Cazafallas Relief Valve PDF

EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGIN...
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Producto: EXCAVATOR
Modelo: E200B EXCAVATOR 4SG04715
Configuración: EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGINE
Localización y Solución de Problemas

E200B & EL200B EXCAVATORS HYDRAULIC AND ELECTRONIC SYSTEMS
Número de medio -SENR4527-01 Fecha de publicación -01/01/1991 Fecha de actualización -11/10/2001
Checking Procedures (Hydraulic System)

Checking Procedures (Hyd No.)
(Hyd #1) Hydraulic Oil Supply
Refer to "Operation and Maintenance".
(Hyd #2) Suction filter clean up or return filter replacement
Refer to "Operation and Maintenance"
(Hyd #3) Setting procedure of main relief valve pressure
Refer to the section "Hydraulic System Testing And Adjusting".
(Hyd #4) Main Relief Valve
Main Relief Valve

(1) Spring. (2) Valve body. (3) Pilot spring. (4) Plug. (5) Nut. (6) Main poppet. (7) Pilot poppet. (8) Adjusting screw.
1. Pressure Adjustment
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EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGIN... Page 2 of 20
6V4161 Pressure Kit. 49000 kPa (7100 psi)8T0470 Thermometer Group.
Spanner 17 mm (0.67 in.) for nut (5)Hexagon wrench 6 mm (0.24 in.) for adjusting screw (8)
1. Specification
Relief Setting ... 31400 ± 490 kPa (4600 ± 72 psi)
2. Adjustment Procedure
For adjusting procedure, refer to the section "Relief valves, Adjustment procedure".
3. Possible Problems
Adjustment does not raise the pressure.
a. Spring (1) or (3) is weak or broken.
b. Sliding surface of main poppet (6) is stuck or its seat is damaged.
Or seat of pilot poppet (7) is damaged.
4. Installation/Removal of main relief valve.
Spanner 32 mm (1.26 in.) for valve body (2).
(Hyd #5) Pilot Relief Valve
Pilot Oil Manifold

(35) Pilot relief valve. (36) Tap (pressure gauge).
Pilot Relief Valve

(1) Nut. (2) Set screw. (3) Poppet. (4) Spring.
6V4161 Pressure Gauge Kit.8T0470 Thermometer Group.
Spanner 17 mm (0.67 in.) for nut (1)Hexagon wrench 5 mm (0.2 in.) for set screw (2)
1. Relief Setting Specification
(6KF1-676, 7DF1-1539) 3450 +490 -0 kPa (500 +72 -0 psi)
(6KF677-UP, 7DF1540-UP) 3750 +200 -290 kPa (540 +28 -43 psi)
a. Loosen nut (1) with the spanner. Turn in or out set screw (2) with the hexagon wrench until
adjusted to the specified pressure.
b. After correctly adjusted, tighten nut (1) with the spanner to lock the set screw in place. When
tightening use care to prevent the set screw from turning together with the nut.
3. Possible Problems
a. Spring (4) is weak or broken.
b. Sliding surface of poppet (3) is stuck.
(Hyd #6) Pilot Pressure At Manifold
6V4161 Pressure Gauge Kit.8T0470 Thermometer Group.6V4143 Coupler
Spanner 36 mm (1.4 in.)Spanner 21 mm (0.83 in.)
Pilot Oil Manifold

(17) Pilot relief valve. (18) Tap (pressure gauge).
(6KF1-676, 7DF1-1539) 3450 +490 -0 kPa (500 +72 -0 psi)
(6KF677-UP, 7DF1540-UP) 3750 +200 -290 kPa (540 +28 -43 psi)
2. Measurement
a. Connect pressure gauge to test tap on pilot oil manifold.
b. Measure pilot pressure.
(Hyd #7) Pilot Pressure To Control Valve
(1) Nipple for pressure gauge 6V3966. (2) Tee 2D7325. (3) Coupler for pilot line 8S1506. (4) Coupler for pilot line
8S4600.
Cab Floor From The Bottom

(5) Quick coupler.
(6KF1-676, 7DF1-1539) 3450 +490 -0 kPa (500 +72 -0 psi)
(6KF677-UP, 7DF1540-UP) 3750 +200 -290 kPa (540 +28 -43 psi)
2. Measurement Procedure
a. Connect the Nipple 6V3966, Tee 2D7325, and Coupler 8S1506, 8S4600 to quick coupler (5) of
the pilot line located under the cab floor.
b. Apply pressure by operating the control lever.
c. Measure the pilot pressure.
(Hyd #8) Pilot Control Valve Problem
Pilot Control Valve

