GROUP 4 MAIN CONTROL VALVE (TYPE 1)

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 13031GE18

pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious injury.
※ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so Atr

catch it in oil pan. Btr

Atl

(4) Remove bolts and disconnect pipe. Ba

1
As
Btl

Bs
1
Aa

(5) Disconnect pilot line hoses.

(6) Disconnect pilot piping.
21078MC01
(7) Sling the control valve assembly and
remove the control valve mounting bolt.
·Weight : 200kg(425lb)
(8) Remove the control valve assembly.
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.
21078MC02
(2) Bleed the air from below items.
① Cylinder(Boom, arm, bucket)
② Swing motor
③ Travel motor
※ See each item removal and install.
(3) Confirm the hydraulic oil level and recheck D

the hydraulic oil leak or not.

21078MC03

8-30
2. STRUCTURE(1/5)

551
561
521
511

551 338
561
521 325
511
324

C1

C2

Cp2
391

102 103 601

252
602

425
424
438
401
357

561
602
551

165 254
104

251
101
252
29078MC04

101 Casing A 324 Spring 438 Rod

102 Casing B 325 Spring 511 Poppet
103 Block 338 Stopper 521 Spring
104 Block 357 Oriffice 551 Plug
165 O-ring 391 Travel spool 561 O-ring
251 Control valve 401 Bypass cut spool 601 Main relief valve
252 Lock valve 424 Spring 602 Port relief valve
254 Logic valve 425 Spring

8-31
STRUCTURE(2/5)

203
556
201
164
201 333
331
201 336 334
332 329
336 335 328
273 203 332 379 331
339 262
370
336 372
332 332
374
335 261
333 310
379 332
331
261
337 370 305
378 332
377 307
261
331
262 302
395

392
K
A
W
A
S
A
K
I
T
(L
)
S
B
2
A
1
B
C

29078MC05

164 O-ring 329 Spring 372 Spring

201 Cover 331 Seat 374 Spring
203 Cover 332 Seat 377 Spring
261 O-ring 333 Bolt 378 Spring
273 Socket screw 334 Stopper 379 Spring
302 Arm 1 spool 335 Stopper 392 Bypass cut spool
305 Swing spool 336 Bolt 395 Priority spool
307 Boom 2 spool 337 Stopper 556 Plug
310 Travel spool LH 339 Stopper
328 Spring 370 Spring

8-32
STRUCTURE(3/5)

551
611
561 159
159

K
A
W
A
S
A
K
I
T
(L
)
S
B
2
A
1
B
C

516
523
561
515 552
521
561
511 551
521
561
551
555
Arm1
561
561 551
153
561 602
551
611 169
264
261
264 273
202
204
169

204 332
202 339
376

370
332
336

273
201
164
556
164 154 29078MC06

153 Plug 273 Socket screw 521 Spring

154 Plug 332 Seat 523 Spring
159 Plug 336 Bolt 551 Plug
164 O-ring 339 Stopper 552 Plug
169 O-ring 370 Spring 555 Check valve
201 Cover 376 Spring 556 Plug
202 Cover 551 Poppet 561 O-ring
204 Cover 515 Poppet 602 Port relief valve
261 O-ring 516 Poppet 611 Main relief valve
264 O-ring

8-33
STRUCTURE(4/5)

203

203

201 333
331
201 333 334
331 329
201 336 334 328
332 329
273 331
336 335 328 262
332 379
331
335 370 262
336
379 332
332
370 261 301
335
332
372
261 309
374
332 303
261

304

306
T
(R
)

602
O
P
T
B
1
B
K
A
2

168

165
29078MC07

165 O-ring 303 Boom 1 spool 334 Stopper

166 O-ring 304 Plug 335 Stopper
168 O-ring 306 Arm 2 spool 336 Bolt
201 Cover 309 Spool(Option) 370 Spring
203 Cover 328 Spring 372 Spring
261 O-ring 329 Spring 374 Spring
262 O-ring 331 Seat 379 Spring
273 Socket screw 332 Seat 602 Port relief valve
301 Travel spool RH 333 Bolt

