SECTION 3 COMPONENT OPERATION

Group 3 Control Valve

Outline
The control valve controls the oil pressure, flow rate, and flow direction in the hydraulic
circuit. The major parts are the main relief valve, overload relief valve, flow combiner valve,
anti-drift valve, flow rate control valve, regenerative valve, boom lower meter-in cut valve,
bypass shut-out valve, and spools. The spools are operated by the pilot oil pressure. As for
the spools, in the A side block, travel (right), bucket, boom 1, and arm 2 are arranged in that
order as viewed from the machine front. In the B side block, travel (left), auxiliary, boom 2,
arm 1, and swing are arranged in that order as viewed from the machine front.
Hydraulic Circuit
Main Circuit
Pressure oil from pump 1 flows to each spool of travel (right), bucket, boom 1, and arm 2 at
the 4-spool side of control valve. Pressure oil from pump 2 flows to each spool of swing, arm
1, boom 2, auxiliary, and travel (left) at the 5-spool side of control valve. The parallel circuit
is provided in each main circuit of pump 1 and pump 2, and makes the combined operation
possible. In addition, the flow combiner circuit is provided in both boom and arm circuits so
that pressure oil from pump 1 and pump 2 are combined during a single operation. The main
relief valve (15) is provided in the main circuit (between the pump and the actuator). The
main relief valve (15) prevents the pressure in the main circuit from exceeding the set
pressure when the spool is operated (when the control lever is operated). The overload relief
valves (6,11,19,22, and 29) are provided in the actuator circuits (between the control valve
and the actuator) of boom, arm, bucket, and auxiliary. The overload relief valve prevents
surge pressure caused by external force in the actuator circuit does not exceed the set pressure
when the spool is in neutral (with the control lever set in neutral). In addition, boom overload
relief valve (low pressure) (22) is provided in the boom lower circuit. Boom overload relief
valve (low pressure) (22) decreases the relief set pressure in the boom lower circuit and
reduces vibration of the machine during boom lower operation.

Pilot Operation Control Circuit

Pressure oil (indicated with numbers) from the pilot valve acts on the spool in the control
valve in order to move the spool. In the following operations, pressure oil moves the spool
and is routed to the following selector valves.
 During boom lower (2) operation, pressure oil moves the boom 1 spool and the
divided pressure oil shifts bypass shut-out valve (c) through boom lower meter-in cut
valve (b).
In addition, air bleed circuit (a) is located in the upper of control valve and bleeds air
automatically.
External Pilot Pressure Circuit
 Pressure in main relief valve (8) is increased by pilot pressure from 4-spool solenoid
valve unit (SI).
 Arm 2 flow rate control valve (13) is shifted by pilot pressure from 4-spool solenoid
valve unit (SG).
 Bypass shut-out valve (6) is shifted by pilot pressure from 4-spool solenoid valve unit
(SF).
 Swing flow rate control valve (1) is shifted by pilot pressure from 2-spool solenoid
valve unit (SI).
 Boom overload relief control valve (12) is shifted by pilot pressure from 2-spool
solenoid valve unit (SC).
 Flow combiner valve (7) is shifted by pilot pressure from the flow combiner valve
control spool in the signal control valve.
 As arm 1 spool (3) is shifted during arm roll-in operation, pressure oil from the pilot
pump is routed to arm anti-drift valve (4) and releases the lock of arm anti-drift valve
(4).
 As arm 1 spool (3) and boom 1 spool (9) are shifted during combined operation of
arm roll-in and boom lower, pressure oil from the pilot pump is routed to arm anti-
drift valve (4), boom 1 anti-drift valve (10), and boom 2 anti-drift valve (5), and
releases the lock of arm anti-drift valve (4), boom 1 anti-drift valve (10), and boom 2
anti-drift valve (5).
Main Relief Valve
The main relief valve prevents the pressure in the main circuit from exceeding the set
pressure when the actuator such as the motor or the cylinder is operated. Therefore, oil leak
from hose and pipe joints and breakage of the actuator are prevented.
Relief Operation
1. Pressure in port HP (main circuit) is routed to pilot poppet (8) through orifice A (2) in
main poppet (1) and orifice B (3) in seat (4).
2. When pressure in port HP reaches the set pressure of spring B (6), pilot poppet (8) is
opened, pressure oil from passage A (5) flows to port LP (hydraulic oil tank).
3. At this time, a pressure difference is caused between port HP and spring chamber (10) due
to orifice A (2).
4. When this pressure difference reaches the set pressure of spring A (9), main poppet (1) is
opened and pressure oil from port HP flows to port LP.
5. Consequently, the main circuit pressure decreases.
6. When the main circuit pressure decreases to the specified level, main poppet (1) is closed
by the force of spring A (9).
Make-Up Operation
1. When pressure in port HP (actuator circuit) decreases lower than pressure in port LP
(hydraulic oil tank), main poppet (2) is moved to the right.
2. Hydraulic oil in port LP flows to port HP and cavitation is prevented.
3. When pressure in port HP increases to the specified pressure, main poppet (2) is closed by
the force of spring C (7).
Pressure Increasing Operation (Only auxiliary overload relief valve)
1. When pilot pressure from auxiliary control solenoid valve unit (SB) is routed to piston
(11), spring B (6) is compressed.
2. Therefore, force of spring B (6) becomes strong.
3. Consequently, as pressure required in order to open pilot poppet (8) is increased, the relief
set pressure is increased.

