Operational Manual Main Control Valves

Technical Information BCV-65 Rev 1.0 (08.2015)

Main Control Valves

Series BCV-65
Product No.: S01190 (C05), S01130 (C06)

CUSTOMSER : DOOSAN INFRACORE.

Operation Manual (Rev. 1.0)

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

Table of Contents

1. Outline drawing of control valve

2. Hydraulic diagram

3. Operating principles of main components

3.1 Operation at neutral position

3.2 Travel operation
3.3 Boom operation
3.4 Bucket operation
3.5 Arm operation
3.6 Swing operation (left / right)
3.7 Dozer operation (up/down)
3.8 Combined operation (Operation of Travel independence)

4. Disassembly and reassembly of control valve

4.1 General cautions

4.2 Replacing spool assembly (pilot type)
4.3 Replacing main relief valve
4.4 Replacing overload relief valve
4.5 Replacing load check poppet
4.6 Replacing holding valve assembly
4.7 Replacing sub-block assembly

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

1. Outline drawing of control valve

No. Descriptions No. Descriptions

1 COVER 15 SPOOL ASS’Y(SWING)

2 BLOCK ASSEMBLY (SWING) 16 SPOOL ASS’Y(DOZER)

3 BLOCK ASSEMBLY (DOZER) 17 SPOOL ASS’Y(TRAVEL INDEPENDENCE)

4 BLOCK ASSEMBLY (INLET - P3) 18 SPOOL ASS’Y(ARM1)

5 BLOCK ASSEMBLY (ARM1) 19 SPOOL ASS’Y(BOOM2)

6 BLOCK ASSEMBLY (BOOM2) 20 SPOOL ASS’Y(TRAVEL-L)

7 BLOCK ASSEMBLY (TRAVEL - L) 21 SPOOL ASS’Y(SUPPLY.)

8 BLOCK ASSEMBLY (INLET - P1, P2) 22 SPOOL ASS’Y(TRAVEL-R)

9 BLOCK ASSEMBLY (TRAVEL - R) 23 SPOOL ASS’Y(BOOM1)

10 BLOCK ASSEMBLY (BOOM 1) 24 SPOOL ASS’Y(BUCKET)

11 BLOCK ASSEMBLY (BUCKET) 25 SPOOL ASS’Y(ARM2)

12 BLOCK ASSEMBLY (ARM 2) 26 OVERLOAD RELIEF VALVE ASS’Y
13 TIE BOLT 27 MAIN RLIEF VALVE ASS’Y

14 NUT

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

2. Hydraulic diagram

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3. Operating principles of main components

3.1 Operation in neutral position

1) P1

▪ The hydraulic oil discharged from the hydraulic pump flows into the control valve through the P1 port, and then
into the TRAVEL-L valve.

▪ The central bypass passage of the control valve is not shut off in neutral position, and the hydraulic oil flows
into the T1 and T2 ports through the central bypass passages of valves: TRAVEL-R → BOOM1 → BUCKET
→ARM2

2) P2

▪ The hydraulic oil discharged from the hydraulic pump flows into the control valve through the P2 port, and then
into the TRAVEL-L valve.

▪ The central bypass passage of the control valve is not shut off in neutral position, and the hydraulic oil flows
into the T1 and T2 ports through the central bypass passages of valves: TRAVEL-L → BOOM2 →ARM1.

3) P3

▪ The hydraulic oil discharged from the hydraulic pump flows into the control valve through the P3 port.

▪ The central bypass passage of the control valve is not shut off in neutral position, and the hydraulic oil flows
into the T1 and T2 ports through the central bypass passages of the SWING and DOZER valves.

4) Pp

▪ The hydraulic oil having flown into the Pp port flows into the Pp port through the filter and orifice (for signal
line).

▪ Since the hydraulic oil having flown into the control valve flows out to the tank passage of the Boom2 block
through the signal lines of the entire sections and thus the pressure between the signal lines and the tanks
passage becomes equal, the travel independence spool is not switched.

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 Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

▪ Since the tank passage is configured in such a way that it passes through the entire control valve, the
hydraulic oil having flown into the tank passage flows out to the T1 and T2 ports.

