PRESSURE REGULATING VALVE, RE- LIEF_ VALVE, SAFETY VALVE, ETC. Every bridge has its own loading capacity. If trucks heavier than the loading capacity of bridge should cross it, it will be damaged earlier, giving a danger of its breakage. To prevent such a danger, a sign board as shown at right stood at each edge of bridges in the main roads or in those dense in traffic, thereby limiting the ‘weight of trucks o vehicles capable of crossing a bridge. "There is also a limit on the pressure to be applied to the hydraulic or pneumatic circuit to insure its life and operational safety. For this purpose, pressure regulat- ing valve, relief valve, or safety valve is provided in the circuit. Such a symbol as shown at right indicates a relief valve used in the hydraulic cireuit. a Any of these valves will automatically open to permit the oil or air in the circuit to relieve itself into the exhaust opening, if the pressure in the circuit increases, thereby preventing the pressure from exceeding the set pressure. The set pressure, however, can be changed to an optional value. © A pressure regulating vlave serves to adjust the pressure in the circuit so as not to allow the pressure to exceed the preset value and can be actuated whenever necessary. ¢ A relief valve is actuated only in such an abnormal conditions where the pressure in any part of the circuit increases unexpectedly to an excessively high value and is kept closed in the normal operating conditions of the circuit. © A sefety valve is also actuated only when the pressure in an air tank, etc. increases to an excessively high value. These valves ate identical in fuction with each other, although their names are different depending on their respective applications. That is, they open only when the pressure increases and are called relief valves or escape valves from their same function. Now, let us explain the functional princeple of these valves. Each valve has a spring-loaded movable element (valve) held in contact with its seat when the pressure in the circuit is lower than the thrust of spring (spring tension). The pressure exerted on the opposite side to the spring tends to open the valve, but cannot overcome the Spring tension, making it impossible for the oll (or ait in the cireuit to escape from around the seat. SS Vale Pressure inthe Seat Wrenn Higher presure If the pressure in the circuit increases, the pressure tending to open the valve will overcome the spring tension, pushing the seat to allow the oil or air to escape from around the seat Thus, the pressure in the circuit will be prevenved from increasing further. This valve accomplishes the same fuction on both the oil and air. Hereinafter, the valves will be described as those used in the hydraulic circuit. KOMAZSU— 2s —_ Training Aid @ >sping Amount of ol ex ‘through valve ‘Amount of ow avthe set pressure i z a Set pressure Leeknut POPPET-TYPE VALVE CONSTRUCTION AND FUNCTION A valve remains closed, as long as the pressure in the circuit cannot overcome the spring tension in che valve. In a sketch at left, a hole provided in the valve adjusting screw serves to prevent the oil or air entered the spring chamber from distrubing the valve function of io, lepedtng tad tance so sity sakes, By allowing the oil or air to escape tehrefrom. If the pressure in the circuit increases, the spring tension will be overcome by the oil pressure, allowing the valve to open, which will in turn allow the oil to escape through the ‘opening. So long as the oil does not sufficient! flow out of the valve, the oll pressure will increase continuously. Thus, such an increase in the oil pressure in the circuit will cause the oil pressure being ap- plied to the valve to increase, which will in turn compress the spring so as to enlarge the exhaust opening until the pressure stops increasing, allowing more oil to flow out of the valve. ‘The pressure (the set pressure) at which the Pressure stops increasing is higher than the pressure (valve opening pressure) at which the valve opens, and a difference in pressure is larger as more oil escapes. Accordingly, when the set pressure is spoken of, the amount of oil flowing through the valve must be considered. In che hydraulic circuit, the set pressure is normally meant by the pressure at which all the oil discharged from a pump escapes through the valve. With the equal amount of oil flow, che smaller the valve, the larger the pressure diffe- rential will be. Such a large pressure differential is the disadvantage of this type of valve. ADJUSTMENT OF THE SET PRESSURE If the valve opening pressure is upped by increasing the spring tension in the valve in the closed condition, the set pressure will also be increased. To increase the spring tension, the number