8-34
STRUCTURE(5/5)

552 159
561
523 163
516 154
164
LCo 976
159
551 158
561 974
521 553,561
551 511
561
554 521 155
561 511
522 167
513

T
(R
)
551 971

O
P
T
561

B
1
209 Bo
154

B
K
165 164

A
2
975

971
Ao
209

165

169
Boom 264
273
202
202
561 204
204
553
602 204
602

29078MC08

154 Plug 204 Cover 551 Plug

155 Plug 209 Flange 552 Plug
158 Plug 264 O-ring 553 Plug
159 Plug 273 Socket screw 554 Plug
163 O-ring 551 Poppet 561 O-ring
164 O-ring 513 Poppet 602 Port relief valve
165 O-ring 516 Poppet 971 Screw
167 O-ring 521 Spring 974 Screw
169 O-ring 522 Spring 975 Screw
202 Cover 523 Spring 976 Screw

8-35
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) All hydraulic components are manufactured to a high precision. Consequently, 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 remove from the machine, apply caps and masking seals to all
ports. Before disassembling the valve, recheck that these caps and masking seals are fitted
completely, and then clean the outside of the assembly. Use a proper bench for working. Spread
paper or a rubber mat on the bench, and disassemble the valve on it.
(4) Support the body section carefully when carrying or transferring the control valve. Do not lift by
the exposed spool, end cover section etc.
(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 hydraulic test equipment is necessary
for these tests. Therefore, even when its disassembling can be carried out technically, do not
disassemble such components that cannot be tested, adjusted, and so on. Additionally one
should always prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.
2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.

Name of tool Quantity Size(mm)

Vice mounted on bench(Soft jaws) 1 unit -
Hexagon wrench Each 1 piece 5, 6, 10, 12 and 14
Socket wrench Each 1 piece 27 and 32
Spanner Each 1 piece 32(Main relief valve)

8-36
3) DISASSEMBLY
The figure in ( ) shown after the part name
in explanation sentence shows its number
in the construction figures.
(1) Place control valve on working bench.
※ Disassemble the valve in a clean and dry
environment and pay careful attention not
to damage the sealing flange faces.

(2) Travel straight valve block

Loosen hexagon socket head bolts to and
remove straight travel valve block(103) in
its assembled state.
・Hexagon wrench : 14mm

21078MC09

(3) Main spool

① Loosen hexagon socket head bolts(273)
and remove spring cover(201, 203).
・Hexagon wrench : 6mm

21078MC10

② Remove spool, springs, stopper, spring

seats and spacer bolt in spool assembly
condition from casing.
※ When extracting each spool assembly
from its casing, pay attention not to
damage the casing.

21078MC11

8-37
(4) Covers
Loosen hexagon socket head bolts(273)
and then remove the spool cover(202,
204).
・Hexagon wrench : 6mm

21078MC12

(5) Removal of port relief

Remove port relief valves(602) from
casing.
・Socket wrench : 32mm

21078MC13

(6) Removal of plug(Option section)

Remove plugs(553) from casing.
・Socket wrench : 27mm

(7) Lock valve

Loosen hexagon socket head bolts and
remove lock valve(252).
・Hexagon wrench : 5mm

21078MC14

8-38
(8) Negative control relief valve
① Remove plug(551).
・Hexagon wrench : 12mm

21078MC15

② Remove poppet(611), spring(621) and

damping rod(631).

