S0709451K

1PILOT CONTROL
VALVE (WORK LEVER /
JOYSTICK)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

PILOT CONTROL VALVE (WORK LEVER / JOYSTICK)S0709451K

MODEL SERIAL NUMBER RANGE
Solar 300LC-V 1001 and Up
Solar 340LC-V 1001 and Up

Copyright 2002 Daewoo

May 2002

Pilot Control Valve (Work Lever / Joystick) S0709451K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Structure .......................................................................................... 3
Function ........................................................................................... 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Torques ............................................................................................ 5
Performance..................................................................................... 6
Removal ......................................................................................................... 6
Disassembly ................................................................................................... 9
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 13
Reassembly.................................................................................................. 14
Installation .................................................................................................... 19
Start-up Procedures ..................................................................................... 20

S0709451K Pilot Control Valve (Work Lever / Joystick)

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GENERAL DESCRIPTION
THEORY OF OPERATION

Structure
The remote control valve contains four push rods, spring holders, spools and return springs, which are
located in the valve casing. The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port T, and four secondary pressure ports.
The electric horn switch is installed in the valve handle. Gear pump pressure is used for operating control
spools.

Function
1. Neutral Mode
When the lever is in neutral mode, the spool is thrust upward by return spring, and the force of
balancing spring, which determines the secondary discharge pressure, is not transmitted to the
spool. The input port is closed and the pressure of the output port is the same as the pressure of the
tank port T.
2. Control Mode
When push rod is pushed, the balance spring begins to compress, and spring force is conveyed to
the spool. Ports P and T are then connected together and the pilot pressure is conveyed to the area.
Output pressure works on the bottom of the spool, thrusting the spool upward until it is balanced with
the power of the balance spring. The secondary pressure (output pressure), therefore, changes in
proportion to the compression force of the balance spring.

Pilot Control Valve (Work Lever / Joystick) S0709451K

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PARTS LIST

30

29
28

26
27

23 25

24 14

13 20
19
22
18
21
12
17
11
31
8
15
10
16
9
36

32
33
7
34
35 6

1 2 3 5 4

ARS2260L
Figure 1

S0709451K Pilot Control Valve (Work Lever / Joystick)

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 Reference Reference
Description Description
Number Number
1 Case 19 O-ring
2 Plug 20 Rod Seal
3 Plug 21 Plate
4 O-ring 22 Boot
5 O-ring 23 Joint Assembly
6 Spool 24 Swash Plate
7 Shim 25 Hex Nut
8 Spring 26 Handle Bar
9 Spring Seat 27 Nut
10 Spring 28 Boot
11 Stopper 29 Spring Pin
12 Stopper 30 Handle Assembly
13 Spring 31 Bushing
14 Push Rod 32 Terminal
15 Spring 33 Seal Wire
16 Spring Seat 34 Housing
17 Stopper 35 Holder Rear
18 Plug 36 Clip Band

SPECIFICATIONS

Pilot Control Valve Specification

Type Pilot Control (2-Stage Joystick)
(1,3) 28 kg/cm2 @ 6.5 mm Stroke (398 psi @ 0.256 in. Stroke)
Pressure / Stroke
(2,4) 28 kg/cm2 @ 7.5 mm Stroke (398 psi @ 0.295 in. Stroke)
Weight 4.8 kg (10.58 lb)

Torques

Reference
Bolt Size Tool Torque
Number
2 PT 1/8 5 mm L-Wrench 150 kg•cm (36.2 ft lb)
3 PF 3/8 8 mm L-Wrench 500 kg•cm (36.2 ft lb)
24 M14 24 mm Spanner 1,240 kg•cm (89.7 ft lb)
25 M14 22 mm Spanner 1,240 kg•cm (89.7 ft lb)
27 M14 22 mm Spanner 1,240 kg•cm (89.7 ft lb)

Pilot Control Valve (Work Lever / Joystick) S0709451K

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Performance

ARS2270L
Figure 2

REMOVAL
1. Park on firm and level ground.
2. Lower front attachment (bucket) to the
ground.
3. Stop the engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch "ON."

WARNING!
If engine must be run while Figure 3
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
running.

6. Fully stroke work levers (joysticks) in all directions to relieve pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "OFF" position and remove from starter switch.
9. Hang maintenance warning tag on controls.
10. Disconnect negative (-) battery cable leading to frame from battery.

S0709451K Pilot Control Valve (Work Lever / Joystick)

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11. Remove four bolts and washers (2, Figure
4) and cover (1). 1 2
12. Pull cap (5, Figure 4) out and remove two
screws, two bolts and washers (6) and 7 4
cover (3).
3
13. Remove three screws, one bolt and
washers (7, Figure 4) and cover (4).
6

5
ARS2910L
Figure 4
14. Remove four bolts (3, Figure 5) and cover
(2), and pull remote control valve LH (1) 3
out.
15. Tag and disconnect hoses from remote 2
control valve LH (1, Figure 5). Plug and 1
cap hoses and ports to prevent
contamination from entering hydraulic
system or component.

ARS2920L
Figure 5
16. Remove four bolts and washer (2, Figure
6), and cover (2). 2
1
17. Pull cap (5, Figure 6) out and remove
screw, three bolts and washers (6) and
cover (3). 4
3
18. Remove two screws, two bolts and
washers (7 and 8, Figure 6) and cover (4).
6 7

5
8 ARS2930L
Figure 6

Pilot Control Valve (Work Lever / Joystick) S0709451K

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19. Remove four bolts (3, Figure 7) and cover
(2), and pull remote control valve RH (1) 3
out.
20. Tag and disconnect hoses from remote 2
control valve RH (1, Figure 7). Plug and 1
cap hoses and ports to prevent
contamination from entering hydraulic
system or component.