of shims used should be reduced to compress the spring. On the contrary, the spri tension should be reduced for the lower set pressure by increasing the shims in number. In case of a valve provided with the adjusting screw fixed by the locknut, the set pressure can be adjusted by loosening the locknut and turn- ing in or out the adjusting screw.TROUBLES AND CORRECTIVE MEASURES WEAK SPRING If the spring is so weak as to give the low deces wxdiaewlia\mcnikia Seems. the wales will open under low pressure, reducing the set oWhen the spring is not. much weak, the set ressure can be restored to a desired degree by increasing the spring tension with less shims. If the valve comes into contact with the adjusting serew with less shims or if the valve does not fully open with the spring in a close contact with che valve, the spring should be replaced with a new one. If the spring is too weak to give a desired set pressure even without shims, the spring should be replaced. ‘ The spring tension may sometimes be increased temporarily by means of a washer, because no replacement spring is available. In such a case, too, the valve opening must not be limited. LOOSENING OF THE ADJUSTING SCREW If the adjusting screw is loosened, the set pressure will be reduced. Re-tightening the screw will restore the set pressure to the correct value. POOR CONTACT OF VALVE WITH SEAT If the valve does not come into a close contact with its seat due to dust jammed between both, scores on the contacting surfaces, the rusted valve, etc., the oil will leak between the contacting surfaces of both. If such an oil leak is so much as to disturb the oil pressure rise to the value required for the circuit, the cylinder, hydraulic motor, etc. will not be actuated in the worst case. Only a slight oil leak usually causes the operating speed to reduce or the cylinder to lower undee bs own weight. Dust should be washed off by flushing. Rust should be removed to smoothen the valve surface. Defective or scored parts should be renewed. UNSATISFACTORY VALVE OPENING If the valve cannot fully open due to its interference with foreign substance or to. the rust, the oil will be unable to escape fully through the valve, resulting in the abnormally high set pressure, which will in turn deterio: rate the valve function of pressure regulation or prevention or relieving of excessively high pres- sure. |__Amount of flow atthe... ‘et pressure sae a yBnone Sudeoe po Jo tunowyExhaust port Piston valve eel) FSreuit co piston VALVE CHATTERING The valve may chatter or squeal in the repeated opening or closing when the oil is flowing out of the valve. The worn seat is one of its causes. Such a mal-conditioned valve should be replaced. PISTON TYPE VALVE EXAMPLE | CONSTRUCTION AND FUNCTION The pressure in the circuit applies to the end of a piston, pushing the piston valve. The pressure too low to overcome the spring thrust is tunable to push the valve. If the pressure in- creases so much a8 to overcome the spring thrust, the piston will push the valve to open the exhaust port, permitting the oil to flow through the port until the pressure rise stops. In this type of vlave, too, the more the oil escapes through the valve, the larger the differ- ence between the valve opening pressure and the set pressure will be. As compared with a poppet valve, the piston vaive has a really wide oil port for its size, making it easy for the oil to flow through and give a small pressure differential. ADJUSTMENT OF THE SET PRESSURE The set pressure can be adjusted by changing the spring tension with the adjusting screw in the same manner as in a poppet valve. TROUBLES AND CORRECTIVE MEASURES THE WEAKENED SPRING or THE LOOSENED ADJUSTING SCREW will cause the set pressure to drop as is the case with a poppet valve. INSUFFICIENT VALVE OPENING will cause the set pressure to increase, disabling the valve to accomplish its function of regulating the pressure or relieving the excessive pressure as is the ease with a poppet valve. LEAKING VALVE Similarly to a poppet valve, the poor contact of valve with its seat in a piston valve results in the mal-function and speed drop of cylinder or hydradtic motor, and’ che cplindar’ lowering under its own weight. CLOGGED OIL PASSAGE INDICATED BY AN ARROW-HEAD If the oil does not flow to the piston due to the clogged passage, the valve will not open. icewe, ths all Hea bacealejcr eer resistance, resulting in the delay in piston movement. Thus, the valve opening or closing cannot correspond to or keep up with the variation in pressure in the circuit.EXAMPLE 2 (PISTON VALVE) The valve to be introduced hereinafter is a combination of two valves of the same type as described in the preceeding example. This valve js actuated whenever the