2. Assembly of Control Valve Main Unit

2.Assembly of Control Valve Main Unit (1)Assembly of add-on section [1]Install the tie rod (71) to the main unit valve housing (1).

Tighten the tie rod all the way in.If the threaded section is only engaged a little, there is a danger of the add-on section tightening force being inadequate, allowing oil to leak from the matching surfaces and causing malfunction.

When installing the add-on section, avoid any dents, scratches on matching surfaces because there is a danger of them allowing oil to leak from those surfaces and causing malfunction.Also, at the same time, pay particular attention to avoid foreign matter getting trapped on matching surfaces and O-ring falling out of place or being extruded.

When installing the add-on section, always install the tie rod first and use it as the guide for determining the installation position.If position is performed without the tie-rod, there is a danger of matching surface O-rings being extruded, allowing oil to leak and causing malfunction.

Always tighten the hexagon nut to the specified torque.If the tightening torque is too low, there is a danger of inadequate tightening force allowing oil to leak from the matching surfaces.Also, if the tightening torque is too high, there is a danger of spool section valve housing warping making the spool stick and the actuator run wild and making it impossible to stop.

With this control valve, it is possible to attach the add-on section kit afterwards. When doing so, work and pay attention to the cautions according to the assembly and disassembly procedures.

The arm 1 sleeve (44), arm 2 sleeve (37), and straight travel metering sleeve (51) have similar shapes, so be careful to not mix them up.If installation is incorrect, there is a danger of this causing malfunction.

[2]Install the matching surface O-rings (3-5), (3-6), (3-7) and (3-8) on the inlet housing (3-1) and using the tie rod as a guide, mount on the main unit valve housing. [3]Install the matching surface O-rings (2-11), (2-14), (2-15) and (2-16) on the spool section valve housing (2-1) and using the tie rod as a guide, mount on the main unit valve housing. [4]Install the matching surface O-rings (73), (74), (75) and (76) on the outlet housing (33) and using the tie rod as a guide, mount on the main unit valve housing.

[5]Screw the hexagon nut (72) into the tie rod (71) and tighten it. (Tightening torque: 51 ± 2.5 N•m)

(2)Assembly of arm 1, 2 load check section [1]Install the spring (46) and poppet (45) on the outer circumference of the sleeves (37) and (44), and with the poppet (47) and spring (49) inserted into the sleeve, insert into the valve housing. [2]Screw in and tighten the plug (48) with O-ring (50) attached. (Tightening torque: 167 - 196 N•m) (3)Assembly of straight travel metering section (left travel section) [1]With the spring (46) and poppet (45) installed on the outer circumference of the sleeve (51), insert into the valve housing. [2]Screw in and tighten the plug (48) with O-ring (50) attached. (Tightening torque: 167 - 196 N•m)

(4)Assembly of boom 1, 2, swing, bucket, blade (add-on) load check section [1]Insert the poppets (52) and (2-8) and springs (53) and (2-10) in the valve housing. [2]Screw in and tighten the plugs (54) and (2-9) with O-rings (55) and (2-11) attached. (Tightening torque: 88 - 98 N•m) (5)Assembly of pressure damage reduction path check section (right travel section) [1]Insert the poppet (52) and spring (53) into the valve housing. [2]Screw in and tighten the plug (59) with O-ring (55) attached. (Tightening torque: 88 - 98 N•m) (6)Assembly of backup external confluence check section [1]Insert the poppet (56) and spring (58) into the valve housing. [2]Screw in and tighten the plug (57) with O-ring (55) attached. (Tightening torque: 88 - 98 N•m) [3]Screw in and tighten the plug assembly (25) with O-ring mounted. (Tightening torque: 61.8 - 82.4 N•m) (7)Assembly of arm regeneration section [1]Insert the poppet (26) and spring (27) into the valve housing. [2]Screw in and tighten the plug assembly (25) with O-ring attached. (Tightening torque: 61.8 - 82.4 N•m) [3]Install the O-ring (23) and backup ring (24) in the sleeve (22) and insert into the valve housing.

