disassemble them more than
these conditions.

8-42
(6) Disassembling of boom spool
‫ ڸ‬Loosen hexagon socket head bolts(273),
remove spring cover(201), and pull out
boom spool(303), springs(370, 379),
spring seat(332), stopper(335) and
spacer bolt(336) in spool assembly
condition from casing.

‫ ڹ‬Hold plug of spool assembly end in vise,

remove spacer bolt(336), and
disassemble springs(370, 379), spring
seat(332) and stopper(335).

‫ ں‬Except when there is any problem

specially, do not disassemble boom spool
sub(303) more than these conditions. If
this is necessary at any cost,
disassemble it in the following
procedures.
ş Hold middle section of boom spool(303)
in mouthpiece-attached vise and remove
plug(353).
Ɠ Pay attention not to deform boom spool
sub(303) by over tightening vise.

(7) Disassembly of covers

‫ ڸ‬Remove hexagon socket head bolts
(273), and remove spool cover(202).

8-43
(8) Removal of port relief valve
Ɨ Removal
Remove port relief valve(602) from casing.

Ɨ Disassembling
‫ ڸ‬Loosen plug(102), remove springs(521,
522) and seat(541) from inside of body
(101) and take out piston(301) and
plunger(511) from inside of seat(541).

‫ ڹ‬Remove lock nut(671) and adjusting

screw(651) of plug(102) and take out
spring seat(612), spring(621) and poppet
(611).
Since filter(125) and filter stopper(124)
are assembled to plug(102) with C-ring
(123), do not disassemble them more
than these conditions.

(9) Removal of lock valve assembly

Loosen hexagon socket head bolts and
remove lock valve assembly(252).

8-44
(10) Disassembly of negative control relief
valve
‫ ڸ‬Remove plug(551).

‫ ڹ‬Remove poppet(611), spring(621) and

damping rod(631).

(11) Disassembly of check valve

Remove plug(551) and take out poppet
(511) and spring(521).

(12) Disassembly of casing

‫ ڸ‬Except when required specially, do not
disassemble tie bolts of casing A and B.
‫ ڹ‬Since plugs not described in above
disassembling procedures are blind plugs
for sacrifice holes and blind plugs for
casting sanitation, do not disassemble
them as far as not required specially.

8-45
3) INSPECTION AFTER DISASSEMBLING
Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then,
place them on clean papers or cloths for inspection.
(1) Control valve
‫ ڸ‬Check whole surfaces of all parts for burrs, scratches, notches and other defects.
‫ ڹ‬Confirm that seal groove faces of casing and block are smooth and free of dust, dent, rust etc.
‫ ں‬Correct dents and damages on check seat faces of casing and block, if any, by lapping.
Ɠ Pay attention not to leave lapping agent in casing and block.
‫ ڻ‬Confirm that all sliding and fitting parts can be moved manually and that all grooves and paths
are free foreign matter.
‫ ڼ‬If any spring is broken or deformed, replace it with new one.
‫ ڽ‬When relief valve do not function properly, repair it, following its disassembling assembling
procedures.
‫ ھ‬Replace all seals and O-rings with new ones.

(2) Relief valve

‫ ڸ‬Confirm that all seat faces at ends of all poppets and seats are free of defects and are uniform
contact faces.
‫ ڹ‬Confirm manually that main poppet and seat can slide lightly and smoothly.
‫ ں‬Confirm that outside face of main poppet and inside face of seat are free from scratches and so
on.
‫ ڻ‬Confirms that springs are free from breaking, deformation, and wear.
‫ ڼ‬Confirm that orifices of main poppet and seat section are not clogged with foreign matter.
‫ ڽ‬Replace all O-rings with new ones.
‫ ھ‬When any light damage is found in above inspections, correct it by lapping.
‫ ڿ‬When any abnormal part is found, replace it as relief valve assembly.

8-46
4) ASSEMBLING
Ɠ In this assembling section, explanation only is shown. Refer to figures shown in disassembling
section and structure section.
Ɠ Figure in ( ) shown after part name in explanation sentence shows number in structure figure.
Ɠ Cautions in assembling seals
ş Pay attention to keep seals free from defects in its forming and damages in its handling.
ş Apply grease, hydraulic oil or so on to seals and seal-fitting sections for full lubrication.
ş Do not stretch seals so much to deform them permanently.
ş In fitting O-ring, pay attention not to roll it into its position. In addition, twisted O-ring cannot
remove its twisting naturally with ease after being fitted, and causes oil leakage.
ş Tighten fitting bolts at all sections with torque wrench to their respective tightening torques.

(1) Assembling of casing

Fit O-rings(164, 165) to Casing A(101) and Casing B(102) and tighten bolts(974, 975) to specified
torques.
Ɠ Check mating faces for dust, etc. and confirm that O-rings are fitted to O-ring grooves securely.
(2) Assembly of plug
Tighten plug(159) to specified torque.
Ɠ Since plug(159) is applied with special coating, use new one in reassembling without fail.
However, in case of emergency, PT 1/8 plug available on market can be used substitutively with
seal tape turned in one turn and half on it.
In this case pay full attention not to fall piece of seal tape into casing.
Ɠ Use of seal tape may cause malfunction of control valve. Do not use it as far as possible.
(3) Assembly of check valve
Assemble poppets(511, 515, 516, 517, 518) and spring(521, 523). Put O-rings(561) onto
plugs(551, 552) and tighten the latters with their specified torques.
Ɠ Use poppets, springs and plugs in following groups.