21078MC16

(9) Swing logic valve and check valve

① Loosen hexagon socket head bolts(251)
and remove logic valve(251) and take
check valve(254).
② Remove plug(551) or (552) and take out
poppet(511) or (515, 516) and spring
(521) or (523).
・Hexagon wrench : 6, 12mm

21078MC17

(10) Boom priority valve

Loosen hexagon socket head bolts(104)
and remove boom priority valve(104).
・Hexagon wrench : 10mm

8-39
(11) Inspection after disassembly
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
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that seal groove faces of casing and block are smooth and free of dust, dent, rust etc.
c. Correct dents and damages and check seat faces within the casing, if any, by lapping.
※ Pay careful attention not to leave any lapping agent within the casing.
d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and paths
are free from foreign matter.
e. If any spring is broken or deformed, replace it with new one.
f. When a relief valve does not function properly, repair it, following the prescribed disassembly
and assembly procedures.
g. Replace all seals and O-rings with new ones.
② Relief valve
a. Confirm that all seat faces at ends of all poppets and seats are free of defects and show uniform
and consistent contact faces.
b. Confirm manually that main poppet and seat can slide lightly and smoothly.
c. Confirm that outside face of main poppet and inside face of seat are free from scratches and so
on.
d. Confirm that springs are free from breakage, deformation, and wear.
e. Confirm that orifices of main poppet and seat section are not clogged with foreign matter.
f. Replace all O-rings with new ones.
g. When any light damage is found in above inspections, correct it by lapping.
h. When any abnormal part is found, replace it with a completely new relief valve assembly.

8-40
4) ASSEMBLY
(1) General comments
① In this assembly section, explanation only is shown.
For further understanding, please refer to the figures and photographs shown in the previous
disassembly section.
② Figure in ( ) shown after the part name in the explanation refers to the reference identity number
shown on the construction figure shown in the spares section.
③ Cautions in assembling seal
a. Pay close attention to keeping all seals free from handling damage and inspect carefully for
damage before using them.
b. Apply clean grease or hydraulic oil to the seal so as to ensure it is fully lubricated before
assembly.
c. Do not stretch seals so much as to deform them permanently.
d. In fitting O-rings, pay close attention not to roll them into their final position in addition, a twisted
O-ring cannot easily untwist itself naturally and could thereby cause inadequate sealing and
thereby both internal and external oil leakage.
e. Tighten fitting bolts for all sections with a torque wrench adjusted to the respective tightening
torque as shown on the corss section drawings of the spares section.

(2) Check valve

① Assemble poppets(511, 515, 516) and spring(521, 523).
② Put O-rings(561) on to plugs(551, 552).
③ Tighten plugs(551, 552) to the specified torque.
・Hexagon wrench : 12mm
・Tightening torque : 23~27kgf・m(166~195lbf・ft)
(3) Negative control relief valve
① Assemble the poppets, springs and damping rods(611×2) together into casing A(101).
② Put O-ring(561) on to plug(551) and tighten the latter to its specified torque.
・Hexagon wrench : 12mm
・Tightening torque : 23~27kgf・m(166~195lbf・ft)
(4) Lock valve
① Put O-rings onto the casing.
② Tighten hexagon socket head bolts to their specified torques.
・Hexagon wrench : 5mm
・Tightening torque : 1~1.4kgf・m(7.23~10.12lbf・ft)
(5) Assembly of main relief, port relief valves
① Install main relief valve(601), port relief valve(602) into the casing and tighten to the specified
torque.

Tightening torque
Components Tools
kgf・m lbf・ft
Main relief valve Spanner 32mm 7~8 50.6~57.8
Port relief valve Socket wrench 32mm 7~8 50.6~57.8

8-41
(6) Main spools
① Carefully insert the previously assembled spool assemblies into their respective bores within of
casing A(101) and casing B(102).
※ Fit spool assemblies into casing A(101) and casing B(102) carefully and slowly. Do not under
any circumstances push them forcibly in.
(7) Covers
① Fit spool covers(202, 204) to the nonspring assembly end of the spool, and tighten the
hexagonal socket head bolts(273) to the specified torque.
・Hexagon wrench : 6mm
・Tightening torque : 2.5~3.5kgf・m(18~25.3lbf・ft)
※ Confirm that O-rings(169, 264) have been fitted.
② Fit spring covers(201, 203) to the spring end for the spools, and tighten hexagon socket head
bolts(273) to the specified torque.
・Hexagon wrench : 6mm
・Tightening torque : 2.5~3.5kgf・m(18~25.3lbf・ft)
※ Confirm that O-rings(261, 262) have been fitted.
(8) Travel straight valve, swing logic valve and boom priority valve
① Put O-rings onto the casing.
② Tighten hexagon socket head bolts to their specified torques.
Tightening torque
Components Tools
kgf・m lbf・ft
Travel straght valve Hexagon wrench 14mm 28~32 202~231
Swing logic valve Hexagon wrench 6mm 2.5~3.5 18~25.3
Boom priority valve Hexagon wrench 10mm 8.5~11.5 61.5~83.1

