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Excavator Relief Valve runs the hydraulic motor in your excavator and heads the speed of the hydraulic swing and revolving movement. XuGong KS Excavator Relief Valve comes with multiple mounts. This XuGong KS Excavator Relief Valve also has accurate size, enough to handle your excavator’s pump system. Above any certain pressure, XuGong KS Excavator Relief Valve always ensures the system’s good condition.
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Excavator Relief Valve – The Definitive FAQ Guide
Excavator Relief Valve FAQ Guide is a comprehensive guideline containing answers to the most frequently asked questions about the product. Use this space to identify the product’s features and benefits in a clear, concise format.
This will help you understand how a company’s products make your lives easier or provide solutions that you need. This guide contains information on excavator relief valves, problems associated with relief valves, maintenance requirements, cost, components roles, and much more.
1. How would you define an excavator relief valve?
An excavator relief valve plays an essential role in an excavator. An excavator relief valve is a pressure regulating device installed in the hydraulic system of a mobile hydraulic excavator.
Excavator Relief Valve, also known as Safety Pressure Relief Valve, ensures safe and reliable hydraulic system performance in various construction machinery. The point is to prevent the stored pressure in cylinders from acting outside of permissible pressure when it’s being used.
For example, the safety relief valve could control the hydraulic pressure at high-pressure mode and control hydraulic cylinder movements when working at low-pressure methods. Thus, they protect machine components from damage.
2. How do I know if my excavator relief valve is bad?
You can determine that your excavator relief valve is terrible because of several reasons. These reasons are as follows: It will indicate this by the bearing oil temperature rising when in operation, indicating that it gets worse each time you use the excavator.
The idea is that if you have an excessive temperature rise, there is a problem with your relief valve. The reason for this is that the oil in your hydraulic system has become overheated and is burning up as it circulates through the motor, valves, and relief valve.
This causes an increase in pressure inside the hydraulic tank, which will show up on the gauge as an increase in oil temperature. When you suffer from a lousy relief valve, it may result in strange noises from which you can identify it is time to replace it.
3. What to do if the excavator relief valve is leaking?
The excavator relief valve is one of the essential parts of the hydraulic system. When the relief valve on the excavator leaks, it may be due to a situation where the hydraulic system might be under more tremendous pressure than the setting of the relief valve.
This is most likely to occur if the excavator has been working at a high load or is in continuous use. You may also experience a leak in the relief valve when the tripping mechanism leaks or when there’s a bad seal on the leak-off port connecting the relief valve with the tank.
4. Is it normal for an excavator relief valve to leak?
The excavator relief valve is produced from the highest quality raw materials to ensure each valve meets our high manufacturing standards. The material of the valve seat formation process will cause different seats, and this is normal. The machining accuracy of the machine, resulting in seating pressure loss or seat seal quality problems, is why an excavator relief valve is leaking.
It would be best to determine whether a relief valve is leaking too much or operating at an acceptable level. If the leakage is beyond the acceptable limit and results in loss of power, then it is not normal leakage for your excavator relief valve.
5. What is the maximum allowable excavator relief valve setting?
The maximum allowable excavator relief valve setting is decided by the manufacturer based on
- The raw materials used for its manufacturing,
- The machine’s components,
- Usage conditions of the unit,
- Pressure build-up in your cylinder,
- Flow and other factors related to the safety of the excavator cylinder.
The maximum allowable relief valve setting is the outer limit that the excavator’s hydraulic system pressure can reach full load with relief valves closed. For instance, if you want to make the relief valve setting the pressure to 30 psi, then according to ASME, you need to provide an overpressure with a flexibility of 3 psi. Adding these forces and valve spring force above the fluid kinetic pressure will ultimately keep your relief valve close.
6. How often should excavator relief valves be replaced?
Excavators may not be the most glamorous machinery in the construction industry, but they are an integral part of any modern civil works project. That’s why it’s essential to maintain their components properly, including relief valves. When looking at how often relief valves should be replaced on excavators, it is essential to consider the machine’s operating conditions and age.
If the machine is operating under heavy loads and harsh conditions, it may need to be replaced within 2 to 3 years. If the frequency of usage is not more, the average duration of relief valve replacement lies in the range of 3 to 5 years.
7. What causes an excavator relief valve to fail?
An excavator relief valve can fail due to poor installation, lack of maintenance, or simply just old age. The following components are involved in having a properly functioning excavator relief valve:
- Pressure control valve,
- Pressure gauge,
- Raw materials tank,
- Inlet flow control value,
- Relief value assembly and
- Components including spring, diaphragm, safety sleeve, and spring.
When working with hydraulic systems, it is essential to maintain them properly and add product inserts or other methods to prolong the life of your equipment. Excavator relief valves have a finite life and, over time, will begin to fail when greater than their design operating pressure levels are reached. Due to varying conditions such as load, fluid temperature, and stagnation injury, the valve may begin to leak or fail when operating outside of its range of adjustment.
8. How do excavator relief valves work?
The working of the excavator relief valve demonstrates: The flow will be blocked when the pressure across the relief valve exceeds a particular value. When pressure drops below a specific value, the flow restores its normal working state.
