Central Training Centre - L&T Construction & Mining Machinery

Function of valves mounted on OLSS & EOLSS Machines

SL Name Component Function Structure Additional Information Control signals Input Output
TVC Valve (Torque Variable Control valve)
TVC Solenoid - To achieve Pump
TVC valve is responsible for
Engine Mutual Control (PEMC). This 1. All Main pump Pressures
Pump HPV95+95 power balancing between Has spring at one side (Force equal
solenoid controlled by pump "P" Pilot pressure
and HPV160+160 hydraulic HP and engine HP to engine HP) & All Main pump "P" "Pe" pressure to change
1 controller to change engine HP 2. Pe feedback (Flow signal) from Charging
(PC600 & (Reduces pump flow when lines with "Pe feedback" (Hydraulic "Pecn" (Controls pump flow)
setting based on engine speed. Due 3. TVC solenoid mechanical pump
PC1250) hydraulic HP increases more HP) plus TVC Solenoid on other side
to this engine will not lug even if we force
than Engine HP)
load at any rpm

CO Valve (Cut Off Valve)

Cut Off cancel (When heavy lift is

Pump HPV95+95 CO valve reduces relief losses Has spring at one side (Pressure selected) - Pilot line from heavy lift
"Pe" pressure
and HPV160+160 (Reduces pump flow when setting less than MPR value) & solenoid increases the spring setting 1. Particular pump working "Pec" pressure to change
2 from TVC
(PC600 & working pressure comes close Particular pump working pressure to the value which is more than MPR pressure "Pecn" (Controls pump flow)
solenoid
PC1250) to MPR opening pressure) on other side setting value. Due to this cutoff valve
will not function.

NC Valve (Neutral Control Valve)

Works based on the differential

pressure(delta P) created by Jet
Pump HPV95+95 NC valve reduces Neutral Losses Has spring + PD (Pressure Drain) 1. PT (Pressure Take away)
Senor (PT-PD) "Pec" pressure "Pecn" pressure to Servo
and HPV160+160 (Reduces pump flow when signal from Jet sensor on one side from Jet sensor
3 When delta P is more - Reduces from Cut Off valve opposite to spring side
(PC600 & machine is in neutral and and PT (Pressure Take away) from 2. PD (Pressure Drain) from
pump flow valve (Controls Pump flow)
PC1250) increases when lever operated) Jet sensor on other side Jet sensor
When delta P is less - Increase pump
flow

Servo Valve

Has guide valve - The guide valve

The servo valve in conjunction
Pump HPV95+95
with the guide valve controls
and HPV160+160
4 servo piston movement based
(PC600 &
on the Pecn signal it receives
PC1250)
through TVC/CO/NC valve
Servo valve spool has a set of
springs (2 springs for progressivity) charge pressure (control pressure) to
on one side, and it receives the
"Pecn" signal on the other side
Changes the pilot pressure
moves in the same direction as the
connection to Servo piston
servo valve and it connects the
Pilot pressure Spring side & Non Spring
"Pecn" pressure from
from Charging side (Connects to Spring
the spring side of the servo piston to TVC/CO/NC valves
pump side - Pump flow reduces
destroke the pump and non-spring
Connects to Non spring side
side of the servo piston to stroke the
pump flow increase)
pump

Servo Piston (OLSS Pump)

Servo Piston is Mechanically

"Pilot pressure" from Servo
connected with swash plate. It is
Pump HPV95+95 The spring keeps the servo piston valve
divided into two half. One side has
and HPV160+160 Changes pump swash plate such that the swash plate angle is at (Connects to Spring side - Pilot pressure Mechanical force to change
5 a spring and the other side is
(PC600 & angle to change pump flow minimum when the engine is off, or Pump flow reduces from Servo valve swash plate angle
without spring. Both side pilot line
PC1250) pump is in resting position Connects to Non spring
connection is controlled by Servo
side pump flow increase)
valve