8-42
GROUP 4 MAIN CONTROL VALVE (TYPE 2)

1. REMOVAL AND INSTALL OF MOTOR

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 13031GE18

pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious
injury.
※ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(4) Remove the wirings for the pressure
sensor and so on.
(5) Remove bolts and disconnect pipe.
300078MCV01

(6) Disconnect pilot line hoses.

(7) Disconnect pilot piping.
(8) Sling the control valve assembly and
remove the control valve mounting bolt.
·Weight : 200 kg (441lb)
(9) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
300078MCV02
(1) Carry out installation in the reverse order
to removal.
(2) Bleed the air from below items.
① Cylinder (boom, arm, bucket)
Pd4
0 Pa2
1
Pd4
1 Pa2
0

②
Pc4

Swing motor
1
Pb2

③ Travel motor
Pn2

※ See each item removal and install. Pn1

Pb2
0
2
Pc4
Pb4 0
Pc4

(3) Confirm the hydraulic oil level and Pb3

recheck the hydraulic oil leak or not. Pc3

300078MCV03

8-42-1
2. STRUCTURE

59 52 81, 78 1

A A'

B B'

C C1 C1' C'

D D'

E E'

F F'

G G'

59 52 65 24 76

P1 BLOCK SPOOL SECTION

43 88
50

87
44
86
SECTION C1-C1'
59 52 59 52 59 52
1 Housing (P1)
2 Housing (P2)
A A' 24 Plug
43 Orifice-signal
B B' 44 Coin type filter
50 O-ring
C C'
52 Plug
D D'
59 O-ring
65 O-ring
E E' 76 Socket bolt
77 Hex socket head bolt
F F' 78 Hex socket head bolt
81 Spring washer
G G' 86 Poppet
87 Check spring
88 Plug
81, 77 2
A 65, 24
P2 BLOCK SPOOL SECTION VIEW A
3009A2MC10

8-42-2
 59 52 67 20 23 21

82
3 Spool-straight
4 Spool-travel
61 15 Cover-pilot A
64
64 16 Cover-pilot B1
3 18 Cover-pilot A1
52,59 20 Plug
21 Poppet 1-check valve
23 Spring 1-check valve
16
24 Plug
40 Sleeve
41 Piston
15 73 ,79 68 71 58 6046 60 56 44 43 68 73 ,79
43 Orifice-signal
44 Coin type filter
A-A' (STRAIGHT-TRAVEL & SUPPLY)
46 Plug
47 Plug
52 Plug
54 Plug
56 Plug
57 O-ring
15 73,79 68 4 61 67 20 61 57 47
58 O-ring
59 O-ring
60 O-ring
61 O-ring
62 O-ring
64 O-ring
65 O-ring
67 O-ring
68 O-ring
71 Back-up ring
72 Back-up ring
73 Hex socket head bolt
79 Washer
82 Main relief valve
54 67 72 62 65 24 67 20 23 21 72 62 67 54 68 73,79 16

B-B' (TRAVEL RIGHT & LEFT)

300H2MC11

8-42-3
 27

27-7 27-2 27-3

21 23 20 67 27-1 27-6 27-4 27-9
88,50 83 6 27-5
27-10
27-8

34

16

15 73,79 68 5 36 68 73,79

C-C' (SWING & BOOM1)