Poppet Spring Plug Remember that

- 511 in 9 positions
511 521 551
- 517 in 1 positions
517 521 551 - 515 in 1 position
515 521 551 - 516 in 1 position
516 523 552 - 518 in 1 position

(4) Assembling of negative control relief valve

Assemble poppet(611), spring(621) and damping rod(631) to casing A(101). Put O-ring(561) onto
plug(551) and tighten the latter to its specified torque.
(5) Assembling of lock valve assembly
Fit O-ring(163) to lock valve assembly(252) and tighten hexagon socket head bolts with specified
torque.

8-47
(6) Assembling of port relief valve
Assembling port relief valve(602) to casing and tighten it to specified torque.
Ɠ Assembling procedures for relief valve itself are to be as shown in the following.
‫ ڸ‬Fit O-rings(162, 561) and back up ring(562) to plug(102). Fit poppet(611), spring(621) and O-
ring (661) to spring seat(612). Then, assemble spring seat(612) into plug(102) temporarily with
adjusting screw(651) and lock nut(671).
Ɠ Confirm that poppet(611) has been fitted to seat section of plug(102) securely.
‫ ڹ‬Fit O-ring(563) and back up ring(564) to seat(541) of plunger(511). Then, assemble plunger
(511), piston(301) and springs(521, 522)
‫ ں‬Fit seat(541) assembly of item ‫ ڹ‬above to body(101) and tighten plug(102) assembly of item ‫ڸ‬
above to specified torque.
Ɠ Confirm that springs(521, 522) are guided securely.
‫ ڻ‬Since pressure adjustment is carried out according to maintenance standards, keep adjusting
screw(651) as being assembled temporarily.
(7) Assembling of boom spool
‫ ڸ‬Tighten plug(353) to boom spool(303).
‫ ڹ‬Hold boom spool in vise, set spring seat(332), springs(370, 379), stopper(335) and tighten
spacer bolt(336) to specified torque.
Ɠ Before tightening spacer bolt(336), apply Loctite #262 to it.
‫ ں‬Fit spool assemblies of Items ‫ ڸ‬and ‫ ڹ‬above into Casing B(102).
Ɠ Fit spool assemblies into Casing B(102) carefully and slowly. Do not push them forcibly without
fail.
(8) Assembling of arm spool
‫ ڸ‬Hold arm sub-spool(312) in mouthpiece -attached vise, fit spring(329), spring seats(358, 359)
and tighten spacer bolt(343) with specified torque.
Ɠ Before tightening spacer bolt(343), apply Loctite #262 to it.
‫ ڹ‬Insert arm sub-spool(312) assembly into arm spool(302), paying attention not to insert it in wrong
direction.
Confirm that piston(313) has been inserted in plug(341), fit the latter and tighten it with specified
torque.
Ɠ Confirm that arm sub-spool(312) can move lightly in arm spool(302).
‫ ں‬Hold plug(341) at end of arm spool(302) in vise, set spring seat(332), springs(372, 378) and
stopper (335), and tighten spacer bolt(336) with specified torque.
Ɠ Before tightening spacer bolt(336), apply loctite #262 to it.
‫ ڻ‬Fit spool assemblies of Items ‫ ڸ‬and ‫ ڹ‬above into Casing A(102).
Ɠ Fit spool assemblies into Casing A(101) carefully and slowly. Do not push them forcibly without
fail.
(9) Assembling of travel spool
‫ ڸ‬Hold end of travel spool(308) in mouthpiece attached vise, set spring seat(331), springs(328,
329) and stopper(334), and tighten spacer bolt(333) to specified torque.
Ɠ Before tightening spacer bolt(333), apply Loctite #262 to it.
‫ ڹ‬Insert spool assembly into Casing A(101).
Ɠ Fit spool assembly into Casing A(101) carefully and slowly. Do not push it forcibly without fail.

8-48
(10) Assembling of covers
‫ ڸ‬Fit spool covers(202, 204) to sides reverse to spring sides of dozer travel, option, swing, arm1,
boom1, bucket and arm2 spools and tighten hexagon socket head bolts(273) with specified torque.
Ɠ Confirm that O-rings(168, 264) have been fitted.
‫ ڹ‬Fit spring covers(203, 201) to spring sides of travel, dozer, boom1, swing, boom2, arm1, bucket,
swing preferential boom, arm2 and option spools and tighten hexagon socket head bolts (273)
with specified torque.
Ɠ Confirm that O-ring(261 & 262) have been fitted.

(11) Assembling of relief valve block

Fit O-rings(165, 166, 167, 169) to relief valve block(103) and tighten hexagon socket head bolt
with specified torque.
Ɠ Assembling procedures for relief valve block itself are to be as shown in the following.
‫ ڸ‬Hold casing(103) in vise.
‫ ڹ‬Fit main relief valve(601) to casing and tighten it with specified torque.
(Assembling procedures for main relief valve itself are shown separately.)
‫ ں‬Fit poppet(511) and spring(521), and tighten plug(551) with specified torque.
‫ ڻ‬Tighten throttle(357) with hexagon wrench to specified torque. Further, fit O-ring(163) to
plug(156) and tighten plug with specified torque.
(12) Assembling of main relief valve
‫ ڸ‬Fit spacer(122), C-ring(121), O-rings(163, 561) and back up ring(562) to plug(103).
‫ ڹ‬Fit piston(614) and O-ring(661) to stopper(613). Fit them to adjusting plug(104) and assemble
them temporarily with adjusting screw(652) and lock nut(671).
‫ ں‬Fit poppet(611) and spring(621) to plug(103) and fit adjusting plug(104) fitted with O-ring(663,
664).
Ɠ Confirm that poppet(611) has been fitted to seat section of plug(103) securely.
‫ ڻ‬Fit plunger(512) and spring(521) to seat(541).
‫ ڼ‬Fit seat to plug(103) assembly and fix it with C-ring(121).
‫ ڽ‬Since pressure adjustment is carried out according to maintenance standards, keep adjusting
screws(104, 652) as being assembled temporarily.

8-49