Pp

T1 T1
P3

P2
P1

T2

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3.2 Travel operation

1) Forward and backward travel operation

▪ When you perform a forward( or backward) travel operation, the two of TRAVEL spools move to the pulling (or
pushing) direction. (The direction of forward or backward is depending on hose fitting of excavator travel motor)

▪ The hydraulic oil having flown into the pump port flows into the central bypass passages of the inlet blocks (P1
and P2), and then will be supplied to the TRAVEL motor of the A port which becomes opened by the spool
movement.

▪ The hydraulic oil discharged from the TRAVEL motor flows into the control valve through the B Port and then
flows out to the open tank port.

▪ Although its drain lines are blocked by the switching of the left and right TRAVEL spools, the signal line is not
pressurized because the oil is drained at boom2 block.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3.3 Boom operation

1) Boom-up operation (Confluence of P1, P2)

▪ When you perform a boom-up operation, the flow of the P1 port joins with the flow of the P2 port by the
operation of the BOOM2 valve to increase the boom-up speed.

▪ When you perform a boom-up operation, the pilot pressure flows into the pilot ports of the BOOM 1 and
BOOM2 valves to move the Boom1 spool & BOOM2 spool and shut off the central bypass passage.

▪ The hydraulic passage of the A port of the BOOM 1 valve is opened by the movement of the BOOM 1 spool,
and the hydraulic oil having flown into the P1 port flows into the parallel passage of the BOOM 1 valve through
the central bypass passage of the TRAVEL-R valve.

▪ The hydraulic oil having flown into the parallel passage of the BOOM 1 valve flows out to the A port through
the LOAD CHECK valve installed in the parallel passage.

▪ The hydraulic oil having flown into the P2 port flows into the parallel port of the BOOM 2 valve through the
central bypass passage of the TRAVEL-L valve, and the hydraulic passage for the B port of the BOOM 2 valve
is opened by the movement of the BOOM 2 spool.

▪ The hydraulic oil having flown into the parallel passage for the BOOM 2 valve flows out to the B port (BOOM 2)
through the LOAD CHECK valve, becomes connected to the A ort of the BOOM 1 valve through the confluence
passage (external piping), and flows out to the head of the BOOM cylinder to activate the boom-up operation.

▪ The hydraulic oil of the cylinder rod flows out to the B port and flows out to the open tank passage by the
movement of the spool.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

2) Boom-down operation

▪ When you perform a boom-down operation, the pilot pressure flows into the pilot port of the BOOM 1 valve and
the central bypass passage is shut off.

▪ The hydraulic passage for the B port is opened by the movement of the BOOM 1 spool, and the hydraulic oil
having flown into the P1 port flows into the parallel passage of the BOOM 1 valve through the central bypass
passage of the TRAVEL valve.

▪ The hydraulic oil having flown into the parallel passage flows into the B port through the LOAD CHECK valve
installed in the parallel passage of the BOOM 1 valve and flows out to the boom cylinder rod to activate the
boom-down operation.

▪ The hydraulic oil for the cylinder head flows out to the A port and flows out to the open tank passage by the
movement of the spool.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3.4 Bucket operation

1) Bucket-in operation

▪ When you perform a bucket-in operation, the pilot pressure flows into the pilot port of the BUCKET valve to
move the BUCKET spool and shut off the central bypass passage.

▪ The hydraulic passage for the port B is opened by the movement of the BUCKET spool, and the hydraulic oil
having flown into the P1 port flows into the parallel passage of the BUCKET valve through the central bypass
passage of the TRAVEL valve.

▪ The hydraulic oil having flown into the parallel passage flows into the B port through the LOAD CHECK valve
installed in the parallel passage of the BUCKET valve and flows out to the BUCKET cylinder head to activate
the bucket-in operation.

▪ The hydraulic oil for the cylinder rod flows out to the A port and flows out to the open tank passage by the
movement of the spool.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

2) Bucket-out operation

▪ When you perform a bucket-out operation, the pilot pressure flows into the port to move the BUCKET spool
and shut off the central bypass passage.

▪ The hydraulic passage for the A port is opened by the movement of the BUCKET spool, and the hydraulic oil
having flown into the P1 port flows into the parallel passage of the BUCKET valve through the central bypass
passage of the TRAVEL valve.

▪ The hydraulic oil having flown into the parallel passage flows into the A port through the LOAD CHECK valve
installed in the parallel passage of the BUCKET valve and flows out to the BUCKET cylinder head to activate
the bucket-out operation.