34-6 34-13 34-2 34-3 34-4 34-1 34-7

34-5
34-8

34-15 ,34-16

34 DETAIL (HOLDING ASSY)

32072MC12

5 Spool-swing 27-7 Restrictor-lock valve 34-15 Socket bolt

6 Spool-boom 1 27-8 O-ring 34-16 Spring washer
15 Cover-pilot A 27-9 O-ring 36 Logic valve
16 Cover-pilot B1 27-10 Back up ring 50 O-ring
20 Plug 34 Holding kit-A1 56 O-ring
21 Poppet 1-check valve 34-1 Block-H/D P1 66 O-ring
23 Spring 1-check valve 34-2 Piston 1-holding 67 O-ring
27 Holding kit-B 34-3 Guide piston-holding 68 O-ring
27-1 Poppet 34-4 Spring 1-lock valve 70 Back-up ring
27-2 Spring 34-5 Piston 2-holding 73 Hex socket head bolt
27-3 Poppet guide 34-6 Plug 79 Washer
27-4 Pilot poppet 34-7 Plug 83 Overload relief valve
27-5 Poppet seat 34-8 Plug 88 Plug
27-6 C-ring 34-13 Plug

8-42-4
 57 45 11 47 21 23 20 67 55 63 65 2426 25 61 74 68

19 19-6
19-9 19-5
19-4
73,79
19-3
19-2
19-1 16
19-7,19-8
34
68
27-8
15 27-10
73 27-5
27-3
27-9
61 10 21 23 20 67 25 26 24 65 27-1 27-7 27-6 27-2 27-4

27
E-E' (ARM & ARM REGENRATION)

34-6 34-13 34-2 34-3 34-4 34-1

H
34-8

34-5

H'
34-7 34-15 ,34-16

34 DETAIL (HOLDING ASSY)

32072MC13

10 Spool-arm 1 27 Poppet-lock valve 34-13 Plug

11 Spool-arm regeneration 27-1 Poppet 34-15 Socket bolt
15 Cover-pilot A 27-2 Spring 34-16 Spring washer
16 Cover-pilot B1 27-3 Poppet guide 45 Orifice-plug
19 Arm-regeneration 27-4 Pilot poppet 47 Plug
19-1 Block-regeneration 27-5 Poppet seat 55 Plug
19-2 Piston-cut off 27-6 C-ring 56 O-ring
19-3 Stopper-regeneration 27-7 Restrictor-lock valve 57 O-ring
19-4 Spool-regeneration 27-8 O-ring 61 O-ring
19-5 Spring-regeneration 27-9 O-ring 63 O-ring
19-6 Plug 27-10 Back up ring 65 O-ring
19-7 Socket bolt 34 Holding kit-A2 66 O-ring
19-8 Spring wahser 34-1 Block-H/D P2 67 O-ring
19-9 Pin-regeneration 34-2 Piston 1-holding 68 O-ring
20 Plug 34-3 Guide piston-holding 70 Back-up ring
21 Poppet 1-check valve 34-4 Spring 1-lock valve 73 Hex socket head bolt
23 Spring 1-check valve 34-5 Piston 2-holding 74 O-ring
24 Plug 34-6 Plug 79 Washer
25 Poppet 2-check valve 34-7 Plug
26 Spring 2-check valve 34-8 Plug

