Manual 5 Control Hidraulico

SERV1852-02
August 2008
GLOBAL SERVICE LEARNING
TECHNICAL PRESENTATION
320D-336D HYDRAULIC EXCAVATORS -

TIER III ENGINES
MAIN CONTROL VALVE GROUP AND RETURN
SYSTEM
Service Training Meeting Guide

(STMG)
SERV1852-02 -5- Text Reference
08/08 Main Control Valve Group
MAIN CONTROL VALVE GROUP AND RETURN SYSTEM

Stick Cylinder
Bucket Cylinder Boom Cylinders
Swing Motor Travel Motors
Main Control Valve Group

Pilot
Control
Valves
Priority
Pilot Manifold Valves
Main
Pilot M
Hydraulic
Pump
Pumps
Fan
Fan Pump
Motor
Tank
The Fan Motor and Pump are only used on the 330D and 336D
INTRODUCTION
The main hydraulic system is a Negative Flow Control (NFC) System that supplies hydraulic
power at high pressures and high flow rates to perform work. Two main hydraulic pumps
supply oil to the main control valve group. The individual hydraulic circuits are controlled by
valves in the the main control valve group.
The main hydraulic system supplies the following circuits:

- swing
- stick
- left and right travel
- bucket
- auxiliary
- boom
Oil returning from these circuits flows back to through the return system to the hydraulic tank.
4 9
7 10
2 3 5 11
6
13
12
1 8
The main control valve group is located in the center of the upper structure of the machine.
The main control valve group receives pilot oil signals from the operator controls in the cab.
Each pilot signal then causes the appropriate control valve to shift in the correct direction.
When a control valve shifts, oil flows from the main hydraulic pumps to the appropriate
hydraulic cylinder or hydraulic motor to perform work. The medium 320D-336D main control
valve is similar to the medium 300C Series valve. The components shown above include:
- right side NFC relief valve (1) - main relief valve (8)
- stick 2 (2) - left travel (9)
- boom 1 (3) - swing (10)
- bucket (4) - stick 1 (11)
- attachment (5) - boom 2 (12)
- right travel (6) - auxiliary valve for tool control (13)
- straight travel valve (7)
MAIN CONTROL VALVE

NEUTRAL
Parallel
Feeder
Boom Stick Left Passage Right Boom Stick
2 1 Swing Travel Travel Attach Bucket 1 2
NFC Signal Drive Pump NFC Signal

Pressure for Inlet Port Pressure for
Idler Pump Drive Pump
Idler Pump
Inlet Port
Return NFC Return Center Straight Travel Center Return NFC Orifice
Port Orifice Passage Bypass Valve Bypass Passage
Passage Passage
The above illustration shows a cross-sectional view of the main control valve group as viewed
from the rear of the machine, facing forward.
The main control valve group is constructed of two valve blocks that are connected together.
The drive pump provides oil flow for the right side of the main control valve group. The idle
pump provides oil flow for the left side of the main control valve group.
The pilot-operated, open-center control valves are of parallel feeder design. Because the main
control valve group uses the open-center portion of the control valve to generate a NFC signal
for the pumps, the oil must have another path to deliver oil to the work ports. This is
accomplished through a parallel feeder path. A parallel feeder path runs parallel to the
open-center path and supplies oil to the work port of each implement valve.
When all of the joysticks and pedals are in the NEUTRAL position, drive pump oil flows
through the right pump inlet port to the right half of the main control valve group. In the right
half of the main control valve group the oil flows two directions; to the center bypass passages,
and to the parallel feeder passages.
The oil in the center bypass passages flows in series through the center bypass passage of the
travel, the attachment, the bucket, the boom 1, and the stick 2 valves to the NFC control orifice.
The NFC control orifice allows the oil to return to tank with a restriction.
This restriction provides an NFC signal pressure which is sent to the drive pump to maintain
the drive pump at minimum angle when the control valves are all in NEUTRAL. In
NEUTRAL this NFC signal is the same as the supply pressure.
The oil in the parallel feeder passage flows in parallel to the attachment, the bucket, the
boom 1, and the stick 2 valves. Since all of the valves are in NEUTRAL, the oil in the parallel
feeder is blocked by the valve spools, and all oil must flow through the center bypass to the
tank.
The oil from the idler pump flows similarly through the left half of the control valve when all
valves are in NEUTRAL.
MAIN CONTROL VALVE GROUP

NEGATIVE FLOW CONTROL OPERATION - NEUTRAL
Drift
Parallel Feeder Reduction
Passage Valve
Stick Regen Straight Travel

Valve Solenoid
Boom 2 Attachment Bucket
Valve Valve
Right
Boom 1 Stick 2
NFC Straight Travel
Relief Travel
Valve
Stick 1 Swing Left

NFC Travel
Orifice Main
Relief
Swing Variable Swing

Stick Unloading PRV Line Relief Parallel Feeder Boom Regen NFC
Priority Valve
Valve and Makeup Passage Valve Relief
NFC Signal Valve Valve
Line (Idler Pump)
Idler Pump
M NFC Signal
Pilot Oil Line (Drive Pump)
Heavy Lift Drive Pump Pilot Pump
Solenoid
The schematic for the main control valve group is shown above. All of the circuit control
valves are in NEUTRAL.
Oil from the idler pump and drive pumps flows to the straight travel valve. From the straight
travel valve, the supply oils flow through the center envelop of all of the control valves in
NEUTRAL. Some of the supply oil also enters the parallel feeder passages.
Since the control valves are in NEUTRAL the supply oil flows through all of the valves to the
tank. Some of this oil becomes NFC signal oil and destrokes the two pumps.
SERV1852-02 - 10 - Text Reference
Load
Check
Port A Port B CONTROL VALVE
Valve NEUTRAL
Parallel Line Relief

Feeder and Makeup
Passage Valve
Pilot Pilot
Valve Valve
Centering
Spring
Control
Center Spool
Full NFC
Signal Bypass
Passage
Load
Check
Valve
Control valve operation is similar for all of the valves in the main control valve group. The
following explanation is for the basic operation of all of the valves in the main control valve
group. The variations in each individual valve will be discussed later in more detail.
The control valve above is shown in NEUTRAL.
The valve spool is spring centered in NEUTRAL when there is no pilot oil pressure directed to
shift the spool. In the NEUTRAL position, the spool blocks the oil in Port A and Port B.
Oil flows from the pump to the parallel feeder passage. The load check valve is seated because
of the pressure differential and spring force present on the load check valve.
In NEUTRAL, the valve spool allows oil to flow unrestricted through the center bypass
passage, which directs a high NFC signal pressure to the pump control valve. The high NFC
signal pressure causes the pump to destroke to a standby condition.
CONTROL VALVE
Load Check Port A Port B INITIAL MOVEMENT
Valve
Parallel Feeder
Passage
Pilot Pilot
Valve Valve
Center Bypass Control

Passage Spool
Reduced
NFC Signal
When the operator begins to move the joystick to shift the control valve, metered pilot pressure
causes the control valve to shift slightly.
With the spool initially shifted, the center bypass passage begins to close. This movement
causes NFC signal pressure to decrease, which causes the pump to begin to upstroke.
The movement of the spool partially opens a passage allowing the oil from Port B to work with
the load check valve spring to keep the load check valve seated.
The load check valve prevents unexpected implement movements when a joystick is initially
activated at a low pump supply pressure. The load check valve also prevents oil loss from a
high pressure circuit to a lower pressure circuit.
The combined force of the work port pressure from Port B and the force of the spring above the
load check is greater than the pump supply pressure, causing the load check valve to remain
closed.
CONTROL VALVE
FULL SHIFT
Load Check Port A Port B
Valve
Parallel Feeder
Passage
Pilot Pilot
Valve Valve
Control
Center Bypass
Spool
Passage
Reduced
NFC Signal
As the operator moves the joystick for a full shift, the pilot pressure on the end of the spool
increases. This increased pilot pressure causes the spool to fully shift.
The center bypass passage is fully closed, which blocks the oil flow to the NFC signal passage
to the pump control valve. When the NFC signal pressure is fully reduced, the pump fully
upstrokes and flow is increased. The increased flow can no longer return to tank through the
center bypass passage. All oil now flows through the parallel feeder path.
The increased oil flow to the parallel feeder passage causes pressure to rise in the parallel
feeder passage. The increased oil pressure overcomes the force of the load check spring and
the workport pressure in Port B, which causes the load check valve to unseat. Oil flows out to
Port B.
The oil returning from Port A flows past the spool and returns to tank.
NOTE: The load check valve is a loose fit in the load check seat to allow leakage past
the check valve from the spring chamber. A separate spring chamber vent passage is
not required with this load check design.
MAIN CONTROL VALVE GROUP

NEGATIVE FLOW CONTROL OPERATION - CONTROL VALVE SHIFTED
Parallel Feeder Drift

Passage Reduction
Valve
Stick Regen Straight Travel

Valve Solenoid
Boom 2 Attachment Bucket
Valve Valve
Right
Travel Boom 1 Stick 2
NFC Straight
Relief Travel
Valve
Stick 1 Swing Left

NFC Travel
Orifice Main
Relief
Swing Variable Swing

PRV Priority Valve Line Relief Parallel Feeder Boom Regen NFC
Stick Unloading NFC Signal and Makeup Passage Valve Relief
Valve Line (Idler Pump) Valve Valve
Idler Pump
NFC Signal
M
Pilot Oil Line (Drive Pump)
Heavy Lift Drive Pump Pilot Pump
Solenoid
This illustration shows the operation of the main control valve when only the bucket spool has
been shifted.
All of the control valves in the left side are in the NEUTRAL position, and the center bypass
passage is open. All of the flow from the idler pump flows through the center bypass passage
to the NFC orifice. Because all of the oil flow from the idler pump is restricted by the NFC
orifice, the NFC signal pressure is at maximum pressure. The NFC signal pressure flows
through the control line to the idler pump control valve. The NFC signal pressure present at the
pump control valve causes the swashplate to move to the minimum angle position. The output
of the idler pump is decreased to STANDBY due to the increased NFC pressure.
The bucket control spool is fully shifted by pilot oil when the joystick is fully moved. Flow
from the drive pump flows into the right side of the main control valve and into the center
bypass passage to the bucket control valve. Because the bucket control spool is fully shifted,
all of the oil flow from the drive pump flows to the bucket cylinder. No oil flows to the NFC
control orifice and no NFC signal pressure is generated. Because no NFC signal pressure flows
to the pump control valve, the pump control valve moves the pump toward maximum angle.
The drive pump flow output increases to maximum.
The individual circuits of the main control valve group will be covered in more detail later.