▪ The hydraulic oil for the cylinder head flows into the B port and flows out to the open tank passage by the
movement of the spool.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3.5 Arm operation

1) Arm-crowd operation (Confluence of P1 and P2)

▪ When you perform an arm-crowd operation, the hydraulic oil having flown into the P1 and P2 ports joins
outside the main control valve by the operation of the ARM1 and ARM2 valves to increase the arm-crowd speed.

▪ When you perform an arm-crowd operation, the pilot pressure flows into the pilot ports of the ARM1 and
ARM2 valves to move the ARM1 and ARM2 spools and shut off each central bypass passage.

▪ The hydraulic passage for the B port of the ARM1 valve is opened by the movement of the ARM1 spool, and
the hydraulic oil having flown into the P2 port flows into the parallel passage of the ARM1 valve through the
central bypass passage of the TRAVEL-L valve.

▪ The hydraulic oil having flown into the parallel passage of the ARM1 valve flows out to the B port through the
LOAD CHECK valve installed in the parallel passage of the ARM1 valve.

▪ The hydraulic oil having flown into the P1 port flows into the central bypass passage of the ARM2 valve
through the central bypass passage of the TRAVEL-R valve; the switching of the spool by the pilot pressure
shuts off the central bypass line, by which the hydraulic oil flows into the parallel line and joins with the hydraulic
oil of the P1 port through the outside hose.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

▪ The hydraulic oil for the cylinder rod flows out to the A port of the ARM1 valve and flows out to the open tank
passage by the movement of the spool.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

2) Arm-dump operation

▪ When you perform an arm-dump operation, the pilot pressure flows into the pilot port of the ARM1 valve to
move the ARM1 spool and shut off the central bypass passage.

▪ The hydraulic passage of the A port is opened by the movement of the ARM1 spool, and the hydraulic oil
having flown into the P2 port flows into the parallel passage of the ARM1 valve.

▪ The hydraulic oil having flown into the parallel passage flows into the A port through the LOAD CHECK valve
installed in the parallel passage of the ARM1 valve and flows out to the ARM cylinder rod to activate the arm-
dump operation.

▪ The hydraulic oil having flown into the P1 port flows into the central bypass passage of the ARM2 valve
through the central bypass passage of the TRAVEL-R valve; the switching of the spool by the pilot pressure
shuts off the central bypass line, by which the hydraulic oil flows into the parallel line and joins with the hydraulic
oil of the P1 port through the outside hose.

▪ The hydraulic oil from the ARM cylinder flows out to the tank passage through the B port of the ARM1 valve.

B A

P
P

A
B

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3.6 Swing operation (left / right)

▪ When you perform a swing (left/right) operation, the pilot pressure flows into the port to move the SWING
spool and shut off the central bypass passage.

▪ The hydraulic passage of the port B(orA) is opened by the movement of the SWING spool, and the hydraulic
oil having flown into the P3 port flows into the parallel passage of the SWING valve.

▪ The hydraulic oil having flown into the parallel passage flows into the B (or A) port through the LOAD CHECK
valve installed in the parallel passage and then flows out to the SWING motor to activate the swing operation.

▪ The hydraulic oil having flow into the SWING motor flows out to the tank passage through the A (or B) port of
the CONTROL valve.

▪ Since the hydraulic oil of the signal line – among those having flown into the PP port – is drained at the
TRAVEL-L and TRAVEL-R valves, signal pressure is not generated.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3.7 Dozer operation (up / down)

▪ When you perform a dozer (up/down) operation, the pilot pressure flows into the port to move the dozer spool
and shut off the central bypass passage.

▪ The hydraulic passage of the port B is opened by the movement of the dozer spool, and the hydraulic oil
having flown into the P3 port flows into the parallel passage of the dozer valve.

▪ The hydraulic oil having flown into the parallel passage flows into the A (or B) port through the LOAD CHECK
valve installed in the parallel passage and then flows out to the dozer cylinder to activate the cozer operation.

▪ The hydraulic oil having flow into the dozer cylinder flows out to the tank passage through the B (or A) port of
the CONTROL valve.

B A

P3

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3.8 Combined operation of travel and front (boom or arm or buket)

(Operation of P3 selector valve for using P3 oil)

▪ Since the hydraulic oil of the signal line which is connected to the pilot chamber of selector spool – among
those having flown into the Pp port – is drained at the TRAVEL-L block, TRAVEL-R block and arm1 block, no
signal pressure is generated in neutral position.