8-42-5
 7 Spool-swing priority
61 69 65 26 24 25 92 93 94 9 83
8 Spool-boom 2
29
61 9 Spool-arm 2
30
31 12 Spool-bucket
32 13 Spool-option
15 14 BC spool
15 Cover-pilot A
79 ,73
16 Cover-pilot B1
68 17 Cover-pilot B2
17 20 Plug
21 Poppet 1-check valve
7 22 Poppet L/C-bucket
23 Spring 1-check valve
84 58 71 65 46 63 55 8 84 68 24 Plug
65,24 25 Poppet 2-check valve
26 Spring 2-check valve
D-D' (SWING PRIORITY-BOOM2 & ARM2) 29 O-ring
30 Back-up ring
31 O-ring
83 12 22 23 67 42 65 24 61 84 57 68 73,79 16
26
32 Plug
90 25 38 Load check valve assy
67 42 Check valve
89 46 Plug
91 48 Spring-BC spool
15 49 Plug-BC spool
79, 73 51 Negative control valve
68 52 Plug
61 29 53 Flange
32 55 Plug
13 31
29
57 O-ring
30
32 58 O-ring
31 59 O-ring
30 61 O-ring
83 53 75 21 23 20 67 38 75 53 85
63 O-ring
F-F' (OPTION & BUCKET)
65 O-ring
67 O-ring
51 68 O-ring
69 O-ring
71 Back-up ring
73 Hex socket head bolt
51
75 Socket bolt
79 Washer
52
80 Overload relief valve
59
85 O-ring
89 Plug
90 Piston
91 Pilot cover C1
61 14 48 63 49
92 Plug
G-G' (CENTER BYPASS CUT-OFF
& NEGATIVE CONTROL)
93 Poppet
32072MC14 94 Spring

8-42-6
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) As hydraulic equipments, not only this valve are constructed precisely with very small clearances,
disassembling and assembling must be carefully done in a clean place with preventing dusts and
contaminants from entering.
(2) Prepare the section drawing and study the structure of MCV and then start disassembly work.
(3) When removing the control valve from the machine, install caps on every ports, and wash the
outside of the assembly with confirming the existence of caps before disassembling.
Prepare a suitable table and some clean papers or rubber mat on the table for disassembling.
(4) If the components are left disassembled, they may get rust. Make sure to measure the greasing
and sealing.
(5) For carrying the control valve, never hold with pilot cover or relief valve and overload relief valve
and carefully treat the valves.
(6) Do not tap the valve even if the spool movement is not smooth.
(7) Several tests for such as relief characteristics, leakage, overload relief valve setting and flow
resistance are required after re-assembling, and the hydraulic test equipments for those tests are
needed.
Therefore, do not disassemble what cannot perform test adjustment, even if it can disassemble.

※ Be sure to observe the mark (※) description in the disassembly and assembly procedures.

2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.

Name of tool Quantity Size (mm)

Vice mounted on bench (soft jaws) 1 unit

Hexagon wrench Each 1 piece 5, 6, 10, 12 and 14
Socket wrench Each 1 piece 27 and 32
Spanner Each 1 piece 26 and 32 (main relief valve)

8-42-7
3) DISASSEMBLY
(1) Removing spool
① The case of the section without holding valve
Instruction for removing the travel spool (for instance) is follows :
Remove two hex socket bolts by 5 mm allen key wrench, then remove pilot cover.
※ Pay attention not to lose the O-ring under the pilot cover.
As the return spring portion of travel spool comes out, pull the spring straight slowly, by which
spool assembly is removed.
※ The spools have to remove from the spring side.
Other spools (no lock valve type) can be removed in the same manner but the swing priority
spool is reversed.
※ When spool replace, do not disassemble of a spool by any cases. Please replace by spool
assembly.
※ Please attach using a tag etc. in the case of two or more kinds of spool replace, and understand
a position.

RETURN SPRING

PILOT COVER

O-RING

HEX SOCKET BOLT

29098MC01

8-42-8
② The case of the section with holding valve
Instruction for removing the boom spool (for instance) is follows :
Remove five hex socket bolts with washer by 5 mm allen key wrench. Then remove pilot cover
with internal parts below figure.
※ Be careful not to separate O-ring and poppet under pilot cover.
※ Pay attention not to damage the exposed piston A under pilot cover.
As the return spring portion of boom 1 spool comes out, pull the spring straight slowly, by which
spool assembly is removed.
※ The spools have to remove form the spring side.
※ When spool replace, do not disassemble of a spool by any cases, please replace by spool
assembly.