CTC - Kanchi
 Central Training Centre - L&T Construction & Mining Machinery
Servo piston (EOLSS Pump)
HPV375+375
Changes pump swash plate
6 (PC800 &
angle to change pump flow
PC2000)
VC Valve (Volume Control valve)
HPV375+375 Controls the Large diameter
7 (PC800 & side connection to increase or other side. Also it has contact on
PC2000) reduce pump flow
EPC Solenoid valve (Electromagnetic Proprtional Control)
It increase or reduces EPC out creates electromagnetic force to
HPV375+375 pressure to increase or reduce
8 (PC800 & pump flow based on the
PC2000) current received from pump
controller
Shuttle valve
Shuttle valve selects higher
HPV375+375
pressure between "Pilot line
9 (PC800 &
and Main pressure line" to give
PC2000)
input to VC valve
CTC - Kanchi
Servo piston has different
If the large diameter end
diameters on both ends in the ratio
"Connects to Tank - Pump
of 1:2. The small diameter end is
The servo piston is also in contact strokes" Pilot pressure or
always connected to the output of Mechanical force to change
with the VC valve spool through CAM "Connects to shuttle valve Main pressure
the shuttle valve, while the swash plate angle
to stabilise the pump flow output - Pump De strokes" from VC Valve
connections of the large diameter
"If blocked - Pump gives
end is dependent on the working of
steady flow"
the VC valve
Controls servo piston larger
EPC solenoid output diameter side connection
VC valve has spring at one side and
On HPV 375+375 pumps the VC valve pressure "Connects to Tank - Pump
EPC solenoid output pressure on Output pressure
is the main valve to control the pump "EPC output increases - strokes"
from the shuttle
flow , power regulation and PEMC. It Pump flow increases" "Connects to shuttle valve
the Cam of servo piston to stabilise valve
is mounted on the servo valve block "EPC output reduces - output - Pump De strokes"
the pump flow
Pump flow reduces" "If blocked - Pump gives
steady flow"
EPC solenoid has a coil which
This EPC solenoid and pump EPC Pressure to control VC
controller does the Jobs of "TVC, CO, Command current from Pilot pressure valve
throttle pilot pressure
& NC valves" of the OLSS System. Pump controller (Need to from the SPRV "EPC pressure increases -
"High current from controller - High
"EPC output pressure" can be check only current. Do not mounted on the Pump flow increases"
EPC pressure"
compared with "Pecn" pressure of check voltage" pump "EPC pressure reduces -
"Less current from controller - Less
OLSS system Pump flow reduces"
EPC pressure"
Whichever is higher
In "E OLSS(PC800/PC2000)" pump Pilot pressure between Pilot and Main
Has a ball at centre which closes
swash plate is controlled by either from SPRV and pressure to
the low pressure input side and -
"Pilot pressure" or "Main pressure" Main working 1. Servo piston Small
give only high pressure as output
whichever is higher pressure diameter
2. VC valve
 Central Training Centre - L&T Construction & Mining Machinery
Jet sensor
It gives input regarding machine
condition (Neutral or in
Operation) to NC valve by
10 Control valve
creating "Delta P (PT-PD)" for
increasing or reducing pump
flow
It has two small orifices which
creates PT (Pressure take away)
and a bigger drain passage which
creates PD (Pressure Drain) signal.
"Jet sensor has two orifices facing
each other. A Jet is created in the
first orifice and when it comes
through the second orifice it forms
the Jet Pressure( Pt). Pt is
connected to the NC valve
Opposite to the spring. Part of the
flow that does not form the jet
goes to tank creates Pd. This Pd
goes to the spring side of the NC
valve
Jet sensor is mounted at the end of
neutral line(Not the return Tank line)
Neutral passage
of the control valve. If all the spools
line of the
are in neutral then the pump flow
control valve
passes through the neutral passage "Delta P" (PT-PD) signal
(If Machine
of the spools and go to tank after If Delta P is more - Indicates
control levers in
passing through the jet sensor. - machine in neutral
Neutral delta P
On PC2000- the output of jet sensor If Delta P is less - Indicates
will be more and
goes to jet sensor differential machine in operation
if the lever is
pressure sensor and the differential
operated delta P
pressure is converted into an
will be less)
electrical signal and fed to the pump
controller as input

Jet sensor Relief valve limits the It has a poppet reinforced with a
maximum pressure in the jet
sensor and the neutral line. It
11 Jetsensor relief valve Control valve dumps the excess oil coming to neutral line pressure if the pressure machine only when the machine is in
the jet sensor when the engine
starts or an operation is
stopped
Main Pressure Relief valve (MPRV)
MPRV limits the maximum
working pressure of the system.
It drains the pump line to tank
when the working pressure
12 Control valve reaches to set pressure. It is
mounted in the pump main line
to safe guard pump. This valve
need to handle more amount of
oil at high pressure
spring to limit the neutral line
pressure. Poppet receives the It acts like the unload valve of CLSS Neutral passage
- line of the Drains the excess oil to tank
increases more than the spring neutral control valve
pressure then the poppet lift up
and drains the oil to tank
It has a poppet reinforced with a
spring. Poppet receives the working
pressure. If the pressure increases
During Heavy lift operation Spring
more than the spring pressure then
side of the MPRV receives additional
the poppet lift up and drains the oil Drains the pump delivery oil
pilot line from the heavy lift solenoid
to tank. Output from the heavy lift to tank when the actuator
to increase the force on spring side. Main pressure
It has a relief valve and a dump solenoid when heavy lift is stooped moving due to
Due to this the opening pressure of line
valve. Relief valve controls the selected and solenoid is ON heavy load or at the end of
the relief valve increases and
pressure and the dump valve dump stroke
machine working pressure can be
huge amount of oil to tank by
increased to get higher force.
creating bigger passage to tank.
This reduces heat generation in the
system during relief operations