[4]Screw in and tighten the plug assembly (21) with O-ring attached. (Tightening torque: 167 - 196 N•m) (8)Assembly of common check section [1]Insert the poppet (69), spring (70), and spacer (68) into the valve housing.

[2]Screw in and tighten the plug assembly (28) with O-ring attached. (Tightening torque: 106 - 141 N•m)

Be careful to assemble O-rings and backup rings in the correct locations.If they are assembled in the wrong positions, there is a danger of an O-ring being cut and causing actuator malfunction.

Be careful to install so that the spring rides correctly on the spacer seat. If the spring does not ride on the spacer seat, there is a danger of the spring being cut by the poppet, fragments getting into the flow path, and malfunction of various operating sections.

(9)Assembly of boom antidrift valve section [1]Insert the poppet (41) into the valve housing. [2]Insert the spacer (34) with O-ring (35) and backup ring (36) attached into the valve housing together with the spring (42).

[3]Install the assembled antidrift valve assembly (40) into the main unit and tighten the socket head bolt (43). (Tightening torque: 8.8 - 11 N•m) (10)Assembly of arm cylinder port section plate [1]Insert the spacer (34) with O-ring (35) and backup ring (36) attached into the valve housing. [2]Install the plate (38) with O-ring (79) mounted and tighten with the hexagon socket head bolt (39). (Tightening torque: 8.8 - 11 N•m) (11)Assembly of other plugs [1]Screw in and tighten the PP port section plug assembly (62) with O-ring mounted. (Tightening torque: 49 - 59 N•m) [2]Screw in and tighten the PA port section plug (67) with O-ring (55) mounted. (Tightening torque: 88 - 98 N•m) [3]Screw in and tighten the plug (65) with O-ring (66) mounted on the option and straight travel section cap sections. (Tightening torque: 19 - 22 N•m) [4]Screw in and tighten the plug (63) with O-ring mounted. (Tightening torque: 13.5 - 16.5 N•m) [5]Screw in and tighten the plug (64) with the O-ring mounted on the straight travel section cap sections. (Tightening torque: 19 - 22 N•m) [6]Screw in and tighten the plug (25) with O-ring mounted. (Tightening torque: 61.8 - 81.4 N•m) [7]Screw in and tighten the plug (28) with O-ring mounted. (Tightening torque: 106 - 141 N•m) (12)Assembly of relief valve [1]Screw in and tighten the overload relief valve (60) in the main unit valve and (2-12) in the add-on spool section. (Tightening torque: 59 - 69 N•m) [2]Screw in and tighten the main relief valve (61) in the main unit valve and (3-2) in the add-on inlet section. (Tightening torque: 49 - 54 N•m)

Be careful to install so that the spring rides correctly on the spacer seat. If the spring does not ride on the spacer seat, there is a danger of the spring being cut by the poppet, fragments getting into the flow path, and malfunction of various operating sections.

(13)Assembly of shut-off valve [1]Screw in and tighten the assembled shut-off valve (29). (Tightening torque: 59 - 69 N•m) [2]Screw in the set screw (29-6), securely seat the poppet (29-1), and fasten by tightening the hexagon nut (29-5). (Tightening torque: 19 - 22 N•m) (14)Assembly of spool section [1]Install the O-ring (19) and (2-13) in the valve housing cap matching surface groove. [2]Install the assembled spools (4) - (13), and (2-2) in the same location as before disassembly.

[3]Install the long caps (14) and (2-3) and short caps (15) and (2-4) and tighten the hexagon socket head bolts (39) and (2-17). (Tightening torque: 8.8 - 11 N•m) [4]Insert the neutral cut spool (30) into the valve housing and install the spring (32). [5]Screw in and tighten the plug (31) with O-ring (50) mounted. (Tightening torque: 78 - 88 N•m)

Be sure to install the spools in the same locations they were in before disassembly.If installation is incorrect, there is a danger of this causing an actuator operation defect.

Line up the spool straight with the opening and insert it slowly. After inserting the spool, slide it by hand to check for any sticky or rough feeling.If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation defect.

After assembly is complete, recheck that all disassembled parts have been assembled and tightened.A part whose tightening is omitted could cause an oil leak. All the indicated tightening torque values are for the wet state (with hydraulic oil).