Boom Overload Relief Valve (Low Pressure)

The boom overload relief valve (low pressure) is provided in the boom lower circuit. The boom
overload relief valve (low pressure) is shifted by pilot pressure from 2-spool solenoid valve unit (SC)
and relieves the boom cylinder rod side circuit with low pressure. Therefore, vibration of the
machine is reduced during boom lower operation.

NOTE: Two overload relief valves are provided in the boom lower circuit.The relief pressure of
overload relief valve (low pressure) is set lower than that of other overload relief valve.

Operation

1. In normal, pressure oil in port HP flows to chamber c through piston (6) and is routed to main
poppet (5). Therefore, main poppet (5) is kept closed.

2. When pilot pressure from 2-spool solenoid valve unit (SC) is routed to piston (1), piston (1) opens
poppet (2). When poppet (2) opens, chambers a, b are connected to port LP through the external
circumference of sleeve (7).

3. When pressure in chamber c reaches the set pressure of spring (3), pilot poppet (4) opens. When
pilot poppet (4) opens, pressure in chamber c decreases.

4. Therefore, piston (6) and main poppet (5) move to the left. As main poppet (5) opens, pressure oil
flows to port LP from port HP.

5. Consequently, as the set pressure at cylinder rod side decreases, vibration of the machine during
boom lower operation is reduced.
Regenerative Valve
The regenerative valves are provided in the arm rollin and bucket roll-in circuits. The
regenerative valves increase cylinder speeds in order to prevent cylinder hesitation, and
improve machine controllability.
Bucket Regenerative Valve, Arm Regenerative Valve
The bucket regenerative valve and arm regenerative valve supply returning oil from the
cylinder rod side to the bottom side, prevent cylinder hesitation, and increase bucket roll-in
and arm roll-in operating speed during bucket roll-in and arm roll-in operation.
NOTE: The bucket regenerative valve is explained here.
Operation (during Bucket Regenerative Operation)
1. Returning oil from the bucket cylinder (1) rod side is routed to check valve (2) through
hole (4) of bucket spool (3) during bucket roll-in operation.
2. At this time, when pressure in the cylinder (1) bottom side is lower than the rod side, check
valve (2) is opened.
3. Consequently, returning oil from the cylinder (1) rod side flows to the bottom side and is
combined with pressure oil from pump 1. The combined pressure oil is delivered to the
cylinder (1) bottom side so that regenerative operation is done. This prevents cylinder
hesitation and increases bucket roll-in operating speed during bucket roll-in operation.
Operation (during Bucket Regenerative Cut Operation)
1. Pressure oil from pump 1 is routed to piston (7) of the bucket regeneration cut valve. When
cylinder (3) is fully stroked or digging loads increase during bucket roll-in operation, pressure
in the cylinder (3) bottom side is higher.
2. Piston (7) compresses spring (2) and moves upward (to the left in the circuit diagram).
3. Therefore, pressure in the cylinder (3) bottom side is higher than the rod side. As check
valve (4) of the bucket regenerative valve is kept closed and pressure oil from the cylinder (3)
rod side does not flow to the bottom side, regenerative operation is not done.
4. Pressure oil from the cylinder (3) rod side flows to the hydraulic oil tank through bucket
spool (5) and the external circumference of plunger (6).
5. Therefore, pressure in the cylinder (3) rod side decreases and digging force is improved.
Anti-Drift Valve
The anti-drift valve is provided in the circuits of the boom cylinder bottom side and arm
cylinder rod side, and reduces the cylinder drift.
NOTE: The arm 1 anti-drift valve is explained here.
Holding Operation
1. As pressure oil from the pilot valve is blocked by arm 1 spool (4) with the control lever set
in neutral (the spool in neutral), the selector valve in anti-drift valve is not shifted.
2. Therefore, pressure oil from the arm cylinder (1) rod side flows to the spring (5) chamber
and spring (6) chamber in selector valve (3) through orifice (7) in check valve (2).
3. Consequently, as check valve (2) is pushed and the return circuit from cylinder (1) is
blocked, the cylinder (1) drift is reduced.
Releasing Operation

