MCV116G4201 MCV116A3204 MCV116A3501 MCV116A3102 Danfoss Pressure Control Pilot 350 bar

Product Overview

The MCV116 series Pressure Control Pilot (PCP) valves are precision electro-hydraulic control components engineered by Danfoss (formerly Sauer-Danfoss) for the Series 90 variable displacement piston pumps. These valves are widely used for pump displacement control and pressure regulation in construction machinery, agricultural equipment, material handling, marine, mining, and industrial hydraulic systems.

The MCV116 series features a torque-motor actuated, double-nozzle flapper pilot stage. The torque motor receives a DC milliamp current signal and drives the flapper via electromagnetic torque, producing a differential pressure output proportional to the control signal. This pilot pressure directly actuates the servo piston of the Series 90 pump for electro-hydraulic proportional pump displacement control.

The MCV116 series is a single-stage, standalone, closed loop pressure control valve that uses internal hydraulic pressure reactions to achieve its closed loop control characteristics—no external pressure sensors or additional feedback loops are required.

This product range covers the following models:

• MCV116G4201: MCV116 series PCP valve, Type 4, torque-motor actuated, double-nozzle configuration, weight approx. 1.0 kg

• MCV116A3204: MCV116 series PCP valve, input signal 4–20 mA DC, 24V DC supply

• MCV116A3501: MCV116 series PCP valve, typical supply pressure 17.2 bar

• MCV116A3102: MCV116 series PCP valve, designed for precision pressure control hydraulic systems

Technical Specifications

MCV116 Series General Specifications (Torque-Motor Actuated)

• Product Series: Danfoss MCV116 series Pressure Control Pilot (PCP) valve

• Product Type: Electro-hydraulic proportional pressure control pilot valve

• Brand: Danfoss (Sauer-Danfoss)

• Actuator Type: Torque motor

• Pilot Stage: Double-nozzle flapper

• Control Type: Single-stage, standalone, closed loop pressure control

• Feedback Method: Internal hydraulic pressure reactions – no external sensors required

• Compatible Pump Series: Danfoss Series 90 variable displacement pumps

• Maximum System Pressure: 350 bar (5000 psi)

• Ambient Operating Temperature: -40°C to +93°C (-40°F to +200°F)

• Oil Temperature Range: -20°C to +107°C (-20°F to +225°F)

• Oil Viscosity Range: 40 – 1400 SSU

• Design Life: ≥10,000 hours or ≥10,000,000 cycles minimum

• Application Range: 5–50 gpm pilot-operated flow control valves, pilot-operated variable pumps and motors

• Standard Features: Standard manual override

• Approvals: EN ISO 12100

MCV116G4201 (Type 4, Torque-Motor Actuated)

• Product Series: Danfoss MCV116 series Pressure Control Pilot valve

• Model Code: MCV116G4201

• Product Type: Pressure Control Pilot (PCP) valve, Type 4

• Actuator Type: Torque motor actuated

• Pilot Stage: Double-nozzle configuration

• Maximum System Pressure: 350 bar (5000 psi)

• Control Type: Single-stage, standalone, closed loop pressure control

• Weight: Approx. 1.0 kg

• Packing Size: 15 cm × 9 cm × 6 cm

MCV116A3204 (4–20 mA Control)

• Product Series: Danfoss MCV116 series Pressure Control Pilot valve

• Model Code: MCV116A3204

• Product Type: Pressure Control Pilot (PCP) valve

• Maximum Operating Pressure: 350 bar

• Maximum Flow: 60 L/min

• Input Control Signal: 4–20 mA DC

• Supply Voltage: 24 VDC

• Body Material: Iron or steel alloy

• Operating Temperature: -20°C to +80°C

• Weight: Approx. 1.8–2.0 kg

• Approvals: EN ISO 12100

MCV116A3501 (Pressure Control Pilot Valve)

• Product Series: Danfoss MCV116 series Pressure Control Pilot valve

• Model Code: MCV116A3501

• Product Type: Pressure Control Pilot (PCP) valve

• Typical Supply Pressure: 17.2 bar

• Maximum Voltage: 30 V

• Maximum Current: 46 mA

• Ambient Operating Temperature: -40°C to +93°C

• Weight: Approx. 0.8–1.0 kg

• Packing Size: Approx. 15 cm × 9 cm × 6 cm

• Connector: Weather-Pack connector for enhanced dust and moisture resistance

MCV116A3102 (Pressure Control Pilot Valve)

• Product Series: Danfoss MCV116 series Pressure Control Pilot valve

• Model Code: MCV116A3102

• Product Type: Pressure Control Pilot (PCP) valve

• Response Time: ≤20 ms

• Repeatability: ±1%

Key Technical Advantages

1. Torque-Motor Actuation for High-Precision Electro-Hydraulic Proportional Control

The MCV116 series utilizes a torque motor as the electro-mechanical transducer. The torque motor receives a DC milliamp current signal and drives the flapper via electromagnetic torque, producing a differential pressure output proportional to the control signal. Compared to conventional proportional solenoids, the torque motor delivers superior control precision, faster response, and lower hysteresis—the core technology enabling closed-loop pump displacement control.