ARS2920L
Figure 7

S0709451K Pilot Control Valve (Work Lever / Joystick)

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DISASSEMBLY
1. Lift up the boot (28) and pull the switch
cord through the hole in the case (1).

Figure 8

Figure 9
2. Loosen nut (27) from hex nut (25) and
remove handle assembly (30).

Figure 10

Pilot Control Valve (Work Lever / Joystick) S0709451K

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3. Remove hex nut (25) and swash plate
(24).

Figure 11
4. Remove joint (23) from case (1).

Figure 12
5. Remove plate (21).

Figure 13
6. Press spring (10) and remove plug (18).

Figure 14

S0709451K Pilot Control Valve (Work Lever / Joystick)

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7. Remove pressure reduction valve (6, 7, 8,
9, 11) and spring (10).

IMPORTANT
Mark valve disassembling position
(port).

Figure 15
8. Remove plug (3) and four plugs (2).

Figure 16
9. Remove stopper (11) from pressure
reduction valve (6, 7, 8, 9, 11).

Figure 17
10. Remove spool (6), spring seat (9), spring
(8) and shim (7).

Figure 18

Pilot Control Valve (Work Lever / Joystick) S0709451K

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11. Remove push rod (14) and plug (18).

Figure 19
12. Remove O-ring (19) from plug (18).

Figure 20
13. Remove seal (20) from plug (18).

Figure 21

S0709451K Pilot Control Valve (Work Lever / Joystick)

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CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
Clean all parts and dry them with compressed air. Keep all parts free from dust. Lubricate all moving parts.

Pilot Control Valve (Work Lever / Joystick) S0709451K

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REASSEMBLY
1. Tighten plug (3) slowly.
NOTE: Tightening torque: 350 kg•cm
(25.3 ft lb).
Tighten four plugs (2).
NOTE: Use Loctite #592 pipe sealant
on plugs.
NOTE: Tightening torque 150 kg•cm
(10.9 ft lb).

Figure 22
2. Install shim (7), spring (8), spring seat (9),
and spool (6).

Figure 23
3. Press spring (9) and install stopper (11).

Figure 24

S0709451K Pilot Control Valve (Work Lever / Joystick)

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4. Install spring (10) in case (1) and pressure
reducing valve assembly (6, 7, 8, 9, 11).

Figure 25
5. Install seal (20) on plug (18).

Figure 26
6. Install O-ring (19) on plug (18).

Figure 27
7. Install push rod (14) on plug (18).

Figure 28

Pilot Control Valve (Work Lever / Joystick) S0709451K

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8. Install spring (13) on stopper (12).

Figure 29
9. Position stopper (12) and spring (13) on
pressure reducing valve.

Figure 30
10. Install plug (18) in case (1).

Figure 31
11. Install plate (21) and tighten joint (23).

Figure 32

S0709451K Pilot Control Valve (Work Lever / Joystick)

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12. Install swash plate (24) on joint (23).

Figure 33
13. Install hex nut (25) and tighten swash plate
(24).
NOTE: Tightening torque 1,240 kg•cm
(89.7 ft lb).

Figure 34
14. Pull cord and tube out through hole of hex
nut (25).

Figure 35
15. Align the direction of handle (30) and
tighten hex nut (25) and nut (27).
NOTE: Tightening torque 1,240 kg•cm
(89.7 ft lb).

Figure 36

Pilot Control Valve (Work Lever / Joystick) S0709451K

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16. Grease joint (23), swash plate (24) and
push rod (14).

Figure 37
17. Install boot (28).

Figure 38

S0709451K Pilot Control Valve (Work Lever / Joystick)

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INSTALLATION
1. Connect hoses as tagged during removal
to remote control valve RH (1, Figure 39). 3
2. Position remote control valve RH (1, Figure
39) on control stand and install four bolts 2 1
and washers (3) and cover (2).

ARS2920L
Figure 39
3. Install two screws, two bolts and washers
(7 and 8, Figure 40) and cover (4). 2
1
4. Install a screw, three bolts and washers (6,
Figure 40) and cover (3). Push cap (5) into
cover (3). 4
3
5. Install four bolts and washers (2, Figure
40) and cover (1).
6 7

5
8 ARS2930L
Figure 40
6. Connect hoses as tagged during removal
to remote control valve LH (1, Figure 41). 3
7. Position remote control valve LH (1, Figure
41) on control stand and install four bolts 2 1
and washers (3), and cover (2).

ARS2920L
Figure 41

Pilot Control Valve (Work Lever / Joystick) S0709451K

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8. Install three screws, one bolts and
washers (7, Figure 42), and cover (4). 1 2
9. Install two screws, two bolts and washers
(6, Figure 42), and cover (3). Push cap (5) 7 4
into cover (3).
3
10. Install four bolts and washers (2, Figure
42), and cover (1).
6

5
ARS2910L
Figure 42

START-UP PROCEDURES
1. Start engine and set throttle at "LOW
IDLE."
2. Set safety lever on "UNLOCK" position.

HAOB290L
Figure 43
3. Slowly cycle boom, arm, bucket cylinders
and swing motor about five times without a
load to vent air from pilot lines. Do this for
5 minutes.

ARO0470L
Figure 44

S0709451K Pilot Control Valve (Work Lever / Joystick)

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