Load Check
FINE CONTROL
Valve
Parallel Feeder
Passage
Pilot Pilot
Valve Valve
Control
Center Bypass Spool
Passage
Reduced
NFC Signal
When the joystick is partially moved from the NEUTRAL position to perform a fine control
operation, reduced pilot pressure shifts the control spool slightly to the left. The movement of
the control spool partially opens a passage to Port B.
The movement of the control spool also partially blocks the center bypass passage, which
divides the flow from the one drive into two flow paths. A portion of the pump output flows
through the center bypass passage to the NFC orifice at a reduced pressure. The remainder of
the drive pump output flows through the parallel feeder passage and internal passages to Port B.
Because the oil flow from the center passage to the NFC orifice decreases, the NFC signal
pressure to the drive pump control valve decreases. The reduced NFC signal causes the drive
pump to move toward maximum angle. The drive pump output increases proportional to the
reduction in NFC signal pressure.
10
Additional Components
The main relief valve (1) is located in the left half of the main control valve group. The main
relief valve limits the maximum operating pressure of the the travel and implement hydraulic
circuits. For the NACD market the 300D Series main relief valve has two settings. One
setting is for the standard maximum pressure and the other setting is for Heavy Lift. In all
other markets Heavy Lift is optional.
When energized the heavy lift solenoid (not shown) sends a pilot signal through the line (2) at
the top of the relief valve to increase the pressure setting of the main relief valve.
When heavy lift is selected, the Machine ECM limits engine speed to speed dial 6 and activates
the heavy lift solenoid The heavy lift solenoid directs pilot oil to the main relief valve to
increase the relief valve setting. At the same time the Machine ECM increases the power shift
pressure to decrease the pump output flow. Decreasing the pump output flow provides
increased controlability and hydraulic smoothness during a heavy lift operation.
The Heavy Lift Mode limits the pumps to a maximum of approximately 60% of the normal
hydraulic horsepower. Heavy Lift Specs:
- Engine rpm for Heavy Lift is the engine speed dial 6 setting.
- Hydraulic horsepower is limited to 60% of full power during Heavy Lift.
- Main relief maximum pressure during Heavy Lift is 36000 kPa 490 kPa
(5225 70 psi).
1
11
12
Heavy lift is activated by pressing the heavy lift switch (1) on the soft switch panel (2) in the
operators station. The heavy lift switch is an input to the Machine ECM.
The heavy lift solenoid (3) is located near the hydraulic tank and below the main control valve
group.
STRAIGHT TRAVEL CONTROL VALVE

Heavy Lift
AND MAIN RELIEF VALVE Solenoid
Pilot Oil
Main
Control Valve
Straight
Travel Solenoid Straight Travel
Main Solenoid
Travel Relief
Control Valve
Parallel Valve
Center
Feeder
Bypass Right
Left Straight Travel
Control Valve
Center Parallel
Bypass Right Feeder Right
Center
Bypass
Left Main
Relief Drive
Check
Valve Pump
Valves
Center
Bypass Left
Parallel
Feeder Right
Idler
Idler Pump
Pump
E
Drive
Pump Parallel
Feeder Left
Straight Travel
Control Valve
Pilot Oil
Heavy Lift
Solenoid
13
The drive pump oil flow enters the main control valve group through the upper delivery line.
The idler pump oil flow enters the main control valve group through the lower delivery line.
The drive pump oil and idler pump oil pressures work against the two check valves.
The oil from both pumps is directed to the appropriate passages by the straight travel valve.
The check valves ensure that only the higher pressure from the idler or the drive pump flows to
the main relief valve. The check valves also ensure that flow from the highest supply pressure
circuit does not enter the other supply pressure circuit if the pressure is lower.
For example, if the bucket was being closed at a high pressure and no other function was active,
the lower check valve would close. The check valve would prevent the drive pump oil from
flowing through the center bypass in the left circuit. This action ensures that the higher supply
pressure is always sensed at the relief valve.
The relief valve will open when a circuit is stalled, limiting the maximum system pressure.
MAIN RELIEF VALVE
Heavy Lift Heavy Lift Heavy Lift

Solenoid HEAVY LIFT OFF Solenoid Solenoid
HEAVY LIFT OFF HEAVY LIFT ON
Pilot Pilot Pilot

Oil Oil Oil
Adjustment Adjustment
Nut Nut
Lock Nut Lock Nut
Lock Nut Lock Nut

Spindle
Spindle
Piston Piston
Poppet Poppet Unloading

Unloading
Spool
Spool
Orifice
Orifice
Pump Pump Pump

Supply Supply Supply
CLOSED OPEN CLOSED
14
The above illustration shows the pilot operated main relief valve equipped with the heavy lift
solenoid.
At lower system pressures the poppet is held against the the seat by the force of the spring.
System pressure in the passage flows through the orifice into the spring chamber above the
unloading spool. When the force applied by system pressure is less than the value of the upper
spring, the poppet remains seated, causing the oil pressure in the lower spring cavity to equal
system pressure. The combined force of the lower spring and system pressure holds the
unloading spool down.
As the system pressure nears the main relief valve pressure setting, the force of the system
pressure in the lower spring chamber overcomes the force of the upper spring. This causes the
poppet to unseat, allowing system oil to flow around the poppet to the return passage. As the
oil in the lower spring chamber flows around the poppet, additional system pressure oil flows
through the orifice into the lower spring chamber at a reduced pressure.
System pressure overcomes the force of the oil pressure in the lower spring chamber and the
spring, causing the unloading spool to move upward. As the unloading spool moves upward,
system pressure oil is allowed to flow to the return passage.
The amount of spring force acting on the poppet determines the main relief valve pressure
setting. Adjustments to the main relief valve pressure setting are made by changing the spring
force of the upper spring.
Heavy Lift increases the maximum system pressure. When the Heavy Lift is activated, the
Heavy Lift solenoid is energized sending pilot hydraulic oil to the top end of the main relief
valve.
The pilot hydraulic oil pushes the piston down compressing the poppet spring to increase the
maximum system pressure.
To adjust the maximum system pressure turn the adjustment nut in or out.
To adjust the Heavy Lift pressure setting, the spindle must be turned in or out. The Heavy Lift
pressure setting should be adjusted first before adjusting the normal relief pressure.
LINE RELIEF AND MAKEUP VALVE
CLOSED RELIEF MAKEUP
Poppet
Poppet Spring
Spring
Chamber Chamber
Spring
Spring
Inner Step
Inner Spool
Spool
Outer Outer Outer

Spool Spool Spool
Piston Piston
15
The above illustration shows a combination line relief and makeup valve in the closed, relief,
and makeup positions.
At lower system pressures, the poppet is held against a seat by the force of the upper spring.
The circuit pressure in the passage flows through a cross-drilled orifice in the piston to the
spring chamber above the inner spool. When the force applied by system pressure is less than
the value of the upper spring, the poppet remains seated, causing the oil pressure in the lower
spring cavity to equal system pressure. The combined force of the lower spring and system
pressure keep the inner spool seated.
As the system pressure nears the line relief valve pressure setting. The force of the system
pressure in the lower spring chamber overcomes the force of the upper spring. This causes the
poppet to unseat, allowing system oil to flow around the poppet to the return passage. As the
oil in the lower spring chamber flows around the poppet, additional system pressure oil flows
through the orifice in the piston from the lower spring chamber at a reduced pressure.
System pressure overcomes the force of the oil pressure in the lower spring chamber and the
spring, causing the inner spool to move upward. As the inner spool moves upward, system
pressure oil is allowed to flow to the return passage.
The amount of spring force acting on the poppet determines the line relief valve pressure
setting. Adjustments to the line relief valve pressure setting are made by changing the spring
force of the upper spring. The position of the adjustment screw determines the spring force of
the upper spring.
The makeup function of the line relief valve prevents cavitation and voiding in the various
circuits of the hydraulic system.
Under normal operating conditions, the outer spool of the line relief valve is seated. The valve
is held in the seated position by spring force and the hydraulic pressure in the spring chamber
above the inner spool.
If hydraulic circuit pressure becomes lower than the tank pressure, the pressure in the spring
chamber is reduced. Tank pressure surrounds the outer spool, and creates a force on the step of
the outer spool. This force unseats the outer spool and oil flows from the return system to the
lower pressure hydraulic circuit.
NFC Signal END HOUSINGS

