GROUP 4 MAIN CONTROL VALVE

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 Bracket

sensor and so on.

(5) Remove bolts and disconnect pipe.
2209S8MC01

(6) Disconnect pilot line hoses.

(7) Disconnect pilot piping.
(8) Sling the control valve assembly and
remove the control valve mounting bolt.
Weight : 220 kg (485 lb)
(9) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
2209S8MC02
(1) Carry out installation in the reverse order
to removal.
(2) Bleed the air from below items.
Cylinder (boom, arm, bucket) 0 Pa2
1
Pd4
1 Pa2
0

1 Pd4

Pc4

Swing motor
1
Pb2

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

8-30
2. STRUCTURE

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
64 O-ring
E E' 65 O-ring
76 Socket bolt
F F' 77 Hex socket head bolt
78 Hex socket head bolt
G G'
81 Spring washer
86 Poppet
81,77 2 87 Spring check
64,24
88 Plug
P2 BLOCK SPOOL SECTION

29092MC40

8-31
 59 52 67 20 23 21

82

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

83 65 24 67 20 23 21 83 68 73,79 16

2209S2MC11
B-B' (TRAVEL RIGHT & LEFT)

8-32
 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 C
27-10
27-8 D

34

16
C' D'

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

H

34-5
34-8

H'
34-15 ,34-16 SECTION H-H'

34 DETAIL (HOLDING ASSY)

300H2MC12

5 Spool-swing 27-7 Restrictor-lock valve 34-14 Plug

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

8-33
 57 45 11 94 21 23 20 67 75 53 85 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
35
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)

35-6 35-13 35-2 35-3 35-4 35-1

H
35-8

35-5

H'
35-7 35-15 ,35-16 SECTION H-H'

35 DETAIL (HOLDING ASSY)

300H2MC13

10 Spool-arm 27 Poppet-lock valve 35-13 Plug

11 Spool-arm regeneration 27-1 Poppet 35-15 Socket bolt
15 Cover-pilot A 27-2 Spring 35-16 Spring washer
16 Cover-pilot B1 27-3 Poppet guide 45 Orifice-plug
19 Arm-regeneration 27-4 Pilot poppet 53 Flange
19-1 Block-regeneration 27-5 Poppet seat 56 O-ring
19-2 Piston-cut off 27-6 C-ring 57 O-ring
19-3 Stopper-regeneration 27-7 Restrictor-lock valve 61 O-ring
19-4 Spool-regeneration 27-8 O-ring 65 O-ring
19-5 Spring-regeneration 27-9 O-ring 66 O-ring
19-6 Plug 27-10 Back up ring 67 O-ring
19-7 Socket bolt 35 Holding kit-A2 68 O-ring
19-8 Spring wahser 35-1 Block-H/D P2 70 Back-up ring
19-9 Pin-regeneration 35-2 Piston 1-holding 73 Hex socket head bolt
20 Plug 35-3 Guide piston-holding 74 O-ring
21 Poppet 1-check valve 35-4 Spring 1-lock valve 75 Socket bolt
23 Spring 1-check valve 35-5 Piston 2-holding 79 Washer
24 Plug 35-6 Plug 85 O-ring
25 Poppet 2-check valve 35-7 Plug
26 Spring 2-check valve 35-8 Plug

8-34
 7 Spool-swing priority
84 61 69 65 24 26 25 92 94 93 9 83
8 Spool-boom 2
61
9 Spool-arm 2
12 Spool-bucket
13 Spool-option
15 14 BC spool
15 Cover-pilot A
79 ,73 16 Cover-pilot B1
34
68 17 Cover-pilot B2
17
20 Plug
35 21 Poppet 1-check valve
7 22 Poppet L/C-bucket
23 Spring 1-check valve
84 58 71 60 46 63 55 8 84 68 24 Plug
65,24
25 Poppet 2-check valve
26 Spring 2-check valve
34 Holding kit
D-D' (SWING PRIORITY-BOOM2 & ARM2)
35 Holding kit
38 Load check valve assy
83 12 22 23 67 42 65 24 61 84 57 68 73,79 16 39 Overload relief valve
26 42 Check valve
90 25 46 Plug
67
48 Spring-BC spool
89
49 Plug-BC spool
91 51 Negative control valve
15
52 Plug
79, 73
53 Flange
68 55 Plug
61 57 O-ring
58 O-ring
39 33,66 59 O-ring
13 60 O-ring
61 O-ring
63 O-ring
83 53 75 21 23 20 67 38 75 53 85 80
65 O-ring
F-F' (OPTION & BUCKET) 67 O-ring
68 O-ring
69 O-ring
51
71 Back-up ring
73 Hex socket head bolt
75 Socket bolt
51 79 Washer
80 Overload relief valve
52 83 Overload relief valve
59 84 Overload relief valve
85 O-ring
89 Plug
90 Piston
61 14 48 63 49 91 Pilot cover C1
92 Plug
G-G' (CENTER BYPASS CUT-OFF
& NEGATIVE CONTROL) 93 Poppet
2209S2MC14 94 Spring

8-35
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)

8-36
3) DISASSEMBLY
(1) Removing spool
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

8-37
 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

8-38
(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

8-39
(3) Removing load check valve and negative relief valve
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

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.

8-40
(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

8-41
(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
(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

8-43
4) ASSEMBLY
(1) Precaution
When you assemble, please wash all parts by pure cleaning liquid.
For re-assembling, basically use only bland new seals for all portions.
Apply grease or hydraulic oil to the seals and seal fitting section to make the sliding smooth,
unless otherwise specified.
Pay attention not to roll the O-ring when fitting and it may cause oil leakage.
Do not tap the valve even if the spool movement is not smooth.
Prepare the section drawing and study the structure of MCV and then start disassembly work.
Tighten bolt and parts with thread for all section by torque wrench to the respective tightening
torque.

8-44
(2) Assembly
Explanation only is shown for the assembly, refer to the figures shown in the previous
disassembly section.
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 kgfm (57.8~65.1 lbfft)

MAIN RELIEF VALVE

32mm HEX

29098MC06

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

32mm HEX 36mm HEX

29098MC07

8-45
 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 kgfm (43.4~50.6 lbfft)

PLUG

SPRING

LOAD CHECK VALVE

29098MC04

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 kgfm (57.8~65.1 lbfft)

BODY COIN FILTER POPPET SPRING PLUG

29098MC05

8-46
 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 kgfm (43.4~50.6 lbfft)
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 : 1~1.1 kgfm (7.2~7.9 lbfft)
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

8-47
 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 : 1~1.1 kgfm (7.2~7.9 lbfft)

RETURN SPRING

PILOT COVER

O-RING

HEX SOCKET BOLT

29098MC01

8-48
 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 kgfm (21.0 lbfft)
- 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 kgfm (10.8 lbfft)

BODY 2

PLATE

BODY 1

PISTON ROD

SPRING

CHECK POPPET

29098MC08

8-49
 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 kgfm (21.0 lbfft)
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 kgfm (10.8 lbfft)

BODY 2

PILOT SPRING

PLATE

PISTON

BODY 1

PILOT POPPET

SPRING & SEAT

CHECK POPPET

29098MC09

8-50