pressure in either the red-colored or the blue-colored circuit reaches the excessively high vale. ‘The abnormally high pressure built up in the red_curcuit will be applied to the piston end Surface. That pressure built up in the Blue circuit will be applied to the stepped area of piston. Thus, the piston valve will be pushed under such an excessively high pressure, communicating the red and blue circuits with each other, which will allow the oil to flow from the high-pressure area to the low-pressure area. The overflowing oil will flow out of the area BEFORE EXPLAINING A PILOT-OPERATED VALVE Look at a sketch at the right. The oil levels in two containers are equal to each other. No oil flow takes place in the pipe connecting both containers, because the pres- sures of an equal value are applied to the oil at both ends of pipe. If the oil levels in these containers vary, the oil will flow from the container with a high level to that with a low level, because both ends are different in the pressure value from each other. The larger the pressure differential, the more the oil will flow. Conversely speaking, where the oil does not flow, the pressure values at both ends are equal to each other. Where the oil is flowing, the pressure at the inlet port is higher than that at the outlet port. ‘The higher the flow rate, the larger the pressure differential will be. The above facts are applied to the main valve to be described below. ©. If the oil does not flow through the balanc- ing port, the valve will not be actuated, because the pressure values on both sides of valve are equal to each other. © Where the oil is flowing, the pressure on the inlet side will be higher and the valve is thrusted on the inlet side. Then, the higher the flow rate, the larger the thrust will be given to the valvePILOT-OPERATED VALVE CONSTRUCTION AND FUNCTION This type of valve has a pilot valve buit in. If this pilot valve opens, a small amount of oil will flow through its opening. By utilizing such a small amount of oil flow is actuated the main valve to let a large amount of oil to escape through the main valve. The pilot valve is one of poppet type valves and its funetion is in the sime manner as previously explained. Where the main valve closes the main port under the thrust of a weak spring, the pilot valve is also under the pressure in the circuit through the balancing port. If the pressure in the circuit is low, the pilot valve will close, blocking the oil flow to the balancing port. Then, che main valve will not be actuated because of the equal pressure values on both sides. If the pressure in the circuit rises so much as to allow the oil to escape through the pilot valve, the oil will flow into the balancing port, giving rise to a difference in the pressure values on both sides of the main valve. If the pressure rise continues to increase the Peer tobigt pi prchicsiagcvaorig ar toes a the flow rate of oil in the balancing port will also increase, which will in turn increase a pressure differential on the main valve. For this reason, the main valve will gradually open the main port until the pressure rise ceases, increas- ing the amount of oil flowing out. This valve has the exactly same funciton only with the pilot valve in a different position, This valve is higher in operating efficiency, because less oil escapes below the set pressure due to a smaller difference between the main port opening pressure and the set pressure. The oil escaping through the pilot valve is trifle. 009d ADJUSTMENT OF THE SET PRESSURE The set pressure can be adjusted by changing connection point 3 L--Amoun of tow a the spring tension with the pilot valve adjusting z:) the set pressure screw in the same manner as in a poppet valve. eS) i TROUBLES AND CORRECTIVE MEASURES 3f : $3] i The higher the flow rate of oll through the F | Flowoutofthe pilot valve |! balancing port, the larger the pressure differen- i 1 { tial (actuating force) on the main valve. The enoeaw a flow rate is determined depending on the Taentintheckeut 9g i amount of oil escaping through the pilot valve. cee The higher the pressure in the circuit, the more $45 the oil will escape through the pilot valve. a4 a2WEAKENED SPRING AND LOOSENED ADJUSTING SCREW IN THE PILOT-OPERAT- ED VALVE Since the pilot vlave opens at a low pressure, the set pressure will also drop. For the repair of such a spring and screw, refer to the paragraphs relating to a poppet valve. LEAKING PILOT VALVE Poor contact of the valve with its seat or its unsatisfactory buildup wll aus che ol leakage, If much oil leaks, the main valve will be actuated, allowing the oil to escape through the port. (For the causes and repair of oil leakage, refer to the poppet valve.) UNSATISFACTORY OPENING OF PILOT