NEGATIVE FLOW
CONTROL
NFC Orifices
NFC
Relief Valve
From Center
Bypass Passage
16
A NFC relief valve and orifice is located in the housing at each end of the main control valve
group. The NFC relief valve on the right half of the main control valve group controls the NFC
signal to the drive pump. The NFC relief valve on the left half of the main control valve group
controls the NFC signal to the idler pump. The two reliefs work similarly.
Oil enters the NFC orifices from the center bypass passage. The returning oil flows through the
NFC orifices to the return passage when the system is in STANDBY. The orifices restrict the
flow back to tank, which causes an increase in pressure through the center bypass passages.
This NFC signal is sent to the pump control valve of the main hydraulic pump.
When a hydraulic function is activated in the main control valve group, the center bypass
passage is blocked. The NFC pressure at the pump control valve bleeds off through the NFC
orifices to tank.
The NFC relief valve is normally closed by spring force. The NFC relief valve is not
adjustable.
NOTE: The left and right NFC relief valves can NOT be swapped from one end of the
main control valve group to the other for diagnostic testing purposes.
The NFC relief valve only opens under sudden pressure spikes in the return system, which
would occur if the pump was fully upstroked and a control valve was returned suddenly to
NEUTRAL.
A sudden pressure spike in the return system would cause high flow through the center bypass
passage. The high volume of oil could not flow quickly enough through the NFC orifice to the
return system. The high pressure generated in the center bypass passage would open the NFC
relief valve, which would relieve the sudden pressure spike.
The relief valve would close again once the pressure spike was diminished.
RETURN HYDRAULIC SYSTEM
Slow Return Bypass

Check Valve Check Valve
Return Filter
Cooler Bypass
Valve Group
Cooler
Tank
Case Drain Filter
17
Return Hydraulic System
The return hydraulic system transfers all of the hydraulic oil that has been used in the system to
do work back to the hydraulic tank.
The return hydraulic system has the following components:
- slow return check valve
- cooler bypass check valve group
- hydraulic oil cooler
- hydraulic oil filters
- hydraulic oil tank

18
The slow return check valve and the bypass check valve are in the cooler bypass valve group
(arrow).
The slow return check valve restricts return oil flowing from the main control valve, which
maintains a constant back pressure in the return hydraulic system. The back pressure ensures
that oil is available when needed for makeup in the various machine hydraulic circuits.
The bypass check valve regulates return oil flow through the hydraulic oil cooler.
SLOW RETURN CHECK VALVE AND BYPASS CHECK VALVE
Slow Return Return Passage from

Check Valve Main Control Valve Group
Inlet Line Makeup Line

to Oil Cooler from Swing Motor
Plug
Bypass
Check Valve
Return Line from Return Line to

Hydraulic Oil Cooler Return Filter
19
Return oil from the main control valve flows from the return line into the housing for the slow
return check valve as shown above. The return oil flows to the slow return check valve and to
the makeup line for the swing motor. The back pressure created by the slow return check valve
ensures that makeup oil is available at the swing motor and the various makeup valves in the
hydraulic system.
After flowing through the slow return check valve, oil flows to the cooler inlet line and the
bypass check valve. At low temperatures, the high viscosity of the oil flowing through the
hydraulic oil cooler causes the pressure to rise. The rising pressure causes the bypass check
valve to open. Most of the oil flows through the bypass check valve. Because only a small
amount of oil flows through the cooler, the oil temperature increases.
As the oil temperature increases, the bypass check valve begins to close and a greater portion of
the oil flows through the hydraulic oil cooler. The bypass check valve maintains the oil at the
optimum operating temperature.
The plug located below the makeup line to the swing motor can be removed to install a minimal
back pressure return for a hydraulic attachment, such as a hydraulic hammer.
20
The hydraulic oil cooler (1) is part of the cooling package (2) on the left side of the machine at
the rear.
The hydraulic oil cooler reduces the temperature of the hydraulic oil in the system.
Oil enters the hydraulic oil cooler from the slow return check valve. After passing through the
cooler, oil flows to the hydraulic return filter.
1
2
4
21
Return oil flow from the hydraulic oil cooler flows into the return filter (1), which is mounted
at the rear of the hydraulic tank on smaller machines. On larger machines, the filter is inside
the hydraulic tank. The return filter has a bypass valve that directs the return oil to the
hydraulic tank if the filter becomes plugged.
The tank has a vacuum breaker to limit the maximum tank pressure to 55 kPa (8 psi). The
breaker opens at 13 kPa (-2 psi) to prevent damage to the tank.
Oil in the hydraulic tank flows through the suction screen located inside the tank before being
delivered to the main hydraulic pump group.
The hydraulic tank sight gage (3) is located to the right of the return filter.
The case drain filter (4) receives case drain oil from the swing motor, idler and drive main
hydraulic pumps, and left and right travel motors. On the 330D/336D the filter also receives
case drain oil from the fan motor.
Oil from the case drain filter flows into the hydraulic tank. The purpose of the case drain filter
is to reduce hydraulic contamination to the hydraulic system if a pump or motor fails.
08/08 Implements
IMPLEMENT CIRCUITS
Stick Cylinder
Bucket Cylinder Boom Cylinders
Swing Motor Travel Motors

Pilot
Control
Valves
Priority
Pilot Manifold Valves
Main
Pilot M
Hydraulic
Pump
Pumps
Fan
Fan Pump
Motor
Tank
The Fan Motor and Pump are only used on the 330D and 336D
INTRODUCTION
This presentation covers in more detail each implement circuit used for the 320D-336D
Hydraulic Excavators. The circuits to be covered include:
- boom
- stick
- bucket
The idler pump provides oil to the boom 2 and stick 1 control valves. The drive pump provides
flow to the bucket, boom 1, and stick 2 control valves.
The boom, stick, and bucket control valves are shifted by pilot oil from the joystick pilot valves
when they are activated.
NOTE: The main control valve group and return system are covered in another
presentation. The attachment/auxiliary circuits will be covered in the electronic or tool
control section. The ISO schematics were created primarily from "325D Hydraulic
Schematic" (KENR6157). Hydraulic schematics for other 320D-336D excavators
may/will have variations from illustrations shown.
08/08 Implements
4 3
1 5
2
The boom circuit uses two control valves to control the boom operation, boom 1 (1) and boom
2 (2). Both spools shift when fast boom movement is required. Both pumps provide flow to
the boom for this condition. Boom 1 valve provides single pump flow, whenever the boom is
shifted for slow movement.
The stick circuit also uses to two control valves to control the stick operation, stick 1 (3) and
stick 2 (4). Both spools shift when fast stick movement is required.
The boom circuit and stick circuits also use regeneration valves and drift reduction valves. The
regeneration valves (not shown) provide improved efficiency and require less engine
horsepower for BOOM LOWER and STICK IN.
The drift reduction valves reduce cylinder drift when the boom or stick are in NEUTRAL.
Only one control valve is required to control the bucket. The bucket circuit is supplied with oil
only from the drive pump.
08/08 Implements
1
2
The two joysticks in the cab are used to control the movements of the boom, stick, swing and
bucket circuits.
- right joystick (1) to control the bucket and boom (SAE excavator pattern)
- left joystick (2) to control the swing and stick (SAE excavator pattern)
08/08 Implements
MAIN HYDRAULIC SYSTEM Boom

BOOM CIRCUIT COMPONENTS Cylinders
Drift
Reduction
Valve
Boom 2
Boom 1
NFC
Orifice Main
Relief
Boom Regen
Valve
Heavy Lift Idler Pump

Solenoid
Swing / Stick Boom / Bucket Pilot Pump
Pilot Valve Pilot Valve M
Drive Pump
Boom
Priority
Valve
AEC Pressure
Switch
Pilot Manifold
Boom Circuit
The boom circuit consists of the following major components:

- boom 1 spool
- boom 2 spool
- two boom cylinders
- drift reduction valve
- Heavy Lift solenoid
- boom priority valve (pressure reducing)
- boom lowering control valves (if equipped - not shown))
- boom regeneration valve
- SmartBoom (if equipped - not shown))
NOTE: 325D Hydraulic Schematic (KENR6157) was used to develop the ISO
schematics.
08/08 Implements
Boom 1 Spool: The boom 1 spool controls oil flow from the drive pump. The boom 1 spool
receives a BOOM RAISE pilot signal on the bottom of the valve, and a BOOM LOWER pilot
signal on the top of the valve.
Boom 2 Spool: The boom 2 spool controls oil flow from the idler pump. The boom 2 spool
receives a BOOM RAISE pilot signal from the joystick on the top of the valve stem, when
active. The boom 2 spool does not operate during BOOM LOWER. The boom 2 spool has no
provisions for return oil from the boom cylinders.
Boom Cylinders: The boom cylinders work in parallel to control the raise and lower
movement of the boom. When oil is supplied to the head end of the boom cylinders, the boom
will raise. When oil is supplied to the rod end of the boom cylinders, the boom will lower.
Boom Drift Reduction Valve: The boom drift reduction valve prevents oil from leaking from
the head end of the boom cylinders. For BOOM LOWER, pilot oil from the joystick is used to
unlock the lock check valve in the drift reduction valve.
Heavy Lift Solenoid: The heavy lift solenoid is activated to increase the maximum system
pressure for lifting. (Refer to the "Main Control Valve Group and Return Group" for more
details on Heavy Lift operation.)
Boom Priority Valve: The boom priority valve (pressure reducing) is used to reduce the pilot
pressure to the stick 2 valve whenever both the BOOM RAISE and STICK IN are activated at
the same time. The higher the boom pilot pressure to the boom priority valve the less pilot
pressure is available to shift the stick 2 control valve, resulting in more pump flow going to the
boom cylinders.
Boom Lowering Control Valves: The boom lowering control valves are infinitely variable,
pilot operated control valves that control the movement of the boom during lowering. The
boom lowering control valves prevent boom cylinder drift with valving mounted directly on
each of the boom cylinders, that controls boom cylinder head end oil flow.
Because the valves are mounted directly to each of the boom cylinders, the boom lowering
control valves will prevent the boom from falling, even if a hose becomes defective from the
main control valve to the cylinders.
The boom lowering control valves also work in conjunction with the SmartBoom system to
control the boom with the function active.
Regeneration Valve: The regeneration valve allows return oil from the head end of the boom
cylinders to be directed into the rod end of the cylinders when the boom is lowered fast.
SmartBoom: The SmartBoom attachment enhances operation of the boom function and
significantly reduces cycle times of the machine. The SmartBoom is essentially a boom float
attachment, which allows the operator to lower the boom under its own weight or for the boom
to raise up due to stick force. The SmartBoom attachment is typically used in EAME.
08/08 Implements

NEUTRAL
Load
Check
Valve Line Relief
and Makeup
Valve
Pilot Pilot
Valve Valve
Control
Parallel Spool
Center
Feeder
Bypass
Passage
Passage
As previously discussed, the control valve operation is similar for all of the valves in the main
control valve group including the boom, stick, and bucket valves. Pump flow is provided by
the drive and/or idler hydraulic pump. Which pump is used depends on the circuit.
The centering spring force holds the valve spool to NEUTRAL when there is no pilot oil
pressure directed to shift the spool.
In NEUTRAL the valve spool allows oil to flow unrestricted through the center bypass passage,
which directs a high NFC pressure signal to the pump control valve. The high NFC pressure
causes the pump to destroke to a standby condition, as explained previously.
08/08 Implements
MAIN HYDRAULIC SYSTEM

BOOM RAISE - SLOW SPEED
Drift
Reduction
Valve
Boom 2
Stick 2
Boom 1
NFC
Orifice Main
Relief
Boom Regen
Valve NFC
Orifice

Swing Solenoid
Swing / Stick Boom / Bucket Priority Pilot Pump
Pilot Valve Pilot Valve Valve M
Drive Pump
Boom
Priority
Valve
AEC Pressure
Switch
Pilot Manifold
When the boom joystick is moved less than half of the travel distance for BOOM RAISE, low
pilot oil pressure is supplied to the boom 1 control valve and the boom 2 control valve.
The force of the centering spring in the boom 1 control valve is less than the force of the
centering spring in the boom 2 control valve. When the boom is raised at a low speed, the
boom 1 control valve opens and the boom 2 control valve remains closed due to the low pilot
pressure.
The drive pump supply oil flows past the boom 1 control valve and unseats the check valve in
the drift reduction valve and flows to the head end of the boom cylinders.
Return oil from the rod end of the boom cylinders returns back to the tank through the boom 1
control valve.
With the boom valve partially shifted less oil is directed to the NFC relief valve. Less oil to the
NFC relief valve results in a reduced NFC signal to the drive pump. The drive pump control
valve causes the pump to upstroke to provide flow to operate the boom.
A BOOM RAISE operation at low speed is accomplished when only the drive pump is supplied
to the head end of the boom cylinders.
08/08 Implements
BOOM 1 CONTROL VALVE

BOOM RAISE PARTIAL SHIFT
Boom Boom
Head End Rod End
Load NFC Signal

Check Valve
Parallel
Feeder
Passage
Joystick
Center
Bypass Boom
Passage Regen Valve
When the operator begins to move the joystick to shift the boom 1 control valve, metered pilot
pressure causes the control valve to shift slightly.
With the spool initially shifted, the center bypass passage is partially closed. This movement
causes NFC pressure to decrease, which signals the drive pump to begin to upstroke.
The load check valve prevents unexpected implement movements when a joystick is initially
activated at a low pump delivery pressure. The load check valve also prevents oil loss from a
high pressure circuit to a lower pressure circuit.
As the pump supply pressure increases, the load check valve opens to allow pump supply oil in
the parallel feeder passage to flow to the control spool.
The control spool meters pump supply oil to the head ends of the boom cylinders.
08/08 Implements

BOOM RAISE - FAST SPEED
Drift
Reduction
Valve
Boom 2
Boom 1
NFC
Orifice Main
Relief
Boom Regen
Valve

Swing Solenoid
Drive Pump
Boom
Priority
Valve
AEC Pressure
Switch
Pilot Manifold
A BOOM RAISE operation at high speed is accomplished when supply oil from both the idler
pump and the drive pump is supplied to the head end of the boom cylinders.
Boom 1 control valve and boom 2 control valve are both shifted during high speed operation.
08/08 Implements

BOOM RAISE FULL SHIFT
Boom Boom
Head End Rod End
Load
Check Valve
NFC Signal
Parallel
Feeder
Passage
Joystick
Boom
Regen Valve
Center
Bypass
Passage
As the operator moves the joystick farther, the pilot pressure on the end of the spool increases.
The increased pilot pressure causes the boom 1 spool to shift further to the right.
The center bypass passage is now closed, which blocks the oil flow to the NFC signal port on
the right pump control valve. When the NFC signal is reduced, the pump upstrokes and flow is
increased. The increased flow can no longer return to tank through the center bypass passage.
All oil now flows through the parallel feeder path.
The increased oil flow to the parallel feeder passage causes pressure to rise in the parallel
feeder passage. The increased oil pressure overcomes the force of the load check spring and
the boom head end pressure, which causes the load check valve to unseat. Oil flows out to
boom cylinders.
The oil returning from the rod end of the cylinders flows past the spool and returns to tank.
08/08 Implements
Variable Swing
Priority Valve BOOM 2 CONTROL VALVE
FAST BOOM RAISE
Swing Priority
Pressure
Reducing Valve
Boom Cylinder
Head End
Parallel Feeder
Passage Load Check
Valve
Center Bypass
Passage Control Spool
10
The pilot oil flow shifts the boom 2 control valve. The idler pump supply oil in the parallel
feeder passage flows past the check valve and flows out to the head end of the boom cylinders.
The idler pump supply oil combines with the drive pump supply oil at the boom drift reduction
valve (not shown) and flows to the head end of boom cylinders.
Return oil from the rod end of boom cylinders flows to the boom 1 control valve and then to
the tank. The boom 2 control valve does not handle any of the return flow for the boom circuit.
NOTE: The swing priority valve does not affect the operation of the boom 2 control
valve.
08/08 Implements

BOOM PRIORITY - BOOM RAISE AND STICK IN
Drift
Reduction
Valve
Stick Regen
Valve
Boom 2
Stick 2
Boom 1
Stick 1
NFC
Orifice Main
Relief
Boom Regen
Stick Unloading Valve
Valve

Swing Solenoid
Drive Pump
Boom
Priority
Valve
AEC Pressure
Switch
Pilot Manifold
11
During combined operations of BOOM RAISE and STICK IN, the boom raise pilot oil pressure
shifts the pressure reducing valve for the boom priority valve to reduce the stick in pilot
pressure for the stick 2 control valve. With the reduction in stick in pilot pressure to the stick 2
control valve, more pump flow is directed to the boom cylinders during this combined
hydraulic operation.
NOTE: For STICK IN, the stick circuit regeneration valve will shift to direct return oil
from the rod end of the stick cylinder to the head end of the cylinders.
When the joystick for the stick is moved to the STICK IN position, a portion of the pilot oil
from the pilot control valve for the stick flows through the pressure reducing valve for the
boom priority to the stick 2 control valve. As the joystick for the boom is moved farther for a
BOOM RAISE, pilot oil pressure from the pilot control valve for the boom increases. This
gradual increase in pilot oil pressure causes the spool in the pressure reducing valve for the
boom priority to gradually shift.
A portion of the pilot oil to the stick 2 control valve from the stick pilot control valve is
restricted by the boom priority valve. The pilot oil pressure acting on the stick 2 control valve
decreases.
08/08 Implements
The stick 2 control valve shifts toward the NEUTRAL position. The amount of oil flow from
the main pumps to the stick hydraulic circuit decreases. This change causes a greater portion of
the oil flow from the main pumps to flow to the head end of the boom cylinders.
Since the pilot oil pressure from the boom pilot control valve directly corresponds to the
amount of movement or position of the boom joystick a gradual change to boom priority
occurs.
Thus, boom priority is controlled by the position of the joystick for the boom and boom priority
automatically activates when the joystick reaches a certain position during a BOOM RAISE
operation.
The above information describes the condition of BOOM RAISE and STICK IN. During any
combined function of BOOM RAISE and STICK IN, the pressure reducing valve for boom
priority reduces pilot pressure to the stick 2 control valve.
NOTE: If the joysticks are fully shifted for BOOM RAISE and STICK IN, stick in pilot
pressure on the bottom of the boom 2 cancels the boom raise pilot pressure on top of the
boom 2 spool. At the same time the boom priority valve prevents stick in pilot pressure
from going to the stick 2 control valve.
These two actions result in the drive pump supplying oil to the boom cylinders and the
idler pump providing oil to the stick cylinder.
08/08 Implements