(1) Push rod. (2) Spring seat. (3) Metering spring. (4) Spring. (5) Spool.
1. Spring (4) or metering spring (3) is weak or broken. Defective spring causes the valve to
malfunction in half way of its stroke, and not in its full stroke.
2. Sliding surface of spool (5), spring seat (2) or push rod (1) sticks.
The valve becomes closed, open or half open, depending on the position where sticking occurred.
(Hyd #9) Pump Flow
Refer to the section "Pump flow test, Horsepower control Test".
(Hyd #10) Pressure And Flow Adjustment Of Pumps
Refer to the section "Pump flow test, Horsepower control characteristic adjustment".
(Hyd #11) Pump Regulator Problem
Pump Regulator (6KF1-589, 7DF1-1404)

(1) Adjusting screw for high pressure cut-off. (2) Pilot piston. (3) Piston. (4) Adjusting screw for flow and pressure
control. (5) Spring. (6) Sleeve. (7) Spool. (8) Spring. (9) Spring. (10) Adjusting screw for maximum flow. (11)
Adjusting screw for minimum flow.
1. Check for broken or weak springs.
* Spring (5), (8), (9).
2. Check sliding surface for sticking.
* Spool (7), sleeve (6), pilot piston (2), piston (3).
Pump Regulator (6KF590-UP, 7DF1405-UP)

(2) Pilot piston. (3) Piston. (4) Adjusting screw for flow and pressure control. (5) Spring. (6) Sleeve. (7) Spool. (8)
Spring. (9) Spring. (10) Adjusting screw for maximum flow. (11) Adjusting screw for minimum flow.
1. Check for broken or weak springs.
* Spring (5), (8), (9).
2. Check sliding surface for sticking.
* Spool (7), sleeve (6), pilot piston (2), piston (3).
(Hyd #12) Line Relief Pressure Check
Same tools as used for (Hyd #4).
1. Specification (6KF1-676, 7DF1-1539) 33300 ± 980 kPa (4800 ± 140 psi) for both head end and
rod end of boom, stick and bucket cylinders.
(6KF677-UP, 7DF1540-UP) 34300 ± 980 kPa (5000 ± 140 psi) for both head end and rod end of
boom, stick and bucket cylinders.
Refer to the section "Relief valves, Adjustment procedure".
(Hyd #13) Line Relief Valve
Line Relief Valve

(1) Main poppet. (2) Check valve poppet. (3) Valve body. (4) Nut. (5) Piston. (6) Spring. (7) Pilot poppet. (8) Spring. (9)
Adjusting screw.
Same tools as used for (Hyd #4).
1. Specification
Refer to (Hyd #12).
3. Line Relief Valve Problem
a. Spring (6) or (8) is weak or broken.
b. Sliding surface of main poppet (1) sticks or seat of pilot poppet (7) is damaged.
4. Removal and installation of line relief valve.
Spanner 32 mm (1.26 in.) for valve body (3).
(Hyd #14) Cylinder Ring Problem
Sectional View Of The Hydraulic Cylinder

(1) Piston. (2) Seal ring. (3) Slide ring. (4) Slide ring.
Seal ring (2) in the piston center and slide rings (3) and (4) positioned at both sides of the seal ring
(2) are sometimes damaged by the foreign substance contained in the hydraulic oil. The results in
internal leakage. Use repair kit shown in the Parts Book to repair.
(Hyd #15) Control Valve Leakage.
1. Specification
Refer to the following items in the section "Hydraulic System Testing And Adjusting".
a. Cylinder Rod Drift
b. Swing Speed and Drift (on Slope)
Replace control valve assembly or the spool.
(Hyd #16) Swing Motor Relief Pressure Check
Spanner 36 mm (1.4 in.)
1. Specification
New machine ... 23500 ± 980 kPa (3400 ± 140 psi)
Machine after overhaul ... 23500 +980 -1960 kPa (3400 +140 -285 psi)
For service limit ... 23500 +980 -2950 kPa (3400 +140 -425 psi)
2. Measurement
(Hyd #17) Swing Motor Relief Valve
1. Removal and installation
Hexagon wrench 14 mm (0.55 in.)
EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGI... Page 10 of 20
a. Unscrew cap (1) with the hexagon wrench. And whole relief valve can be removed.
b. Refer to the section "Hydraulic System Testing And Adjusting".
3. Relief Valve Problem
Any sticking of sliding surface, or damage of seat in the poppet allows the oil to vent to the return
line.
Swing Motor Relief Valve