1. Pressure oil from the pilot pump pushes piston (8) of the anti-drift valve and shifts selector valve
(3) during arm roll-in operation.

2. Pressure oil in the spring (5) chamber of check valve (2) is returned to the hydraulic oil tank
through the passage of selector valve (3).

3. When pressure in the spring (5) chamber decreases and its pressure and the spring (5) force are
lower than pressure in the cylinder (1) rod side, check valve (2) moves upward (to the right in the
circuit diagram).
4. Consequently, returning oil from the arm cylinder rod side flows to the hydraulic oil tank. In
addition, orifice (7) of check valve (2) decreases pressure in the spring (5) chamber slowly so that
check valve (2) is prevented from moving quickly and shock during arm roll-in operation is reduced.

Flow Rate Control Valve

The flow rate control valve is provided in the arm 1, arm 2, boom 1, and swing circuits, restricts oil
flow rate in the circuit during combined operation, and gives priority to other actuators.
Each flow rate control valve is operated during combined operation as shown below.

Arm 1, Boom 1, Swing

NOTE: The arm 1 flow rate control valve is explained here.
Flow Rate Control OFF
1. Pressure oil from pump 2 is routed to check valve (4) of poppet valve (3).
2. Normally, selector valve (2) is kept open so that pressure oil from pump 2 opens check
valve (4) and flows to the arm 1 spool through selector valve (2).
3. When load in the actuator side is high, poppet valve (3) is opened and pressure oil from
pump 2 flows to the arm 1 spool.
4. Therefore, pressure oil flow rate flowing to the arm 1 spool increases and arm operating
speed becomes fast.
Flow Rate Control ON
1. Selector valve (2) of the arm 1 flow rate control valve is shifted by pilot pressure from the
arm 1 flow rate control valve control spool in the signal control valve.
2. Therefore, back pressure in poppet valve (3) increases and the force to close poppet valve
(3) appears.
3. Therefore, the opening clearance of poppet valve (3) is reduced so that pressure oil flow
rate to the arm 1 spool is restricted.
4. Consequently, pressure oil from pump 2 flows to the boom 2 spool first.
Arm 2 Flow Rate Control OFF
1. Normally, selector valve (2) is kept open so that pressure oil from pump 1 is routed to
poppet valve (3).
2. The back pressure in poppet valve (3) increases by the pressure oil from pump 1 so that the
force to close poppet valve (3) appears.
3. Therefore, the opening clearance of poppet valve (3) is reduced so that pressure oil flow
rate to the arm 2 spool is restricted.
4. Consequently, pressure oil from pump 1 flows to the bucket, boom 1 spools first.
Flow Rate Control ON
1. Selector valve (2) of the arm 2 flow rate control valve is shifted by pilot pressure from 4-
spool solenoid valve unit (SG).
2. Therefore, the pressure oil from pump 1 is blocked so that poppet valve (3) is opened and
pressure oil from pump 1 flows to the arm 2 spool.
3. Therefore, pressure oil flow rate flowing to the arm 2 spool increases and arm operating
speed becomes fast.
Boom Lower Meter-In Cut Valve
The boom lower meter-in cut valve is provided in the boom lower circuit. In case boom lower
meter-in cut control is deactivated with the track raised, the boom is given priority to operate
and jack-up force increases. The boom falls due to own weight by the regenerative circuit
from boom 2 spool (2) and allows pressure oil from the pump to other actuator.
Consequently, operating speed of other actuator increases. (Refer to SYSTEM/ Hydraulic
System.)
Operation (Boom Lower with Front Attachment above Ground)
1. Pilot pressure is routed to boom 1 spool (6) and boom 2 spool (2) when lowering the boom.
2. The returning oil from the boom cylinder (1) bottom side is divided into two directions.
3. One is routed to spool (4) through orifice (8). When pressure from the boom cylinder (1)
bottom side exceeds the spring (9) force, spool (4) compresses spring (9) and moves to the
left (upward in the circuit diagram).
4. Pressure oil from port 4PC11 (12) flows to selector valve (3) of the boom flow rate control
valve through spool (4).
5. Therefore, selector valve (3) of the boom flow rate control valve is shifted and pressure oil
which flows to boom 1 spool (6) from pump 1 (11) is reduced. (Refer to Flow Rate Control
Valve.)
6. Other flows to boom 2 spool (2). Pressure oil is supplied to the boom cylinder (1) rod side
through the regenerative circuit.
7. Therefore, as boom cylinder (1) falls due to own weight, the boom is lowered. 8.
Consequently, during combined operation of boom lower and other actuator, more pressure
oil is supplied to other actuator and speed of actuator increases.