BOOM LOWER WITH REGENERATION
Drift
Reduction
Valve
Boom 2
Boom 1
NFC
Orifice Main
Relief
Boom Regen
Valve

Swing Solenoid
Drive Pump
Boom
Priority
Valve
AEC Pressure
Switch
Pilot Manifold
12
For BOOM LOWER only the boom 1 control valve is used. The drive pump partially strokes
to provide flow to the rod end of the boom cylinders.
When the joystick is shifted pilot oil moves the boom 1 control spool down, the regeneration
valve right, and unlocks the drift reduction valve. When the boom 1 control spool is fully
shifted, the center bypass valve is never fully closed off. By not closing off the center passage,
there is an NFC signal to the drive pump. The drive pump never fully upstrokes.
Due to the force of gravity, with the lock valve unlocked, the weight of the boom and the load
on the boom, force the return oil out of the cylinder head ends back to the regeneration valve
and the boom 1 control valve.
The boom 1 control valve restricts the return oil flow. Whenever the return oil pressure is
higher than the supply pressure in the rod end of the cylinders, the return oil from the boom
cylinder head ends unseats the check valve above the regeneration valve.
The return oil from the head end enters the supply passage to the rod end to help fill the
cylinders and prevent cylinder cavitation. The regeneration valve allows the excavator to
operate more efficiently. The main pump supply oil not required to lower the boom is available
to operate another circuit.
08/08 Implements

BOOM LOWER
Load Check Head End Rod End

Valve
NFC Signal
Parallel
Feeder
Passage
Center Boom
Bypass Regen Valve
Passage
13
The boom pilot oil flow from shifts the boom control spool to the left against the force of the
centering spring. Supply oil from the drive pump in the parallel feeder passage flows past the
load check valve to the rod end of the boom cylinders.
Some of the oil in the center bypass passage flows past the center land to provide a reduced
NFC signal. The reduced NFC signal causes the drive pump to only partially upstroke.
Part of the return oil from the head end of boom cylinders flows to the boom drift reduction
valve.
08/08 Implements
BOOM REGENERATION VALVE

Low Boom Down SLOW BOOM DOWN
Pilot Pressure
Check
Valve
From Boom
Spool
A A
To Boom
Spool
Regen Spool
A-A
14
The boom regeneration valve has two components, the boom regeneration valve itself and the
check valve.
During a slow BOOM DOWN, the low pilot pressure is not able to move the regeneration valve
down so return oil from the the boom cylinder head ends is not able to flow to the boom
cylinder rod ends.
08/08 Implements
High Boom Down BOOM REGENERATION VALVE

Pilot Pressure
FAST BOOM DOWN
Check
Valve
From Boom
Spool
A A
To Boom
Spool
Regen Spool
A-A
15
When boom lower pilot pressure increases, the boom regeneration valve is pushed down, a
passage is opened allowing boom head end oil to flow to the check valve. If the boom rod end
pressure is lower than the boom head end oil pressure, then the check valve opens allowing
boom head end oil to be directed to the boom rod end.
The check valve closes if the boom rod end oil pressure is higher than the boom head end oil
pressure, such as when the boom is being powered down.
08/08 Implements
BOOM DRIFT REDUCTION VALVE

BOOM RAISE
Manual Bleed
Valve
Line Relief
Valve B
Check Valve B
Boom 2
Shuttle
Valve
A-A
Boom 1
From Boom 1
And Boom 2
Control Valves
To Boom Cylinders Lock Check

Head End Valve
Shuttle Valve
A A
Line Relief Valve Line Relief Shuttle

Valve Valve
B-B
16
Boom Drift Reduction Valve: The boom drift reduction valve prevents oil from leaking from
the head end of the boom cylinders. The boom drift reduction valve is located on the main
control valve group. The boom drift reduction valve has the following components:
- shuttle valve
- lock check valve
- line relief valve
In NEUTRAL, the shuttle valve and check valve are closed by spring force. Oil is blocked
between the boom control valve and the boom cylinders.
For BOOM RAISE, the shuttle valve is closed by spring force. When closed, the shuttle valve
allows oil from the boom control valves to act on one end of the lock check valve.
Oil pressure from the boom control valves acts on the other end of the lock check valve. The
lock check valve opens (due to pressure differential on check valve) to allow oil flow to the rod
end of the boom cylinders.
08/08 Implements
BOOM DRIFT REDUCTION VALVE

BOOM LOWER
Manual Bleed
Valve
Line Relief
Check Valve Valve B B
Boom 2
Shuttle To Tank
Valve
Boom 1
To Boom 1
Control Valve
From Boom Cylinders

Head End Check
Valve
Shuttle Valve
A A
Line Relief Valve Line Relief Shuttle

Valve Valve
B-B
17
For BOOM LOWER, the shuttle valve is opened by pilot oil from the joystick. The shuttle
valve allows oil from the spring end of the lock check valve to return to tank.
Oil pressure from the boom cylinder head end opens the lock check valve. The lock check
valve allows oil flow from the head end of the boom cylinders to return to the boom control
valve.
08/08 Implements
5 4
2
6
18
Boom Lowering Control Valves: The boom lowering control valves (1 and 2) are mounted on
the head end of the boom cylinders. If the machines are equipped with the optional boom
lowering valves, the drift reduction valve for the boom is not installed on the machine.
The boom lowering control valves serve several purposes:

- prevent the boom from falling rapidly in case of hose failure
- provide BOOM LOWER control with SmartBoom (if equipped) activated
- prevent boom drift
The lowering control valves are equipped with head end line relief valves (3) to protect the
cylinders from sudden shocks.
A pilot line (4) directs pilot oil to unlock the lowering control valve so the boom can be
lowered.
The tube (5) provides supply oil from the boom control valve.
A hose (6) connects both lowering control valves. The line provides for equalization of
pressures in the head end of the cylinders when the boom is raised or lowered to provide
smooth movement.
08/08 Implements
Boom
Down Pilot
BOOM LOWERING CONTROL VALVE
NEUTRAL
Boom Cylinder Head End

Line Relief Valve Tank
Boom Control
Valve Check Valve
Boom Control
Boom Lowering Valve
Control Valve
Equalization
Passage
Opposite
Cylinder
Manual
Lower
Boom Orifice Opposite

Down Pilot Cylinder
Boom Control
Valve
Head End
19
When the boom circuit is equipped with boom lowering control valves (or load control valves),
the lowering control valves are attached directly to each of the boom cylinders.
The following major components are used in the boom lowering control valves :
- boom head end line relief
- check valve
- boom lowering control valve spool
- orifice
- manual lower
08/08 Implements
Boom Head End Line Relief: The boom head end line relief protects the boom head end
circuit from damage if the pressure in the circuit exceeds the line relief setting.
Check Valve: The check valve holds the high pressure of the boom cylinder head end
from leaking off. Because the weight of the boom, stick, and work tool are always applied
to the head end of the boom cylinder, the check valve is needed to prevent the high
pressure from leaking off and allowing the boom to drift. The check valve also provides
an unrestricted means for the high pressure/high flow oil from the main control valve to
enter the boom cylinder head end during BOOM UP.
Boom Lowering Control Valve Spool: The infinitely variable boom lowering control
valve spool controls the flow of oil exiting the boom cylinder head end. The top of the
spool receives pilot pressure from the boom lower joystick. When the valve opens, oil
flows from the head end back to the main control valve. Because the valve is infinitely
variable and controlled by boom lower pilot pressure, the speed that the boom lowers is
controlled by the boom lowering control valve spool.
Orifice: The boom lowering control valves on each cylinder are connected by a small
hose. The hose ensures that pressure is always equal in the two cylinders. The orifice in
each of the boom lowering control valves restricts the amount of oil that flows from one
cylinder to the other. The restriction created by the orifice will allow control over the
boom in the event that the hose ruptures. Under normal operation the orifice plays no role
in boom operation.
Manual Lower: Manual lower allows the boom to be lowered if the engine will not run.
The valve allows the oil pressure in the head end of the cylinder to bleed to the tank.
NEUTRAL: When no boom function is performed the boom lowering control valve is in
NEUTRAL. In NEUTRAL no oil flows to or from the boom cylinders, and the boom does not
move.
In NEUTRAL, the check valve is seated by the combination of the spring force and the high
pressure oil in the head end of the boom cylinders. The boom lowering control valve spool is
seated by spring force.
The boom lowering control valves have no effect on the flow of oil to/from the rod end of the
boom cylinders.
NOTE: Manual lower may be done differently depending on the lowering control
valves used. Some machines may have a manual lowering valve separate from the
lowering control valves.
08/08 Implements
Boom Lowering
BOOM CIRCUIT WITH LOWERING Cont rol Valve
CONTROL VALVES
NEUTRAL
Boom Down
Pilot
Boom 1
Spool
Straight
Travel
Main
Boom 2 Relief
Boom Rod End
Spool
Line Relief Valve
Boom Regen
Valve
Boom Up Pilot Idler