(1) Cap.
(Hyd #18) Swing Motor Performance Problem
Same tools as used for (Hyd #4)Spanner 22 mm (0.87 in.)Plug PF 3/8Measuring container
a. Disconnect the drain hose of the swing motor from the block.
b. Put the end of the drain hose into the container for measuring the case drain.
c. Operate the swing lever, keeping the swing frame locked with swing lock pin.
d. Measure the quantity of case drain for a minute.
2. Specification
a. Swing motor relief pressure should be referred to (Hyd #16).
b. Maximum case drain
New machine ... 7 liter/min(1.8 U.S. gpm)
After overhaul ... 10 liter/min(2.6 U.S. gpm)
Service limit ... 15 liter/min(4.0 U.S. gpm)
(Hyd #19) Swing Motor Check Valve
Any sticking of sliding surface, or damage of seat in the check valve allows the oil to vent to the
return line.
Swing Motor
(1) Plug. (2) Spring. (3) Check valve. (4) Relief valve.
* Removal and installation of check valve (3).
Hexagon wrench 14 mm (0.55 in.) for plug (1).
(Hyd #20) Check Of Travel Motor Crossover Relief Pressure
Standard
Machine after overhaul ... 33300 ± 980 kPa (4800 ± 140 psi)
Service limit ... 33300 +980 -2950 kPa (4800 +140 -425 psi)
Measuring procedure
Refer to the section "Hydraulic System Testing And Adjusting".
(Hyd #21) Travel Motor Crossover Relief Valve
Spanner 24 mm (0.94 in.) for lock nut (4).Hexagon wrench 10 mm (0.4 in.) for set screw (5).
Pressure adjusting procedure
* Refer to the item of travel motor crossover relief pressure adjustment in the section "Hydraulic
System Testing And Adjusting".
Travel crossover relief valve trouble Adjustment does not raise the pressure.
Spring (3) is weak or broken.
Sliding surface of poppet (2) sticks or its seat is damaged.
Travel Brake Valve

(1) Counterbalance spool. (2) Poppet. (3) Spring. (4) Lock nut. (5) Set screw.
(Hyd #22) Travel Motor Counterbalance Valve Trouble
Traveling is impossible even though the crossover relief pressure is over the normal range.
Spool (1) of the counterbalance valve sticks.
(Hyd #23) Travel Motor Performance Deteriorated
Spanner 27 mm (1.06 in.)Leading hose for case drainDrain hose plug (931320)O-ring (951586)
Measuring containerTrack stopper
Leading Hose For Case Drain
1. Measuring Procedure
a. Disconnect drain pipe from the drain port (1) of the travel motor.
b. Connect the leading hose.
c. Put the end of leading hose into the measuring container.
d. The disconnected drain hose must be plugged. Use O-ring.
e. Fix the track with stopper. Operate the traveling lever.
f. Measure the quantity of case drain for one minute.
2. Specification
a. Pressure
After overhaul ... 33300 +980 -1960 kPa (4800 +140 -285 psi)
Service limit ... 33300 +980 -2950 kPa (4800 +140 -425 psi)
b. Case drain
New machine ... 15 liter/min.(4.0 U.S. gpm)
After overhaul ... 15 liter/min.(4.0 U.S. gpm)
Service limit ... 20 liter/min.(5.3 U.S. gpm)
Travel Motor
(1) Drain port.
(Hyd #24) Rotary Joint Trouble
Damaged seals (2) at both ends of the rotary joint allows oil to vent to the drain. This causes a loss
of oil to the travel motor.
Rotary Joint
(1) Outside body. (2) Seals. (3) O-ring. (4) Inside body.
(Hyd #25) Disconnection Of The Negative Control Hose
Spanner 19 mm (0.75 in.)Two sets of plugs (931319) for pump bodies and hoses.
Plugs
(Hyd #26) Machine does not travel straight because negative control pressure is
not correct.
Disconnection Procedure
* Disconnect negative control hoses (9) and (8) from N1 inlet of the front pump and N2 inlet of the
rear pump.
* Plug N1 and N2 inlets and ends of the negative control hoses removed from the pump.
Front Pump Negative Control

(N1) Inlet. (9) Hose. Rear Pump Negative Control (N2) Inlet. (8) Hose.
Hydraulic Diagram For Negative Control System (6KF1-589, 7DF1-1404)

(1) Center bypass passage. (2) Check valve. (3) Return line. (4) Check valve. (5) Center bypass passage. (6) Line. (7)
Parallel feeder passage. (8) Hose (rear pump negative control). (9) Hose (front pump negative control).
Hydraulic Diagram For Negative Control System (6KF590-UP, 7DF1405-UP)

(1) Center bypass passage. (2) Check valve. (3) Return line. (4) Check valve. (5) Center bypass passage. (6) Line. (7)
Parallel feeder passage. (8) Hose (rear pump negative control). (9) Hose (front pump negative control).
When the machine travels, negative control pressure is acting on each pump regulator as described
below.
Return oil from left and right travel motors flows into return line (3) at points R1 and R2
respectively. Combined flow returns to the tank through point R3.
Resistance to flow in the circuit past R1 creates higher pressure at R1 than R3. This pressure
difference is 390 kPa (56 psi) when the machine travels on a flat ground.
Pressures at N1' and N2' of the control valve are equal to negative control pressures at N1 and N2 of
the pump regulators. N1' and N2' do not differ from R1 and R3 respectively. Differential pressure that
exists between N1 and N2, therefore, is also 390 kPa (56 psi) approximately.
1. Machine does not travel straight because of missing or incorrect negative control adjusting
shim.
Regulator Section (6KF1-589, 7DF1-1404)