BOOM 1 SPOOL

PILOT COVER HEX SOCKET BOLT

POPPET POPPET SEAT O-RING PISTON "A"

29098MC02

8-42-9
(2) Removing holding valve
Remove the pilot cover with the holding valve as described on previous page.
※ Do not disassembled internal parts of the pilot cover.
Loosen the poppet seat by 26 mm spanner and remove the poppet, the spring seat, the spring
and the check in order.
※ Pay attention not to lose the poppet.
※ Do not disassembled internal parts of the check because the plug, functioning orifice, can
damage easily.

BOOM 1 SPOOL

PILOT COVER HEX SOCKET BOLT

SPRING

POPPET SEAT

CHECK POPPET
SPRING SEAT

29098MC03

8-42-10
(3) Removing load check valve and negative relief valve

① The load check valve

- Fix the body to suitable work bench. Loosen the plug by 10 mm allen key wrench.
- Remove the spring and the load check valve with pincers or magnet.

PLUG

SPRING

LOAD CHECK VALVE

29098MC04

② The negative relief valve

Loosen the socket by 12 mm allen key wrench.
Remove the spring, the spring holder, the piston and the negative control poppet.

BODY COIN FILTER POPPET SPRING PLUG 29098MC05

※ Do not disassemble the coin filter inside the negative control poppet because of forced fit.

8-42-11
(4) Removing main relief valve and overload relief valve
Fix the valve body to suitable work bench. Remove the main relief valve by 32 mm spanner and
remove the overload relief valve 32 mm spanner (standard) or 36 mm spanner (optional).
※ When disassembled, tag the relief valve for identification so that they can be reassembled
correctly.
※ Pay attention not to damage seat face of disassembled main relief and overload relief valve.
※ Main relief and overload relief valve are very critical parts for performance and safety of the
machine. Also, the pressure set is very difficult. Therefore, any abnormal parts are found, replace
it with completely new relief valve assembly.

MAIN RELIEF VALVE

32mm HEX

29098MC06

OVERLOAD RELIEF VALVE(STD) OVERLOAD RELIEF VALVE(OPT)

32mm HEX 36mm HEX

29098MC07

8-42-12
(5) Removing the swing logic valve and bucket logic valve
- Fix the valve body to suitable work bench.
- Loosen the body 2 by 32 mm spanner (swing logic valve) or 24 mm spanner (bucket logic valve)
and remove it.
- Remove the banjo plate.
- Loosen the body 1 as the same spanner of body 2 and remove it.
- Remove the check poppet and spring.
※ Pay attention not to damage seat face of removed check poppet.
※ Do not disassemble the check poppet and replace it with a assembly in case any abnormal
parts are found.
※ Pay attention not to lose and separation while disassembling and assembling.

BODY 2

PLATE

BODY 1

PISTON ROD

SPRING

CHECK POPPET

29098MC08

8-42-13
(6) Removing the option ON/OFF valve
- Fix the valve body to suitable work bench.
- Loosen the body 2 by 24 mm spanner and remove it.
- Remove the banjo plate.
- Loosen the body 1 as the same spanner of body 2 and remove it.
- Remove the pilot poppet, spring and seat.
- Remove the check poppet.

BODY 2

PILOT SPRING

PLATE

PISTON

BODY 1

PILOT POPPET

SPRING & SEAT

CHECK POPPET

29098MC09

8-42-14
4) ASSEMBLY
(1) Precaution
① When you assemble, please wash all parts by pure cleaning liquid.
② For re-assembling, basically use only bland new seals for all portions.
③ Apply grease or hydraulic oil to the seals and seal fitting section to make the sliding smooth,
unless otherwise specified.
④ Pay attention not to roll the O-ring when fitting and it may cause oil leakage.
⑤ Do not tap the valve even if the spool movement is not smooth.
⑥ Prepare the section drawing and study the structure of MCV and then start disassembly work.
⑦ Tighten bolt and parts with thread for all section by torque wrench to the respective tightening
torque.