Bypass Shut-Out Valve

The bypass shut-out valve is provided in the rear of 4-spool and 5-spool side circuits. The
bypass shut-out valve blocks the neutral circuit (return circuit to hydraulic oil tank) in 4-spool
and 5-spool sides so that pressure oil in pumps 1 and 2 are combined. Therefore, amount of
oil which flows to the cylinder increases and operating speed of the cylinder increases.
NOTE: The bypass shut-out valve at 5-spool side is explained here.
Operation
1. Pilot pressure from 4-spool solenoid valve unit (SI) shifts bypass shut-out valve (2) at 5-
spool side.
2. Therefore, as the neutral circuit in 5-spool side is blocked, pressure oil from pump 2 (3)
flows to the 4-spool side, is combined with pressure oil from pump 1 (4) so that combined
pressure oil is supplied to bucket spool (5).
3. Consequently, operating speed of the bucket increases.
Auxiliary Flow Combiner Valve
The auxiliary flow combiner valve is provided in the pump 1 flow combiner circuit.
Flow Combiner Control OFF
1. Pressure oil from pump 1 is routed to check valve (2) of poppet valve (3).
2. Normally, selector valve (1) is kept open so that pressure oil from pump 1 opens check
valve (2) and flows to poppet valve (3) through selector valve (1).
3. The back pressure in poppet valve (3) increases by the pressure oil from selector valve (1)
so that the force to close poppet valve (3) appears.
4. Therefore, the opening clearance of poppet valve (3) is reduced so that pressure oil flow
rate to auxiliary spool (5) is restricted.

Flow Combiner Control ON

1. Selector valve (1) of the auxiliary flow combiner valve is shifted by pilot pressure from
auxiliary control solenoid valve unit (SA).
2. Therefore, back pressure in poppet valve (3) decreases and the force to close poppet valve
(3) is reduced.
3. Therefore, the opening clearance of poppet valve (3) increases so that pressure oil flow rate
to auxiliary spool (5) from pump 1 increases.
4. Consequently, pressure oil flow rate to auxiliary spool (5) from pump 1 increases.
 SECTION 3 COMPONENT OPERATION
Group 4 Pilot Valve

Outline
The pilot valve controls pilot pressure oil in order to move the spool in the control valve. The
pilot valve outputs pressure according to the control lever stroke by PPC (Pressure
Proportional Control Valve) function and moves the spool in the control valve. The 4-port
pilot valves for front attachment / swing and for travel are standard. The 2-port pilot valve is
for auxiliary (optional) and for counterweight removal and installation (optional).
Operation (Front Attachment / Swing and Travel Pilot Valves)

The spool (7) head comes in contact with the upper surface of spring guide (4). Spring guide (4) is
kept raised by return spring (6).

NOTE: Total lever strokes for front attachment and swing controls are determined by stroke
dimension (E) of pusher (2).Total lever stroke for travel control is determined by stroke dimension
(E) of cam (1).