▪ Although the tanks passage of Travel L & R valves is blocked when those spools are switched, the selector
spool is not switched because signal lines are connected and drained to arm1 block

▪ If any of boom, arm, bucket, dozer or swing operation is activated with the TRAVEL (R/L) spools switched, a
signal pressure is generated as all of drain lines are blocked, thus the selector spool is switched.

▪ As the travel independence spool is switched, the hydraulic oil having flown into P3 port is connected to the
each parallel line of boom, arm, bucket, swing, dozer .

P3 Pp

Travel-L

P2
P1 Travel-R

Arm
Boom
Bucket
Swing
Dozer

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

4. Disassembly and reassembly of control valve

4.1 General cautions

In principle, the disassembly and reassembly of a control valve should be performed at the
manufacturer’s factory, and the cautions below must be observed when disassembly and reassembly
at the jobsite is inevitable.

1. Control valves are precisely machined and clearance of each section is very small. Therefore,
perform disassembly and reassembly at a clean area with a careful attention to ensure that foreign
materials such as dust and sand cannot enter into the inside of the control valve during work.

2. Prepare reference drawings (e.g.: structural drawings) and fully understand the structure of the
control valve before starting disassembly and reassembly.

3. Install a cap on each port when you remove the control valve from the machine, check again if the
caps are installed properly, and then clean the outside of the assembly before disassembly.

4. Leaving the control valve disassembled may cause rust. Therefore, be sure to apply anti-rust oil
and seal the assembly.

5. Never hold the pilot cap, relief valve, or overload relief valve when you transport or move the
control.

6. Do not apply excessive force to the control valve even when disassembly and reassembly work is
not smooth.

7. Attach an identification tag on each disassembled component for accurate reassembly.

8. Replace O-rings and backup rings with new ones and ensure that those parts are not damaged
during reassembly work (apply a small amount of grease for smooth assembly).

9. Apply specified torques when you fasten bolts or nuts for the overload relief valve and the main
relief valve.

10. Various tests (relief characteristics, leakage, operating, etc) are required after the disassembly
and reassembly of the control valve. Therefore, do not disassemble the control valve if those tests are
unavailable.

11. Ensure that there is no scratch on the body of the control valve where O-rings contact to prevent
oil leakage.

12. The control valve is a very heavy assembly. Therefore, pay a special attention when handling it.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

4.2 Replacing spool assembly (pilot type)

Procedures Descriptive pictures

1. Removing pilot cap (on the side of return

spring):

▪ Loosen the two bolts of the pilot cap using

an L wrench (5 mm) and remove them
along with the washers.

▪ Remove the pilot cap and place the

disassembled components on a clean
workbench in order.

2. Removing spool:

▪ After fixing the body, remove the spool

from the body by pulling it slowly in the
horizontal direction (parallel with the spool
hole) while holding the exposed return
spring of the spool.

▪ Applying excessive force may cause a

damage to the spool body. In case the
spool is stuck, therefore, push it back again
and remove it while rotating slowly.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3. Assembling spool:

▪ Insert the spool into the fixed body while

holding the return spring of the spool and
paying attention to the assembly direction.

▪ Applying excessive force may cause a

damage to the spool body. In case the
spool is stuck, therefore, pull it back again
and insert it while rotating slowly.

4. Assembling pilot cap (on the side of

return spring):

▪ Cover the pilot cap on the side of spool’s

return spring assembled in the body and
fasten the two bolts with the specified
torque using a torque wrench (5 mm).

▪ Torque: 1.2 kgf•m

◆ Must replace the spool sub-assembly when replacing a spool.

◆ Ensure that the assembly position can be identified with identification tags when replacing more than one
type of spool.

◆ Ensure that no foreign material can enter into the valve body when you disassemble and reassemble the
spool sub-assembly.

◆ Insert the spool sub-assembly slowly and smoothly to prevent a scratch on the spool and the block.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

4.3 Replacing main relief valve

Procedures Descriptive pictures

1. Removing main relief valve:

▪ Remove the hex head of the main relief

valve with a spanner (30 mm) after fixing
the valve body.