8-42-15
(2) Assembly
Explanation only is shown for the assembly, refer to the figures shown in the previous
disassembly section.
① Main relief and overload relief valve
Fix the valve body to suitable work bench.
Install main relief valve and overload relief valve into the body and tighten to the specified torque
by 32 mm torque wrench.
·Tightening torque : 8~9 kgf·m (57.8~65.1 lbf·ft)

MAIN RELIEF VALVE

32mm HEX

29098MC06

OVERLOAD RELIEF VALVE(STD) OVERLOAD RELIEF VALVE(OPT)

32mm HEX 36mm HEX

29098MC07

8-42-16
② Load check valve
Assemble the load check valve and spring.
Put O-rings on to plug and tighten plug to the specified torque by 10 mm torque wrench.
·Tightening torque : 6~7 kgf·m (43.4~50.6 lbf·ft)

PLUG

SPRING

LOAD CHECK VALVE

29098MC04

③ Negative control relief valve

Assemble the nega-con poppet, piston, spring holder and spring into body in order and tighten
the socket to the specified torque by 12 mm torque wrench.
·Tightening torque : 8~9 kgf·m (57.8~65.1 lbf·ft)

BODY COIN FILTER POPPET SPRING PLUG

29098MC05

8-42-17
④ Holding valves
Assemble the check, spring seat and poppet into the hole of valve body in order.
Tighten the poppet seat to the specified torque by 25 mm torque wrench.
·Tightening torque : 6~7 kgf·m (43.4~50.6 lbf·ft)
Fit the "piston A" under pilot cover with internal parts into hole on the poppet seat.
Tighten hexagon socket head bolt to specified torque by 5 mm torque wrench.
·Tightening torque : 2.5~3 kgf·m (18.1~21.7 lbf·ft)
※ Pay attention poppet not to separation.
※ Confirm that O-rings have been well fitted on the groove of body. (apply grease on O-ring)

BOOM 1 SPOOL

PILOT COVER HEX SOCKET BOLT

SPRING

POPPET SEAT

CHECK POPPET
SPRING SEAT

29098MC03

8-42-18
⑤ Main spool
Put the spool position upward and fix it to the vise. Carefully insert the previously assembled
spool assemblies into their respective bores within of body.
Fit spool assemblies into body carefully and slowly. Do not under any circumstances push them
forcibly in.
Fit the pilot cover to the groove of the valve body.
Confirm that O-rings have been fitted on the groove of body. (apply grease on O-ring)
Tighten the two socket bolt to the specified torque by 5 mm torque wrench.
·Tightening torque : 2.5~3 kgf·m (18.1~21.7 lbf·ft)

RETURN SPRING

PILOT COVER

O-RING

HEX SOCKET BOLT

29098MC01

8-42-19
⑥ The swing logic valve and bucket logic valve
- Assemble the piston rod, spring and check poppet into the body 1 in order.
- Install the body 1 assembly into valve body and tighten to the specified torque.
·Tightening torque : 2.9 kgf·m (21.0 lbf·ft)
- Assemble the banjo plate.
※ Confirm O-ring has been seated on the groove of banjo plate.
- Tighten the body 2 to the specified torque.
·Tightening torque : 1.5 kgf·m (10.8 lbf·ft)

BODY 2

PLATE

BODY 1

PISTON ROD

SPRING

CHECK POPPET

29098MC08

8-42-20
⑦ Option ON/OFF valve
- Assemble the check poppet into the valve body.
※ Push the check poppet about half of hole.
- Assemble the pilot poppet, spring and seat into check poppet.
※ As it can not be fixed, hang it diagonally.
- Insert the end of pilot poppet into the machined center hole of body 1 and push it complete
- slowly. Then tighten to the specified torque.
·Tightening torque : 2.9 kgf·m (21.0 lbf·ft)
※ Tighten socket piston.
- When push the piston to the end, confirm the repulsive spring force.
- Assemble the banjo plate.
- Put the pilot spring into body 2 and assemble it into body 1 and then tighten to the specified
torque.
·Tightening torque : 1.5 kgf·m (10.8 lbf·ft)

BODY 2

PILOT SPRING

PLATE

PISTON

BODY 1

PILOT POPPET

SPRING & SEAT

CHECK POPPET

29098MC09

8-42-21