2. Double-Nozzle Flapper Pilot Stage for Precise Differential Pressure Output

The MCV116 series features a double-nozzle flapper pilot stage. As the flapper deflects under torque motor actuation, the outlet pressures of the two nozzles change in opposite directions—one increasing while the other decreases—producing a differential pressure output proportional to the control signal. This differential pressure directly drives the servo piston of the Series 90 pump for precise pump displacement control.

3. Single-Stage Standalone Closed-Loop Control – No External Feedback Required

The MCV116 series is a single-stage, standalone, closed loop pressure control valve. It uses internal hydraulic pressure reactions to achieve its closed loop control characteristics—no external pressure sensors or additional feedback loops are required. This design significantly simplifies system integration and reduces total cost.

4. Rugged Construction for Harsh Operating Conditions

The MCV116 series is constructed from high-strength iron or steel alloy and withstands mobile equipment vibration and shock conditions. Design life is ≥10,000 hours or ≥10,000,000 cycles minimum. Ambient operating temperature range -40°C to +93°C and oil temperature range -20°C to +107°C meet the most demanding global construction machinery requirements.

5. Broad Application Range with Flexible Configurations

The MCV116 series is compatible with Danfoss Series 90 variable displacement pumps. The valve is designed to control 5–50 gpm pilot-operated flow control valves, pilot-operated variable pumps and motors. Multiple configuration versions (G4201/A3204/A3501/A3102) are available for diverse OEM and control requirements.

6. Standard Manual Override and Self-Contained Pressure Feedback

The MCV116 series features a Standard Manual Override for emergency manual operation during power loss. Self-contained pressure feedback ensures a constant scale factor across varying pilot pressure conditions.

7. 100% Direct Interchangeability and Simulated Condition Testing

The MCV116 series strictly adheres to Danfoss original mounting dimensions and interface standards. Valves of different configurations within the same series are physically and functionally identical, enabling 100% direct interchangeability without pump modification or system adjustment. Every unit undergoes 100% simulated operating condition bench testing prior to shipment.

Application Areas

• Construction Machinery: Electro-hydraulic pump displacement control for excavators, wheel loaders, motor graders, road rollers

• Agricultural Machinery: Displacement control for hydrostatic transmission (HST) systems in large tractors and combines

• Material Handling Equipment: Pump displacement control for forklifts and reach stackers

• Road Construction Equipment: Travel drive system control for pavers and rollers

• Marine & Offshore: Pressure and flow control for marine hydraulic systems

• Mining Equipment: Hydrostatic drive systems for underground LHDs and mining trucks

• Industrial Applications: Injection molding machines, presses, and other electro-hydraulic systems requiring pilot differential pressure actuation

Expert Maintenance Tips

1. Verify Model and Pump Compatibility Prior to Installation

The MCV116 series is a dedicated control valve for Series 90 variable displacement pumps. Confirm that the model matches the pump displacement and control requirements—different models (G4201/A3204/A3501/A3102) correspond to different Stage and configuration versions. Mismatched models will result in abnormal control characteristics and significantly impair system performance.

2. Electrical Wiring Precautions

• MCV116A3204: Input control signal 4–20 mA DC, supply 24V DC

• MCV116A3501: Maximum voltage 30 V, maximum current 46 mA

• The MCV116 series is driven by a torque motor—high voltage or high current signals must never be applied, as this will damage the torque motor coils

3. Oil Cleanliness Management

The MCV116 series pilot stage features extremely tight clearances (double-nozzle flapper gaps typically in the micron range) and demands high oil cleanliness. Recommended system cleanliness: ISO 4406 Class 18/16/13 or higher. Install high-precision filters (filtration rating ≤10μm) in the system return line and inspect filter elements regularly.

4. Installation Torque and Sealing

Use a torque wrench to tighten mounting bolts to the values specified in Danfoss technical manuals. Use OEM-specification O-rings for sealing—inspect seal condition prior to installation and replace if worn or damaged. Do not apply excessive sealant, as sealant debris may enter the valve body.

5. System Commissioning and Calibration

After replacing the MCV116 control valve, recalibrate the pump displacement control. Conduct preliminary commissioning at low pressure and low speed to verify that the proportional relationship between control signal and pump displacement output meets expectations. Gradually load to rated conditions while monitoring system response for smooth operation, oscillation, or hysteresis.

6. Periodic Maintenance and Inspection

Perform functional checks every 2,000 operating hours or annually, including: linearity verification between control signal and displacement output, response time testing (≤20 ms), and leakage inspection. Design life is ≥10,000 hours or ≥10,000,000 cycles minimum. If sluggish response, non-linear behavior, or increased leakage is observed, arrange for servicing or replacement.