6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

1 General
As shown in the figure below, the valve consists of a pressure control block, 4-series for jack-up and 2series for retract electromagnetic function blocks and a tank plate to return the unload line to the tank. In
the configuration, blocks and plate are tightened with tie rod bolts to combine the joints.
This valve becomes onload by switching solenoid valve SV1 (by shutting off the relief valve from the
tank line). With solenoid valve SV1 off, the valve becomes relief unloaded. The valve is installed by a
Tightening Torque
foot fixed to a block with tie bolts.
5.88 to 7.85 Nm
(4.32 to 5.76ft/lbs)

1.1 Configuration of Valve

Pilot Pressure
Adjusting Bolt

Tightening Torque
3.92 to 4.9 Nm
(2.9 to 3.6ft/lbs)
7

Tightening Torque
44.1 to 53.9 Nm
(32.4 to 39.6ft/lbs)

Tightening Torque
68.6 to 78.5 Nm
(50.4 to 57.6ft/lbs)

Tightening Torque
21.6 to 23.5 Nm
(15.8 to 17.3ft/lbs)

PG
P

81

82

83

84

85

86

A1

A2

A3

A4

A5

A6

Tightening Torque
68.6 to 78.5 Nm
(50.4 to 57.6ft/lbs)

A
B

Tightening Torque
44.1 to 53.9 Nm
(32.4 to 39.6ft/lbs)

Tightening Torque
68.6 to 78.5 Nm
(50.4 to 57.6ft/lbs)
Right
Left
Right
Left
Front Jack Front Jack Rear Jack Rear Jack

Main Pressure
Adjusting Bolt
20.6MPa
(2988psi)

CEA0694U-B

Tightening Torque
39.2 to 49.0 Nm
(28.8 to 36.0ft/lbf)
Solenoid Valve

A0

Tightening Torque
3.92 to 4.9 Nm
(2.9 to 3.6ft/lbs)

ECE5-233S

Tightening Torque
3.92 to 4.9 Nm
(2.9 to 3.6 ft/lbf)
Tightening Torque
1.96 to 2.45 Nm
(1.44 to 1.80ft/lbf)
P1

Right
Left
Retract Retract

Tightening Torque
3.92 to 4.9 Nm
(2.9 to 3.6ft/lbf)
ECE5-219S

No.
1

Part

Tightening Torque
3.92 to 4.9 Nm
(2.9 to 3.6ft/lbf)

Function group

Connector connection diagram

Inlet
(P, T port)

RGB block

Jack-up

Jack-up

Electromagnetic (ON/OFF) function block

SB
SA

61
62
63
64

Jack-up

When neutral, P.A block, B to T connection type

SV1

91
92

Jack-up

Retract Side Frame Electromagnetic (ON/OFF) function block

Retract Side Frame When neutral, P.T.A.B block type

Tank plate

0411

62 61
64 63

92 91

ECE5-220S

For unload line to tank line connection

1/12

View from arrow A

(six points)
View from arrow B
(one points)

6-Series Control Valve Structure And Operation

X
(P1) X T

ES05-40-0004.0R1S

Parallel Circuit
Parallel Circuit Parallel Circuit Parallel Circuit Parallel Circuit Parallel Circuit
Right Front
Left Front
Right Rear
Left Rear Right Side Frame Left Side Frame
Retract
Jack
Jack
Jack
Jack
Retract

SA1

SB1

SA2

SB2

SA3

SB3

SA4

SB4

SA5

SB5

SA6

SB6

SV1

X P
(PG)

A1 B1

A2 B2

A3 B3

A4 B4

A5 B5

A6 B6
ECE5-221S

2 Configuration
2.1 Entire Assembly Diagram
11

14
15

3B1

3B2

3B3

3B4

3B5

3B6

3A1

3A2

3A3

3A4

3A5

3A6

16

17

PG
81

A1

82

A2

83

84

A3

85

A4

A5

86

A6

Up (mounting position)

10

22

20

18

19

21

23

Function block

Function block

Tank port plate

Foot

Spacer

Tie rod bolt

Tie rod bolt

Name plate

10

Solenoid valve

11

Harness

12

Hexagon nut

13

Plain washer

14

Hexagon socket head cap screw

Insulation lock tie

Coating clip

17

EXP. plug

18

Lever Assy

12

19

Lever Assy

20

Lever Assy

21

Lever Assy

22

Lever Assy

23

Lever Assy

13

8
5

ECE5-222S

2/12

Quantity

RGB block

16

0411

Part name

15

Name Plate

Down (mounting position)

No.