Safety valve has a poppet This valve need to handle peek

Safety valve limits the reinforced with a spring to limit the pressures created due to unexpected
maximum pressure in the maximum pressure in the actuator impact loads(Boulder falling on
Safety valve actuator line when the spool is line. Poppet receives the actuator cylinder when spool in neutral) and
Main pressure Drains the oil to tank to
13 Control valve in neutral. It is mounted line pressure if the pressure force created on the cylinders during -
line reduce pressure spikes
between the spool and actuator increases more than the spring operation (While digging load acts on
to safegaurd actuator line from pressure then the poppet lift up all cylinders even if it is not
unexpected load and relieves excessive Pressure to operated). This valve will not handle
tank. high flow of oil.

Suction valve is a check valve

Suction valve avoids
mounted between actuator port Mostly this valve is combined with
cavitation(Negative pressure) in
and Tank line. Whenever the safety valve. If Safety valve of "Port Tank Pressure or Fills the negative pressure
the actuator line by filling oil
14 Suction Valve Control valve actuator pressure reduces less than A" actuates then "Port B" suction - Suction Pressure area with oil to avoid
from control valve tank line. It
Tank pressure this check valve valve need to actuate to avoid line cavitation
is mounted between the spool
opens and fills the chamber with oil cavitation.
and actuator
to avoid cavitation

CTC - Kanchi
 Central Training Centre - L&T Construction & Mining Machinery
On PC1250: This valve throttles the supply to the bucket supply on the swing 4 spool control valve whenever swing is operated so that even if bucket is operated simultaneously, swing
will not be compromised.
15 Throttle valve Control valve
On PC2000- Throttle valve throttles the arm supply on L1 and R2 control valves and boom supply on R1 control valve during different set conditions to help in simultaneous operation.
The valve is a pilot operated check valve with an orifice on the sleeve of the check valve. When the sleeve is locked by working pressure, only the orifice passage is open for oil supply.

Control valve On PC1250 when swing PPC is operated and the pilot pressure becomes greater than 15Kg/cm2 the swing compensation selector valve gets actuated and then is connects the pump
16 Swing compensation selector valve
PC1250 pressure to the throttle valve on the bucket line, to ensure swing assurance function.

On PC1250 straight travel valve is mounted on the RH 4 spool control valve. It prevents any travel deviation if boom, arm or bucket is operated along with travel. It interconnects the
17 Straight travel valve Control valve left and right travel circuits so that same flow is available for both motors and straight travel is achieved.
On PC2000 this is achieved by PPC cut-off valve where during straight travel is operated by L1 and R1 control valve and boom , arm and bucket by L2 and R2 control valve.

Control valve PPC cut-off valve connects or drains certain PPC lines during straight travel and swing priority function based on the actuation of the respective solenoids. It has a spool inside the block
18 PPC cut-off valve
PC2000 which is operated by the solenoid and the connections are changed .

The suction selector valve is located in the cab base and is connected between the PPC and the control valve spools. When a spool is operated the oil from the other end has to return
19 Suction selector valve PC 2000 to tank quickly. A portion of the supply pressure from PPC pushes the spool in the suction selector valve connecting the return line from the other end to tank through the suction
selector valve. Similarly when the main spool returns to neutral oil trom tanks fill the spool cap through the tank line connections in the suction selector valve.

This valve is located in the return line from the control valve. This valve changes the back pressure in the return line from the control valve from a high value during swing or track
operation to a lower value when only attachment other than swing or track is operated. As the anti cavitation requirement is high during swing and travel, the back pressure is kept
20 Variable Back pressure Valve PC2000
high, During boom, arm and bucket operation the back pressure required is low, the variable back pressure valve maintains a lower value . This helps in reducing hydraulic loss and
improving fuel consumption.

CTC - Kanchi