(8) Piston. (9) Shim. (10) Spring (negative control).
Regulator Section (6KF590-UP, 7DF1405-UP)

(8) Piston. (9) Shim. (10) Spring (negative control).
Missing or breakage of the shim (9) reduces compressive force to spring (10). Without the shim,
front pump decreases its flow because of high negative control pressure at N1. The machine
consequently curves to the right the amount front pump has decreased its flow to right travel motor.
2. Machine does not travel straight because of defective check valve (4) or (2).
If sticking occurs or there is a deformed seat in check valve (4) or (2), oil can vent past the check
valve. In such a case, pump oil in parallel feeder passage (7) can reach N1' point from point F1
through check valve (4) and center bypass passage (5). With negative control pressure increased by
the increase of vented flow, the front pump decreases its output flow. The machine then drifts to the
right.
On the other hand, check valve (2), if it is defective, may pass the oil from point F2 of line (6) to N2'
through check valve (2) and center bypass passage (1). This vented flow decreases discharge flow of
rear pump. The machine then drifts to the left in traveling.
Copyright 1993 - 2020 Caterpillar Inc. Fri Mar 20 13:52:34 EST 2020
Todos los derechos reservados.
Red privada para licenciados del SIS.

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EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGIN...

Localización y Solución de Problemas

Checking Procedures (Hydraulic System)

Refer to "Operation and Maintenance".

(Hyd #2) Suction filter clean up or return filter replacement

Refer to "Operation and Maintenance"

(Hyd #3) Setting procedure of main relief valve pressure

Refer to the section "Hydraulic System Testing And Adjusting".

(Hyd #4) Main Relief Valve

Main Relief Valve

6V4161 Pressure Kit. 49000 kPa (7100 psi)8T0470 Thermometer Group.

Relief Setting ... 31400 ± 490 kPa (4600 ± 72 psi)

Adjustment does not raise the pressure.

a. Spring (1) or (3) is weak or broken.

b. Sliding surface of main poppet (6) is stuck or its seat is damaged.

Or seat of pilot poppet (7) is damaged.

4. Installation/Removal of main relief valve.

Spanner 32 mm (1.26 in.) for valve body (2).

(Hyd #5) Pilot Relief Valve

Pilot Oil Manifold

Pilot Relief Valve

6V4161 Pressure Gauge Kit.8T0470 Thermometer Group.

1. Relief Setting Specification

(6KF1-676, 7DF1-1539) 3450 +490 -0 kPa (500 +72 -0 psi)

Adjustment does not raise the pressure.

a. Spring (4) is weak or broken.

b. Sliding surface of poppet (3) is stuck.

(Hyd #6) Pilot Pressure At Manifold

6V4161 Pressure Gauge Kit.8T0470 Thermometer Group.6V4143 Coupler

Spanner 36 mm (1.4 in.)Spanner 21 mm (0.83 in.)

Pilot Oil Manifold

1. Relief Setting Specification

(6KF1-676, 7DF1-1539) 3450 +490 -0 kPa (500 +72 -0 psi)

a. Connect pressure gauge to test tap on pilot oil manifold.

b. Measure pilot pressure.

(Hyd #7) Pilot Pressure To Control Valve

6V4161 Pressure Gauge Kit.8T0470 Thermometer Group.

Cab Floor From The Bottom

1. Relief Setting Specification

(6KF1-676, 7DF1-1539) 3450 +490 -0 kPa (500 +72 -0 psi)

b. Apply pressure by operating the control lever.

c. Measure the pilot pressure.

(Hyd #8) Pilot Control Valve Problem

Pilot Control Valve

(Hyd #9) Pump Flow

Refer to the section "Pump flow test, Horsepower control Test".

(Hyd #10) Pressure And Flow Adjustment Of Pumps

(Hyd #11) Pump Regulator Problem

Pump Regulator (6KF1-589, 7DF1-1404)

1. Check for broken or weak springs.

* Spring (5), (8), (9).

2. Check sliding surface for sticking.

* Spool (7), sleeve (6), pilot piston (2), piston (3).

Pump Regulator (6KF590-UP, 7DF1405-UP)

1. Check for broken or weak springs.

* Spring (5), (8), (9).

2. Check sliding surface for sticking.

* Spool (7), sleeve (6), pilot piston (2), piston (3).

(Hyd #12) Line Relief Pressure Check

Same tools as used for (Hyd #4).

Refer to the section "Relief valves, Adjustment procedure".

(Hyd #13) Line Relief Valve

Line Relief Valve