6-Series Control Valve Structure And Operation

2.2 RGB Block

ES05-40-0004.0R1S

;
a
t
C
C-C

o
p
8
6
r
9

q
e
i

B-B

;aw5423

A-A

0411

3/12

ECE5-223S

No.

Part name

Quantity

Valve body

Cap

Slide valve

Spring (A)

Spring (B)

Spring (C)

Choke (B)

Hexagon socket head cap plug

Hexagon socket head cap plug

10

Steel ball

11

O-ring

12

O-ring

13

O-ring

14

Filter

15

EXP. plug

16

EXP. plug

17

Relief cartridge Ass'y

20.6 Mpa (2988psi)

18

Reducing cartridge Ass'y

19

Hexagon socket head cap plug

20

Flanged hexagon socket head thread plug

21

O-ring

6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

2.3 Function Block for Jack-up

15 16 14 1

29 10 18 28 13

22 11 25 19

8
7
17

12

20 5 23 27

24 6 21 26

ECE5-224S

0411

4/12

No.

Part name

Quantity

Valve body

Spool

Check valve

Spring

Piston

Bushing

Special bolt

Holder (A)

Guide ring

10

Holder (B)

11

Bushing

12

Guide (A)

13

Spring

14

Front cover

15

Backup ring

16

Hexagon socket head cap screw

17

Hexagon socket head cap screw

18

Hexagon socket head cap screw

19

O-ring

20

O-ring

21

O-ring

22

O-ring

23

O-ring

24

O-ring

25

O-ring

26

Backup ring

27

Backup ring

28

EXP. plug

29

Solenoid valve

6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

2.4 Function Block for Retract

15

16 14

29 10 18 28 13

22 11 25 19

8
7
17
12

20 5 23 27

24 6 21 26

ECE5-259S

0411

5/12

No.

Part name

Quantity

Valve body

Spool

Check valve

Spring

Piston

Bushing

Special bolt

Holder (A)

Guide ring

10

Holder (B)

11

Bushing

12

Guide (A)

13

Spring

14

Front cover

15

Backup ring

16

Hexagon socket head cap screw

17

Hexagon socket head cap screw

18

Hexagon socket head cap screw

19

O-ring

20

O-ring

21

O-ring

22

O-ring

23

O-ring

24

O-ring

25

O-ring

26

Backup ring

27

Backup ring

28

EXP. plug

29

Solenoid valve

6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

3 Structure
3.1 RGB Block
RGB block comprises P (pump) port, T (tank) port connecting screws and pilot pressure checking (P1)
port.
It incorporates a back pressure valve to retain the pilot pressure, a reducing valve to retain a certain
pilot pressure and a filter to protect the pilot line.
In addition, it incorporates a relief valve to prevent pump or actuator from being overloaded.
Note: That the relief valve and reducing valve are cartridge types.

Solenoid Valve Mounting Surface

C
C-C

B
A

Filter

B
A

Filter-use Safety Valve

Solenoid Valve Mounting Surface
Slide Valve (Back Pressure Valve)
Reducing Cartridge
Relief Cartridge
B-B

A-A

0411

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ECE5-225S

6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

3.2 Electromagnetic Function Block

3.2.1 Function Block for jack-up
When neutral, actuator-use B port is connected to the tank line. Pump line, tank line and actuator-use
A port are blocked. On the other hand, the pump line is connected to the tank line by means of main body
land and spool, and unloaded. The pump line contains counterflow preventing check (load check).
This block consists of a flow switching spool and a positioner cylinder directly connected to the spool,
two solenoid valves to drive the cylinder and a return spring. One end of the spool is let out via a seal,
which allows pilot operation with solenoid valves and lever operation with lever link serving as a fulcrum.