Neutral (Output Curve: A to B):

1. When in neutral, spool (7) completely blocks pressure oil from port P (pilot pump). In
addition, the output port is opened to port T (hydraulic oil tank) through the inner passage in
spool (7).
2. Therefore, pressure in the output port is equal to that in port T.
3. When the control lever is slightly tilted, cam (1) is tilted and pusher (2) is pushed
downward. Pusher (2) compresses return spring (6) along with spring guide (4) together.
4. At this time, as pressure in the output port is equal to that in port T, spool (7) moves
downward due to the balance spring (5) force while keeping the lower surface of the spool (7)
head in contact with spring guide (4).
5. This status continues until hole (8) on spool (7) is connected to port P.
Full Stroke (Output Curve: E to F)

1. When the control lever is fully stroked, pusher (2) is moved downward until pusher (2) on the
front attachment / swing pilot valve comes in contact with the casing (3) shoulder, or cam (1) on the
travel pilot valve comes in contact with casing (3).

2. At this time, the bottom surface of pusher (2) directly pushes spool (7). Therefore, even if pressure
in the output port increases further, hole (8) on spool (7) is kept open.

3. Consequently, pressure in the output port is equal to that in port P.

Operation (Auxiliary / Counterweight Removal and Installation Pilot Valve)
The spool (7) head comes in contact with the upper surface of spring guide (4). Spring guide
(4) is kept raised by return spring (6).
NOTE: Total lever stroke is determined by stroke dimension (E) of cam (1).

Auxiliary / Counterweight Removal and Installation Pilot Valve Neutral (Output Curve: A to B):

1. When the control lever is in neutral, spool (7) completely blocks pressure oil from port P. In
addition, the output port is opened to port T (hydraulic oil tank) through the inner passage
in spool (7).

2. Therefore, pressure in the output port is equal to that in port T.

3. When the control lever is slightly tilted, cam (1) is moved and pusher (2) is pushed downward.
Pusher (2) compress return spring (6) along with spring guide (4) together.

4. At this time, as pressure in the output port is equal to that in port T, spool (7) moves
downward due to the balance spring (5) force while keeping the lower surface of the spool (7)
head in contact with spring guide (4).

5. This status continues until hole (8) on spool (7) is connected to port P.

NOTE: The lever stroke while hole (8) on spool (7) is connected to port P is play.
During Metering or Decompressing (Output Curve: C to D)
1. When the control lever is further tilted and pusher (2) is moved downward further, hole (8)
on spool (7) is connected to port P and pressure oil in port P flows to the output port.
2. Pressure in the output port acts on the bottom surface of spool (7) so that spool (7) is
pushed upward.
3. When the force to move spool (7) upward is smaller than the balance spring (5) force,
balance spring (5) is not compressed so that spool (7) is not raised and pressure in the output
port increases. 4. As pressure in the output port increases further, the force to move spool (7)
upward increases. When this force overcomes the balance spring (5) force, balance spring (5)
is compressed so that spool (7) is moved upward.
5. As spool (7) is moved upward, hole (8) is closed so that pressure oil from port P stops
flowing to the output port and pressure in the output port stops increasing.
6. As spool (7) is moved downward and balance spring (5) is compressed, pressure acting on
the bottom surface of spool (7) increases until pressure balances with the increasing spring
force. This increasing pressure becomes pressure in the output port.
Shockless Function (Only for Travel Pilot Valve)
The travel pilot valve has damper (1) enabling damping of the speed change shock by travel
control lever (4). Damper (1) is composed of support (5), gear 1 (9) and gear 2 (8) and others.
Gear 1 (9) is connected to support (5).
Support (5) is secure to bracket (6) by spring pin (2). Travel control lever (4) and travel pedal
(3) are secure to bracket (6). Therefore, support (5) rotates transversely around pin (7)
according to movement of travel control lever (4).
Operation
1. If travel control lever (4) is released white traveling, spring force of the return spring
returns travel control lever (4) to the neutral position.
2. At this time, gear 1 (9) and gear 2 (8) inside damper (1) receive opposing force due to
friction.
3. Consequently, as travel control lever (4) gradually returns to the neutral position, the extent
of sudden stop at the time of abrupt release of travel control lever (4) is reduced.