Pump
M
Pilot Oil
Heavy Lift Drive
Solenoid Pump
20
The schematic above shows the two lowering control valves and the boom circuit control
valves in NEUTRAL.
Both pumps are destroked.
NOTE: The stick circuit may also be equipped with a single lowering control valve.
Operation of the stick lowering control valve will be similar. With only a single stick
cylinder there is no need for an equalization passage.
08/08 Implements
Boom
BOOM LOWERING CONTROL VALVE Down Pilot
BOOM UP

Boom Control
Valve
Check Valve
Boom Control
Boom Lowering Valve
Control Valve
Equalization
Passage
Opposite
Cylinder
Boom
Orifice Opposite
Down Pilot
Cylinder
Boom Control
Valve
Head End
21
When BOOM UP is performed the boom lowering control valve allows oil to pass from the
main control valve to the head end of the boom cylinders.
High pressure oil from the main control valve enters the boom lowering control valve.
As the supply pressure increases, the check valve opens and allows oil to flow to the head end
of the boom cylinder.
The boom lowering control valve spool remains seated due to spring force.
08/08 Implements
Boom Lowering
CONTROL VALVES
BOOM UP
Boom Down
Pilot
Boom 1
Spool
Straight
Travel
Main
Boom 2 Relief
Boom Rod End
Spool
Line Relief Valve
Boom Regen
Valve
Boom Up Pilot Idler

Pump
M
Pilot Oil
Heavy Lift Drive
Solenoid Pump
22
For BOOM UP, the pilot pressure shifts both boom spools.
Besides oil from the drive pump, supply oil may also be available from the idler pump for
raising the boom. Other circuits not shown, operating at lower pressures than the boom will
receive the idler pump flow first.
The regen valve has no affect on the operation of the lowering control valves for BOOM UP.
08/08 Implements
Boom
BOOM LOWERING CONTROL VALVE Down Pilot
BOOM LOWER SLOW (METERED)

Boom Control
Valve Check Valve
Boom Control
Boom Lowering Valve
Control Valve
Equalization
Passage
Opposite
Cylinder
Orifice
Boom
Down Pilot
Boom Control
Valve
Head End
23
When the boom is slowly lowered, the boom lowering control valve allows oil to flow at a
controlled rate from the head end of the boom cylinders to the return system.
The boom lower pilot oil from the operator joystick enters the boom lowering control valve
above the boom lowering control valve spool. The pilot pressure moves the spool down against
the spring force.
The movement of the spool partially opens a passage to allow flow from the boom cylinder
head end to the return system. Since this flow is restricted by the spool, the boom lowers at a
controlled rate.
The farther the joystick is moved, the higher the pilot pressure on the spool, the greater the
movement of the spool, and the greater the flow from the boom cylinder head end to the tank
past the boom control valve.
The check valve remains closed.

08/08 Implements
Boom Lowering
CONTROL VALVES
BOOM DOWN SLOW
Boom Down
Pilot
Boom 1
Spool
Straight
Travel
Main
Boom 2 Relief
Boom Rod End
Spool
Line Relief Valve
Boom Regen
Valve
Boom Up Pilot Idler

Pump
M
Pilot Oil
Drive
Heavy Lift Pump
Solenoid
24
For a slow boom down, with boom lowering valves, the boom 1 spool is only partially shifted
by a reduced pilot pressure. The NFC signal to the pump is reduced, so the drive pump only
partially upstrokes.
The boom 2 spool does not shift.
As long as the pilot pressure does not move the regen valve to the right, regeneration does not
occur.
Oil metered through the lowering valves to tank flows back to the tank through the boom 1
spool.
08/08 Implements
Boom Lowering
CONTROL VALVES
BOOM DOWN FAST
Boom Down
Pilot
Boom 1
Spool
Straight
Travel
Main
Boom 2 Relief
Boom Rod End
Spool
Line Relief Valve
Boom Regen
Valve
Boom Up Pilot Idler

Pump
M
Pilot Oil
Drive
Heavy Lift Pump
Solenoid
25
For a full BOOM DOWN, the lowering control valve allows oil to flow with little restriction
from the boom lowering control valve.
The full boom lower pilot signal from the operator joystick enters the lowering control valve
above the boom lowering control valve spool. The pilot moves the spool fully down against the
spring force.
The movement of the spool fully opens the passage to allow oil to flow from the boom cylinder
head end to flow to the regen valve and to the boom control valve.
The check valve remains closed.

08/08 Implements
Boom Lowering
CONTROL VALVES
BOOM DOWN FAST
Boom Down
Pilot
Boom 1
Spool
Straight
Travel
Main
Boom 2 Relief
Boom Rod End
Spool
Line Relief Valve
Boom Regen
Valve
Boom Up Pilot Idler

Pump
M
Pilot Oil
Drive
Heavy Lift Pump
Solenoid
26
For a fast BOOM DOWN, the pilot pressure fully shifts the boom 1 spool, both lowering
control valves, and the regen valve.
With the regen valve shifted, head end return oil flows through the regen valve to mix with the
supply oil from the drive pump to fill the cylinder rod ends.
This action results in the boom lowering rapidly and more efficient operation of the excavator
due to only one pump is providing flow and by using the return oil to supplement the supply
oil.
08/08 Implements

STICK CIRCUIT COMPONENTS
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
Stick 2
NFC Stick Stick 1

Orifice Unloading Main
Valve Relief
Variable Swing
Priority Valve
Idler Pump
Swing Boom
Swing / Stick Boom / Bucket Priority Priority Heavy Lift
Pilot Valve Pilot Valve Valve
M Pilot Pump
Valve Solenoid Drive Pump
Pilot
Manifold
AEC Pressure
Switch
27
Stick Circuit
The stick circuit consists of the following major components:
- stick 1 spool
- stick 2 spool
- stick cylinder
- stick regeneration valve
- stick unloading valve
- stick lowering control valves (not shown)
- stick drift reduction valve
NOTE: The stick priority systems and the stick drift reduction valve will be discussed
in more detail later in this presentation.
08/08 Implements
Stick 1 Spool: The stick 1 spool controls oil flow from the idler pump. The stick 1 spool
receives a STICK OUT pilot signal on the bottom of the valve, and a STICK IN pilot signal on
the top of the valve.
Stick 2 Spool: The stick 2 spool controls oil flow from the drive pump. The stick 2 spool
receives a STICK IN pilot signal from the joystick on the top of the valve stem. The stick 2
spool receives a STICK OUT pilot signal from the joystick on the bottom of the valve stem.
Stick Cylinder: When oil is supplied to the head end of the stick cylinder, the stick will
extend for a STICK IN. When oil is supplied to the rod end of the stick cylinder, the stick will
retract for a STICK OUT.
Stick Regeneration Valve: The stick regeneration valve opens during STICK IN to allow
returning oil from the rod end of the stick cylinder to be directed to the head end of the stick
cylinders during STICK IN. Regeneration is used to reduce "stick wag" and increase the stick
in speed.
Stick Unloading Valve: The unloading valve allows the oil to return to the tank when
regeneration is not necessary.
Stick Drift Reduction Valve: The stick drift reduction valve is placed in the stick circuit
between the main control valve and the stick cylinder. The stick drift reduction valve prevents
oil from leaking from the rod end of the stick cylinder. The stick drift reduction valve also
incorporates the line relief valve for the rod end of the stick cylinder.
NOTE: Approximate spring setting values have been provided to use as reference
values only. The values have been provided to assist in explaining stick operation.
Different pilot pressures are required to shift the stick 1 and the stick 2 control valves.
08/08 Implements
MAIN HYDRAULIC SYSTEM Boom

STICK OUT Cylinders
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
Stick 2
NFC Stick Stick 1

Orifice Unloading Main
Valve Relief
Variable Swing
Priority Valve
Idler Pump
Swing Boom
Swing / Stick Boom / Bucket
Priority Priority Heavy Lift
Pilot Valve Pilot Valve M Pilot Pump
Valve Valve Solenoid Drive Pump
Pilot
Manifold
AEC Pressure
Switch
28
When the stick hydraulic circuit is operated independently of other hydraulic circuits, stick 1
control valve and stick 2 control valve are used for both the STICK IN and STICK OUT
operation. When the stick 1 control valve and the stick 2 control valve are shifted, the supply
oil from the idler pump and the drive pump is combined. The supply oil from both pumps
flows to the stick cylinder.
The supply oil from the drive pump flows through the parallel feeder passage in the main
control valve group to the stick 2 control valve. The supply oil from the idler pump flows
through the center bypass passage in the main control valve group to the stick 1 control valve.
When the joystick for the stick is moved to STICK OUT, the pilot oil flows from the pilot
control valve to the stick 1 control valve and the stick 2 control valve.
The pilot oil shifts the stick 1 and stick 2 control valve spools. Supply oil is directed from both
spools to the stick drift reduction valve. The lock check valve in the drift reduction valve shifts
and combined pump oil flows to the rod end of stick to retract the cylinder.
Return oil from the head end of the stick cylinder flows back to the stick 1 and stick 2 control
valves and to the tank.
08/08 Implements