Solenoid Valve
Load Check
Lever Link
A Port

B Port

Positioner Cylinder

Spool

Return Spring

Valve Body
ECE5-260S

3.2.2 Retract-use function block

When neutral, actuator-use ports A and B, pump and tank line are all blocked. At this time, the pump
line is connected to the tank line by means of main body land and spool, and unloaded. The pump line
contains counterflow preventing check (load check).
This block consists of a flow switching spool and a positioner cylinder directly connected to the spool,
two solenoid valves to drive the cylinder and a return spring. One end of the spool is let out via a seal,
which allows pilot operation with solenoid valves and lever operation with lever link serving as a
fulcrum.
Solenoid Valve
Load Check
Lever Link
A Port

Spool

B Port

Valve Body

Return Spring
Positioner Cylinder
ECE5-227S

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6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

3.3 Structure and Operation of Electromagnetic

Valves
A When neutral
This state means that both the solenoid valves
are turned OFF. In this state, the steel ball in P
port seat is pushed up by pilot pressure oil to rest
in the Q part of A port seat, which causes pilot
pressure oil to be blocked. As shown by arrow
marks in the right figure, both the cylinder chambers
are guided to T line, then to the tank for release. In
this state, the positioner cylinder is kept neutral by
the return spring.

SOL-A OFF

SOL-B OFF

;;;
;;;
;;;
;
;;
;
;
;;;;;
;;;
Q

CE5-228S

B During operation
This state means that one of the solenoid valves
is turned OFF. If the SOL-B is activated on, the
movement of SOL-B plunger is transferred via rod
to three steel balls. This movement force is stronger
than the pushing-up force of pilot pressure oil, which
causes the steel ball in the T-point collar to be
moved until it rests on the edge R of the A port
seat. As a result, the pilot pressure oil is guided to
the cylinder chamber, and the positioner cylinder
moves leftward against the return spring.

;; ;;
;;
;;
;;
;;;;;;;;
;
;
;
;;
;;
SOL-A OFF

SOL-B ON

CE5-229S

0411

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6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

4 Disassembly and Reassembly

4.1 Tightening Torque for Each Part

10

12
16

P1

PG

e
r

81

82

83

84

85

86

A1

A2

A3

A4

A5

A6

13

1
ECE5-234S

No.
1
2
3
4
5

Part
Locknut

Cartridge valve
Tightening
Solenoid coil fixing nut
Tightening
Tie-rod-bolt nut
Tightening
Insulation lock tie mounting bolt
M5
Holder mounting bolt M5

9
10
11

Holder and coating clip mounting

bolt M4
Front cover mounting bolt M4

12

Strainer plug
Tightening
Solenoid valve mounting bolt M4

6
7

13
14
15
16

Solenoid coil fixing nut

Tightening
P1 blocking plug
Tightening
Load check bushing
Tightening

ECE5-230S

Tool to be used
Spanner
(width across flat:17mm)
Spanner
(width across flat:27mm)
Spanner
(width across flat:10mm)
Spanner
(width across flat:13mm)
Hexagonal-head spanner
(width across flat:4mm)
Hexagonal-head spanner
(width across flat:4mm)
Hexagonal-head spanner
(width across flat:3mm)
Hexagonal-head spanner
(width across flat:3mm)
Hexagonal-head spanner
(width across flat:8mm)
Hexagonal-head spanner
(width across flat:3mm)
Spanner
(width across flat:19mm)
Hexagonal-head spanner
(width across flat:6mm)
Spanner
(width across flat:21mm)

4.2 Recommended Tightening Torque for Port Piping

Ports P and T : 68.6-78.5Nm(50.4-57.6ft/lbf)
Ports A and B : 58.8-68.6Nm(43.2-50.4ft/lbf)
Port P1 : 39.2-49Nm(28.8-36.0ft/lbf)