VALVE AND CLOGGED OIL PASSAGE In order for the normal amount of oil to flow, the pressure in the circuit must be higher than the normal value because kof the resistance (in the clogged passage) to the oil flow. In consequence, the set pressure must be increased, Unless the normal amount of oil flows, the main valve will not open. (For the causes of unsatisfactory valve opening, refer to the poppet valve.) CLOGGED BALANCING PORT If the port becomes narrower, the main valve will open earlier due to the increased pressure differential and the set pressure will drop. Where the port is fully closed, the main valve will fully open under the pressure for opening the pilot valve buit up in the circuit. Then, the main valve will never close and remain fully opened because of the negative pressure in the balancing cham- ber. WEAKENED SPRING IN THE MAIN VALVE Since the main valve is actuated by the smallest difference between the pressure values on both sides, the set pressure will drop in this case. Such a spring as permitting the valve to move under the small pressure differential must be replaced. MAL-FUNCTIONING MAIN VALVE If the main valve is not actuated due to the jammed dust, the valve will remain fully opened ‘or closed. The valve will open only under the pressure differential over the normal value due to the resistance by the dust, resulting in the increased set pressure.On the contrary, the valve will close only under the pressure differential below the normal value. That is, the valve will begin closing after the pressure in the circuit. is lowered below the set pressure, ‘Amount of oil owing out Pressure in the balancing chamber Circut/oressure Pressure differential increases. Set oresure corey | Tie ressure rises, ——_Ser Pilot valve opening pressure eee oe 4 Totaly cloggedDON'TS IN USE OF VALVES The following are strictly prohibited for the inherent valve performance. © Replacing a spring with the one out of the specification. @ Working a seat to change ies diameter (in a poppet valve) © Giving Soundsem or austen w the sdaon'of x beleceing poet ADJUSTMENT OF THE SET PRESSURE ‘Afcer adjustement of the set pressure, be sure to make sure that the set pressure is, correct by connecting an oil pressure gauge to the circuit. Then, proceed to the operation. of the hydraulic system. In case of vehicles, too, the braking force must be measured adter adjustment ot a brake, Do not increase the set pressure without a justifiable reason. The set pressure is provided for the purpose of operational safety and life of the hydraulic system. If the set Pressure should be inereased wichout a justifiable reason, the valves provided inthe circuit would be in vain, No body operates a vehicle by removing a brake because of its seizure cor burning, The set pressure is measured under the conditions where all the oil discharged from a pump is being exhausted from the valve. In this case, if the cylinder or hydraulic motor is. Operated, the oil will flow to the other part of circuit, resulting in the lower set pressure. Such a pressure is not a true set pressure. For this reason, the oil pressure should be measured with the cylinder kept extended or contracted all the way to prevent the oil from flowing to the other part of circuit. In measuring the lifting force of a shovel loader, the lift arm should be kept raised all the way. In a cylinder where shocking is prevented by allowing the oil to escape with the cylinder at its upward stroke end, the oil pressure should be measured with the outlet port kept blind. ‘At the high oil temperature, the oil viscosity will be reduced, resulting in the lower set pressure. At the lower oil temperature, the set pressure will be increased. The oil pressure measurement should be made within the specified oil temperature range. TROUBLESHOOTING GUIDE Probable cause Symptom ‘Vales of poppet and piston pe Pilocoperted valve Valve remaining aly 7 Valve or piston impossible co move | > Vale imponible ro move (ame opened {due to the jammed dus, seizure, cuneate fing. et) + Mich ofl leaking thru the pilot + Totally clogged circuit tothe piston |” ae “Totaly clogged balancing port Low set presure + Weekened 4 + Weekened spring 1 Leossned aljaningsxew + Loosened ajunig screw + Partly clogged balancing port High et pressure + Not fly opened valve + Not fully opened pilot valve + Partially clogged ercut tothe pllorvalve Valve remaining filly closed | + Valve o piston imposible ro + Valve imposible to move (same none ao eed di, Pees “ seiturey rusting ee = Por valve ightened excessive Valve ightenalexcesvely 1 Reece clogged cece to the pilot ave Unstable set presure (when + Valve subject to large resitance pened the pesure wil Mrmr SEerWhen closed, the Printed in Ja ‘06-84(08)02 <