STICK IN - SLOW WITHOUT REGENERATION
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
860 >600
kPa kPa
Boom 1 Stick 2
11270
kPa >900
NFC Stick 1 kPa
Orifice Main
Relief
Stick Variable Swing

Unloading Priority Valve
Valve
Idler Pump
Swing Boom
M Pilot Pump
Pilot
Manifold
AEC Pressure
Switch
29
Slow STICK IN - No Regeneration: Depending on the position of the stick, for a slow stick
in, regeneration may not be required due to the supply oil from the pump being able to fill and
pressurize the head end of the stick cylinder to force the stick in.
For a slow STICK IN the pilot signal is reduced and will only partially shift the stick 1 spool.
The stick 2 control valve may or may not shift. Shifting of the stick 2 spool is determined by
how high the pilot pressure to the stick 2 valve is.
Different minimum pilot pressures are required to shift the stick spools.
When pilot pressure is less than approximately 860 kPa (125 psi), the pilot oil is not able to
shift the regeneration valve to the left.
A reduced NFC signal is sensed at the idler pump, and the pump upstrokes to provide flow.
Most of the supply oil from the idler pump is directed to the stick cylinder head end through the
stick 1 control spool.
08/08 Implements
Return oil from the rod end flows to the drift reduction valve. The lock check valve in the drift
reduction valve is unseated and return oil flows back to the tank through the stick 1 control
valve.
Though the return oil is restricted through the stick 1 control spool, to provide precise control
of slow STICK IN.
08/08 Implements
STICK REGENERATION VALVE

Stick In REGENERATION OFF
Stick
Pilot
Regeneration
(<860 kPa)
Valve
From Stick
Control
Valve
Check
Valve Stick
Unloading
Valve
To Stick
Control
Valve
A A
A-A
30
The stick 1 spool restricts the return oil from the stick rod end. The restriction at the stick 1
spool creates a back pressure in the stick cylinder rod end return circuit. The restriction
prevents the stick cylinder from cavitating due to the force of gravity trying to lower the stick
when the stick is being moved from a raised stick out position to a lowered position.
Due to low pilot pressure the regeneration valve does not shift.
Since the regeneration valve has not shifted to allow rod end oil to flow to the check valve, the
check valve remains closed and the rod end and head oil does not mix. Regeneration does not
occur.
A drain passage in the stick regeneration valve vents the upper passage between the stick
unloading valve and the regeneration valve to the tank.
08/08 Implements

STICK IN - FAST WITH REGENERATION (BOOM UP ACTIVATED)
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
860 >600
kPa kPa Boom 1 Stick 2
11270
kPa >900
NFC kPa
Orifice Main
Stick 1
Relief

Valve
Idler Pump
Swing Boom
Swing / Stick Boom / Bucket
Priority Priority Heavy Lift Pilot Pump
Valve Valve Solenoid Drive Pump
Pilot
Manifold
AEC Pressure
Switch
31
Fast STICK IN - Regeneration: Pilot pressure is increased for a fast STICK IN.
The boom 1 circuit has been activated as well, to show the importance of the stick regeneration
valve. With the boom circuit activated the boom priority valve reduces the pilot pressure to the
stick 2 valve, preventing the stick 2 valve from shifting. Only one pump flow from the idler
pump is available to supply the stick 1 circuit.
The higher stick pilot pressure causes the regeneration valve to shift to the left. Return oil from
the rod end flows through the regeneration valve to the check valve. The check valve unseats
due to the return oil pressure being higher than the pump supply pressure from the stick 1
control valve.
When the check valve unseats, the return oil is added to the supply oil going to the head of the
stick cylinder.
The regeneration valve allows the excavator to operate more efficiently. The main pump supply
oil not required to shift the stick in is available to operate another circuit.
08/08 Implements

STICK IN - FAST WITH REGENERATION AND STICK 2
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
Blocked
860 >600
11270 >900
kPa kPA
NFC
Orifice Stick 1 Main
Relief

Valve
Idler Pump
Swing Boom
M Pilot Pump
Pilot
Manifold
AEC Pressure
Switch
32
If the boom circuit was not activated, higher pilot pressure available to the stick 2 valve would
cause the stick 2 control valve to shift.
The stick 2 control valve does not allow return oil from the rod end to return to the tank
through the stick 2 control valve.
Drive pump supply oil is now available to supply the stick cylinder as well as the idler pump
supply oil.
As long as the combined pump supply pressure does not exceed the spring pressure setting of
the unloading valve spring, the return oil from the rod end will be used to add to the two pump
flow.
08/08 Implements
Stick In
Pilot Stick
STICK REGENERATION VALVE
(>860 kPa) Regeneration REGENERATION ACTIVE
Valve Head End Pressure <11270 kPa
From Stick
Control
Valve
Check
Valve
Stick
Unloading
Valve
To Stick
Control
Valve
A A
A-A
33
When the pilot pressure increases to stick in fast, the regeneration valve moves down.
The restriction at the stick 1 spool creates back pressure in the stick cylinder return oil from the
rod end. Because the stick is moving fast, the back pressure is relatively high.
The return oil flows to the check valve between the rod end and head end circuits. The
returning oil pressure overcomes the combined force of the check valve spring and the pump
supply oil from the stick control valve. The check valve opens. Returning oil from the rod end
of the stick cylinder now is redirected to the head end of the stick cylinder.
The stick cylinder head end pressure is sensed by the stick unloading valve. Due to low head
end pressure, the valve remains closed, which blocks the passage to drain for the return oil from
the cylinder rod end.
08/08 Implements

STICK IN - FAST UNLOADING (AND STICK 2)
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
Blocked
860 >600
11270
kPa >900
NFC kPa
Orifice Main
Stick 1 Relief

Valve
Idler Pump
Swing Boom
Swing / Stick Boom / Bucket Priority Priority
Pilot Valve Pilot Valve Valve Heavy Lift M Pilot Pump
Pilot
Manifold
AEC Pressure
Switch
34
Fast STICK IN - Unloading: Whenever the head end supply pressure exceeds the setting of
the unloading valve spring [11270 kPa (1630 psi)] the unloading valve shifts and allows the
return oil from the cylinder rod end to flow directly to the tank.
Typically this will occur whenever the stick reaches the vertical position or as the stick moves
from the vertical position and in closer to the machine.
NOTE: If the stick 2 control valve is also supplying drive pump oil to the stick circuit
along with the idler pump supplying oil, the head end pressure may increase above
11270 kPa (1630 psi), prior to the stick reaching a vertical position to the ground, when
being lowered from a raised position.
08/08 Implements
Stick In STICK REGENERATION VALVE

Pilot Stick UNLOADING ACTIVE
(>860 kPa) Regeneration Head End Pressure >11270 kPa
Valve
From Stick
Control
Valve
Check
Valve Stick
Unloading
Valve
To Stick
Control
Valve
A A
A-A
35
Stick unloading occurs when the stick reaches vertical to the ground and as the stick moves
further in towards the machine. A pressure spike occurs which helps to open the unloading
valve to rapidly reduce rod end pressure. When the unloading valve opens, the oil flow to the
stick cylinder may be from one or both pumps. (Stick 2 flow depends on whether other circuits
are in operation at the same time.)
When the regeneration valve is shifted and the supply oil to the head end of the stick cylinder is
higher than the return oil from the rod end, the check valve will close. No return oil from the
rod end enters the passage to the head end.
At the same time the pressure in the head end of the cylinder increases and moves the
unloading valve down.
When the unloading valve moves down, most of the return oil from the rod end of the cylinder
returns to the tank past the unloading valve instead of through the stick 1 control valve.
When the stick unloading moves down, regeneration no longer occurs.

08/08 Implements
Summary of stick regeneration functions: The main purpose of the regeneration valve is to
allow smooth stick in operation, whenever the pump flow is also being used by other circuits.
Typically, the operator will use the stick, boom, swing, and bucket circuits simultaneously for
some applications. The regeneration valve will actually allow the stick to lower for a stick in
operation with little or no additional pump flow.
Stick regeneration allows the returning oil from the rod end of the cylinders to combine with
main pump flow to move the stick cylinder out.
The regeneration valve also prevents cylinder cavitation, which prevents swing wag from
occurring.
NOTE: If both pump flows were are available for the stick cylinder, the regen valve
would have limited use. The back pressure valve and the makeup valve would probably
be sufficient to prevent swing wag, except for when there is an extremely heavy
suspended load on the stick circuit.
The unloading valve allows a means to relieve the back pressure from the returning rod end oil,
when the oil is no longer needed for regeneration.
08/08 Implements
STICK DRIFT REDUCTION VALVE

A
From Stick 1 NEUTRAL

and Stick 2
Control
Valve
B To Stick
Cylinder
Rod End
To Stick
Cylinder
Rod End
From Stick 2
Control
A Valve
From Stick 1
From Stick 1 Control
and Stick 2 Valve
Control Stick In
Valve Pilot Shuttle
Pressure Valve
Lock Check
Valve
Drain
To Stick
Cylinder
Rod End
B-B
Stick Out
Line Relief
Valve
36
The stick drift reduction valve is located in the stick circuit on the main control valve group as
part of the stick 1 spool. The stick drift reduction valve prevents oil from leaking from the rod
end of the stick cylinder. The stick drift reduction valve has the following components:
- shuttle valve
- lock check valve
- line relief valve
In the NEUTRAL position, the shuttle valve and lock check valve are closed by spring force.
Oil is blocked between the stick control valve and the stick cylinder.
08/08 Implements