0411

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Tightening torque
44.1 to 53.9 Nm
(32.4 to 39.6 ft/lbf)
68.6 to 78.5 Nm
(50.4 to 57.6 ft/lbf)
1.96 to 2.45 Nm
(1.44 to 1.80 ft/lbf)
21.6 to 23.5 Nm
(15.84 to 17.3 ft/lbf)
3.92 to 4.9 Nm
(2.9 to 3.6 ft/lbf)
5.88 to 7.85 Nm
(4.32 to 5.76 ft/lbf)
3.92 to 4.9 Nm
(2.9 to 3.6 ft/lbf)
3.92 to 4.9 Nm
(2.9 to 3.6 ft/lbf)
53.9 to 58.8 Nm
(39.6 to 43.2 ft/lbf)
3.92 to 4.9 Nm
(2.9 to 3.6 ft/lbf)
3.92 to 4.9 Nm
(2.9 to 3.6 ft/lbf)
39.2 to 49.0 Nm
(28.8v36.0 ft/lbf)
68.6 to 78.5 Nm
(50.4 to 57.6 ft/lbf)

11

6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

4.3 Removal/Replacement Procedure of Solenoid Coil

1) Loosen and remove nut 1.

2) Washer 2 and O-ring 3 may be left on the coil.
3) Grasp the outside of coil 4, then pull it out
upward.
4) Remove and keep O-ring 5.
Note:
Take care to prevent washer 2 and O-ring 3 from
being lost as they are easy to lose.
Do not pull harness when removing coil 4.
Nut 1 tightening torque: 1.96-2.45Nm(1.441.80ft/lbf)

1
2
3

4
5

CE5-231S

4.4 Main Relief Cartridge

Adjusting Bolt

0
17 -0.3

M24 x 1.5

0
27 -0.35

6 +0.10
+0.03

ECE5-232S

Procedure for adjusting pressure

Main relief valve pressure increases by rotating the adjusting bolt clockwise using hexagonal-head
spanner 6mm.
One rotation increases the pressure by approximately 8.14 Mpa (1181psi) to be generated.
Note:After adjusting pressure, lock the valve securely.

0411

Part
Lock nut tightening

Tightening torque
44.1 to 53.9 Nm

Spanner (width across flat:17mm)

(32.4 to 39.6ft/lbf)

Relief valve mounting

68.6 to 78.5 Nm

Spanner (width across flat:27mm)

(50.4 to 57.6ft/lbf)

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6-Series Control Valve Structure And Operation

ES05-40-0004.0R1S

5 Precautions for Handling

5.1 Handling
Make sure that hydraulic equipment and hydraulic operating fluid are clean. (Hydraulic operating fluid
cleanliness shall be within NAS11 class.)
The oil temperature shall be 5-70C. If less than 0C, be sure to carry out warming-up.
Do not increase the pressure of the relief reducing valve to more than the specified pressure.
This valve satisfies JIS D 0203 S1 with respect to being waterproof. However, since it consists of
electrical parts, do not install it in a place where water is directly splashed. In particular, be sure not to
perform high-pressure or steam washing. If water may be splashed on the valve by high-pressure
washing or steam washing cover it with a protective cover.
When installing the valve, confirm the position of drain hole (5) on the guide ring, and be sure to set
the hole downward (towards the ground).
The solenoid coil is a plastic mold product, so avoid shocks or loading it with weights.
Pay attention to the harness lead fixing method, taking care to prevent it from tensile strength.
Since the pilot line employs an internal drain method, maintain the back pressure of T port at 0.29 Mpa
(42psi) or less.
5.2 Replacement and Assembly of Parts
Spool clearance from the main body is regulated in pairs and linked to the positioner cylinder, so after
shipment, they cannot be replaced singly. Perform replacement in function block assembly unit.
The solenoid valve control consists of high-precision parts with seat, so do not disassemble it. If it
need be replaced, perform the replacement in function block assembly units as with the spool.
If replacement of a relief reducing valve is necessary, perform the replacement in units of a cartridge.
Use the specified tightening torque.

0411

11/12

12/12