2. Assembling main relief valve:

▪ Assemble the main relief valve to the

fixed body with the specified torque using a
torque wrench (30 mm).

▪ Torque : 6 kgf•m

◆ Ensure that there is no scratch in the seat of the main relief valve.

◆ Since the main relief valve is a very important component related to performance and safety and its pressure
resetting is very difficult, do not disassemble it but replace the entire sub-assembly if required.

◆ Ensure that no foreign material can enter into the valve body when you disassemble and reassemble the
main relief valve.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

4.4 Replacing overload relief valve

Procedures Descriptive pictures

1. Removing overload relief valve:

▪ Remove the hex head of the overload

relief valve with a spanner (22mm) after
fixing the valve body.

2. Assembling overload relief valve:

▪ Install the overload relief valve into the

fixed valve body with the specified torque
using a torque wrench (22 mm).

▪ Torque: 4 kgf•m

◆ Ensure that there is no scratch on the surface of the overload relief valve to be replaced, and do not use it if
there is a scratch.

◆ Since the overload relief valve is a very important component related to performance and safety and its
pressure resetting is very difficult, do not disassemble it but replace the overload relief valve assembly if
required.

◆ Ensure that no foreign material can enter into the valve body when you disassemble and reassemble the
overload relief valve.

◆ Pay a special attention to prevent a damage to the return cap by the spanner when you remove the overload
relief valve.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

4.5 Replacing load check poppet

Procedures Descriptive pictures

1. Removing plug:

▪ Remove the plug with an L wrench (8

mm) after fixing the body.

2. Removing load check poppet:

▪ Pull out the spring and load check poppet

using a tweezers or a magnet.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3. Assembling load check poppet:

▪ Insert the load check poppet from the

above and then insert the spring.

▪ Pay a special attention to the surface

during assembling the poppet.

4. Assembling plug:

▪ Install an O-ring to the plug and fasten the

plug with the specified torque using a
torque wrench (8 mm).

▪ Torque: 3.7 kgf•m

◆ Do not use the disassembled O-ring again.

◆ Ensure that no foreign material can enter into the valve body when you disassemble and reassemble the
load check poppet.

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

4.6 Replacing holding valve assembly

Procedures Descriptive pictures

1. Removing holding valve cover:

▪ Loosen the three bolts of the holding valve

cover with an L wrench (5 mm) after fixing
the body.

▪ Pay a special attention to prevent the

separation of the O-ring or the poppet when
you during removing the holding valve
cover.

▪ Do not disassemble the components

inside the holding valve cover.

2. Replacing holding valve assembly:

▪ Remove the poppet and the pilot poppet

inside the body in order and replace them
with new ones.

▪ Ensure that there is no damage to the

surface of the poppet.

3. Assembling holding valve cover:

▪ Fasten the three bolts of the holding valve

cover with the specified torque using a
torque wrench (5 mm).

▪ Torque: 1.2 kgf•m

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

◆ Ensure that no foreign material can enter into the valve body when you disassemble and reassemble the
holding valve assembly.

4.7 Replacing sub-block assembly

Procedures Descriptive pictures

1. Installing surface plate:

▪ Install a surface plate on a workbench to

replace the sub-block assembly.

2. Removing nuts:

▪ Place the body on the surface plate

installed on the workbench.

▪ Remove the four nuts on the body with a

spanner (13 mm).

▪ Be aware that the body is fixed with two

sets of tie bolts on the both sides of the
inlet blocks (P1, P2).

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Operational Manual Main Control Valves
Technical Information BCV-65 Rev 1.0 (08.2015)

3. Replacing sub-block assembly:

▪ Remove the faulty sub-block assembly

and then assemble new one in order.

▪ Ensure that the assembly positions can

be known with identification tags when you
replace the sub-block assembly.

▪ Ensure that there is no damage to the

front and back joint surfaces of the block
during replacing the sub-block assembly.

4. Aligning sub-block assembly:

▪ Fasten the four nuts slightly with a torque

wrench (13 mm) after replacing the sub-
block assembly with new one, and then
align the body with surface plate.

5. Installing nuts:

▪ Fasten the four nuts with the specified

torque using a torque wrench (13 mm) after
aligning the body.

▪ Torque: 2.05 kgf•m

◆ Ensure that no foreign material can enter into the body when you disassemble and reassemble the sub-block
assembly.

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