A
From Stick 1
STICK OUT
and Stick 2
Control
Valve
B
To Stick
Cylinder
Rod End
To Stick
Cylinder
Rod End
From Stick 2
Control
A Valve
From Stick 1
From Stick 1 Control
and Stick 2 Valve
Control Stick In
Valve Pilot Shuttle
Pressure Valve
Lock Check
Valve
Drain
To Stick
Cylinder
Rod End
B-B
Stick Out
Line Relief
Valve
A-A
37
For STICK OUT, the shuttle valve does not shift. The shuttle valve allows oil from the stick
control valves to act on one end of the lock check valve.
Oil pressure from the stick control valves acts on the other end of the check valve. The check
valve opens (due to the pressure differential on the check valve) to allow oil flow to the rod end
of the stick cylinder.
08/08 Implements
A
To Stick 1 STICK IN
To Stick 1
Control
Control
Valve
Valve
B From Stick
Cylinder
Rod End
From Stick
Cylinder
Rod End
To Stick 2
To Stick 1 Control
Control Valve
A Valve
To Stick 1
Stick In Control
Pilot Shuttle Valve
Pressure Valve
From Stick Drain

Cylinder
Rod End
B-B
Stick Out
Line Relief
Valve
A-A
38
For STICK IN, the shuttle valve is moved down by pilot oil from the joystick.
The shuttle valve allows oil in the lock valve spring chamber to flow to the tank.
Return oil from the stick cylinder rod end moves the lock check valve to the left against the
lock check valve spring.
The open lock check valve allows oil flow from the rod end of the stick to return to the stick 1
control valve and the regeneration valve.
08/08 Implements
Stick
Cylinder
STICK HYDRAULIC CIRCUIT
WITH LOWERING CONTROL VALVE
NEUTRAL
Stick Lowering
Control Valve
Stick Regen
Valve Check
Valve
Straight
Travel
Boom 2 Stick 1 Stick 2

Spool Main
Relief
Stick Unloading Stick Out

Valve PRV1
Stick Pilot Oil M

In Heavy Lift
Solenoid
39
The stick circuit can be equipped with a boom lowering control valve (or load control valve),
which is attached directly to each of the boom cylinders. For 325D and 300D MH (material
handlers), these machines are equipped with two cylinders, with lowering control valves for
each cylinder.
When the machine is equipped with a lowering control valve, the drift reduction valve is not
required.
The schematic above shows the lowering control valve and the stick circuit control valves in
NEUTRAL. Both pumps are destroked.
NOTE: Operation of the stick lowering control valve is similar to the boom lowering
valve. The stick regen valve will also affect the stick in operations of the stick circuit.
Refer to the cutaway illustrations of the boom lowering control valves shown earlier in
the presentation as needed.
08/08 Implements
STICK LOWERING CONTROL VALVE GROUP
NEUTRAL STICK OUT STICK IN WITH

REGENERATION
Line Relief and Check Line Relief and Check Line Relief and Check
Makeup Valve Valve Makeup Valve Valve Makeup Valve Valve
Boom Lowering Boom Lowering

Control Valve Control Valve
Spool Spool
Manual
Stick Control Lower Stick Control Stick Control
Valve Valve Valve
Stick In Stick In Stick In

Pilot Pilot Pilot
Stick Control Stick Control Stick Control

Valve Valve Valve
40
The components of the stick lowering control valve are much the same as for the boom
lowering control valve and include:
- rod end line relief and makeup valve
- check valve: which provides as the similar function
- stick lowering control valve spool
- manual lower
These components provide a similar function as they did on the boom lowering control valve.
When no stick function is performed the stick lowering control valve is in NEUTRAL. In
NEUTRAL no oil flows to or from the boom cylinders, and the boom does not move.
08/08 Implements
In NEUTRAL, the check valve is seated by the combination of the spring force and the high
pressure oil in the rod end of the stick cylinder. The lowering control valve spool is seated by
spring force.
The boom lowering control valves have no effect on the flow of oil to/from the rod end of the
boom cylinders.
NOTE: Manual lower may be done differently depending on the lowering control
valves used. Some machines may have a manual lowering valve separate from the
lowering control valves.
When STICK OUT is performed the lowering control valve allows oil to pass from the main
control valve, through the check valve, and to the rod end of the stick cylinder.
High pressure oil from the main control valve enters the lowering control valve. As the supply
pressure increases, the check valve opens and allows oil to flow to the rod end of the stick
cylinder. The boom lowering control valve spool remains seated due to spring force.
For STICK IN, pilot pressure is required to unseat the lowering control valve spool to allow
return oil from the rod end of the stick cylinder to return to the main control valve group.
Depending on how high the pilot pressure is will determine whether the lowering control valve
fully shifts or partially shifts.
Depending on the position of the stick and how slow or fast of a STICK IN is being done, will
determine whether the regen valve is open or closed, as well as whether the unloading valve
shifts.
- For a metered STICK IN, the regen valve and unload valve are closed.
- For a fast STICK IN the regen valve will shift and allow return oil from the rod end to be
used as additional supply oil for the head end of the cylinder.
- If the pressure increase in the head end is high enough, the unloading valve will shift and
the return oil from the rod end will flow through the unloading valve to the tank.
During STICK in the check valve remains closed.

08/08 Implements

BUCKET CLOSE
Bucket
Cylinder
Bucket
NFC
Orifice Main
Relief

Solenoid
Swing / Stick Boom / Bucket Pilot Pump
Drive Pump
AEC Pressure
Switch
Pilot Manifold
41
Bucket Circuit
The bucket circuit control valve operates as previously discussed. Two line relief valves and
makeup valves are used to protect the lines from high pressures.
The bucket is only supplied by the drive pump. Pilot oil from the joystick is directed to the
bucket control valve to shift the control spool.
When the control spool shifts, the NFC signal to the drive pump is reduced and the pump
upstrokes to provide flow.
For BUCKET CLOSE, the return oil from the rod end of the cylinder is restricted by the
control spool to control the bucket speed.
08/08 Implements
Boom
Cylinder
Snubber Snubber
Stick
Cylinder
Bucket
Cylinder
42
Cylinders
The boom, stick, and bucket use dual acting cylinders. The boom has a snubber for the rod
end, while the stick uses snubbers on the rod and head end.
Snubbers slow the speed of the cylinder as the cylinder reaches the end of the cylinder stroke.
08/08 Implements
SNUBBER OPERATION Passage Snubber
BOOM AND STICK CYLINDER

EXTENDING ROD
Snubber Passage
STICK CYLINDER
RETRACTING ROD
43
As the boom or stick cylinder moves to the end of the extension stroke, oil in the passage will
be restricted by the snubber, which will slow the extension of the cylinder.
As the stick cylinder moves to the end of the retraction stroke oil in the passage will be
restricted by the snubber, which will slow the retraction of the cylinder.

Manual 5 Control Hidraulico

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SERV1852-02

GLOBAL SERVICE LEARNING

320D-336D HYDRAULIC EXCAVATORS -

Service Training Meeting Guide

MAIN CONTROL VALVE GROUP AND RETURN SYSTEM

Swing Motor Travel Motors

Main Control Valve Group

The main hydraulic system supplies the following circuits:

Main Control Valve Group

MAIN CONTROL VALVE

NFC Signal Drive Pump NFC Signal

MAIN CONTROL VALVE GROUP

Stick Regen Straight Travel

Stick 1 Swing Left

Swing Variable Swing

Parallel Line Relief

The control valve above is shown in NEUTRAL.

Center Bypass Control

MAIN CONTROL VALVE GROUP

Parallel Feeder Drift

Stick Regen Straight Travel

Stick 1 Swing Left

Swing Variable Swing

Port A Port B CONTROL VALVE

STRAIGHT TRAVEL CONTROL VALVE

MAIN RELIEF VALVE

Heavy Lift Heavy Lift Heavy Lift

Pilot Pilot Pilot

Lock Nut Lock Nut

Lock Nut Lock Nut

Poppet Poppet Unloading

Pump Pump Pump

CLOSED OPEN CLOSED

LINE RELIEF AND MAKEUP VALVE

CLOSED RELIEF MAKEUP

Outer Outer Outer

NFC Signal END HOUSINGS

RETURN HYDRAULIC SYSTEM

Slow Return Bypass

Case Drain Filter

Return Hydraulic System

The return hydraulic system has the following components:

- slow return check valve

- cooler bypass check valve group

- hydraulic oil cooler

- hydraulic oil filters

- hydraulic oil tank

SLOW RETURN CHECK VALVE AND BYPASS CHECK VALVE

Slow Return Return Passage from

Inlet Line Makeup Line

Return Line from Return Line to

Swing Motor Travel Motors

Main Control Valve Group

MAIN HYDRAULIC SYSTEM Boom

Heavy Lift Idler Pump

The boom circuit consists of the following major components:

Port A Port B CONTROL VALVE

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

BOOM 1 CONTROL VALVE

Load NFC Signal

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

BOOM 1 CONTROL VALVE

STICK DRIFT REDUCTION VALVE

STICK DRIFT REDUCTION VALVE