It supplies the pressure control device to limit the maximum pressure that develops in a machine component or piece of equipment. Excessive pressures can damage components, cause leaks, or render operations unsafe.
Relief valves are typically set open at rated maximum pressures of components or equipment by adjusting an external bonnet nut on the valve’s body. When its set pressure is reached, the valve opens, allowing excess pressure to release out from the system.
9. What materials are used in making an excavator relief valve?
Excavator relief valves are made of various materials depending on the purpose of the valve. The material selection is mainly based on the excavator relief valve’s temperature and pressure endurance limits. They may be made with metals such as carbon steel, stainless steel, nickel and copper alloys, or polymers.
However, the most commonly used material is stainless steel because it resists corrosion from chemicals or saltwater and provides better bond markings. If the pressure-temperature rating of the desired excavator relief valve is high enough, then carbon steel can also be used. Excavator relief valves are manufactured using some of the most high-quality raw materials that ensure durability, quality, and safety.
10. Is noise associated with excavator relief valves?
The answer to this question is yes. Not only is the noise created when an excavator relief valve activates, but the type of pressure that the excavator is operating under can add even more noise into the system.
Three main factors determine the noise associated with an excavator relief valve:
- The design of the relief valve,
- The speed at which the valve is opened,
- The pressure differential across the valve.
In most cases, the noise generated by excavator relief valves is associated with factors such as overfill or blockage. Especially in modern excavator relief valves, even though it is rare, they are available in various materials like ceramics and steel.
11. What is the cost associated with excavator relief valves?
The excavator relief valve has a price that varies depending on multiple factors that you must take into account. These factors include the valve bearing pressure and temperature, the manufacturing material used in construction, specifications, and any warranty associated.
The cost of the excavator relief valve made up of stainless steel and equipped with a warranty of three months lies in the range of $38 to $48.80 per piece. The price of the excavator relief valve made up of high-quality alloy steel with all essential components lies in the range of $20 to $50 per piece. As you may know, without a single doubt, the greater the quality and associated features more significant will be the price associated with this component.
12. What type of oil goes into the excavator relief valves?
The oil used in excavator relief valves has to be formulated to meet the heat and pressure requirements of the valve. The pressure and temperature are very high, which means that ordinary machine oil isn’t suitable for this application. Excavator relief valves use mineral-based oil.
The oil that goes into the excavator relief valve varies depending on the size of the excavator and the model of your excavator. Some can handle 10W-40, 20W-50, 40, or 60 lubricants. Each type of oil has a different job to do. Raw materials include hydraulic oil, synthetic oils, petrolatum or paraffin, as well as unique products for excavator relief valve components.
13. What are the problems associated with excavator relief valves?
The problems associated with excavator relief valves are a high risk of having system blowout, valve failure, and high-pressure stress on the machine. The main problem is high relief flow, which can cause downstream components and equipment to be overcharged. This leads to premature wear on the components and unnecessary power consumption.
The relief valve’s adjustment screw is easily contaminated from sand and other impurities in the hydraulic fluid, causing high flow. Another problem is that since excavator hydraulic systems have many relief valves, determining which relief valve caused the abnormal flow often requires considerable time and effort.
Excavator relief valves may be leaky, unreliable, and way overpriced. Using cheap material components that fail in under a year, those excavator relief valves use outdated technologies.
14. What characteristics are embedded in excavator relief valves oil?
If you’ve ever wondered about the characteristics of oil for excavator relief valves, here’s an inside look. Many design elements have been incorporated into the creation of relief valves oil. Here are several examples:
- Hydraulic fluid is typically used to cushion the valve’s internal components from high pressure and temperature as the machine operates.
- It is embedded with high film strength to prevent corrosion and abrasion on relief valves.
- It is associated with optimum viscosity level to ensure damage from wear and tear.
- It acts as a cooling agent for your excavator relief valve and prevents rising temperature beyond a specific limit.
15. What are the maintenance requirements of the excavator relief valves?
The requirements for the maintenance of the excavator’s relief valves mainly include: First, the vent tube must be kept lubricated. This is to keep the oil in good working order. If this is not done frequently enough, sediment can accumulate inside, and it will rust and cause leakage. Furthermore, if there is too much water around, it can damage other equipment such as seals and seats. So, it is recommended to remove excess water.
The values of the relief valves should be adjusted according to the operation status of the excavator. During a significant change in the flow rate of the working fluid, the pressure in the hydraulic components needs to be adjusted accordingly. However, improper use or maintenance of an excavator relief valve can lead to a costly accident.
16. What is the role of spring in excavator relief valves?
Excavator Relief Valve is that if the spring is good, it can guarantee the regular operation of the relief valve. The spring in the excavator relief valve exerts a certain amount of counterpressure to the hydraulic pressure in the cylinder. Any unintended heavy load would not make the excavator unable to perform the intended function.
This spring also exerts a certain pressure on the movable part of the valve to make it close tightly when the working medium flows out from the cylinder and pushes against this movable part.
The Spring in Excavator Relief Valve prevents over-pressure by allowing excess hammering energy to be absorbed during impact loadings and absorbing shock loads caused by control actuators (governors).
17. What is the role of the lift head in excavator relief valves?
The lift head is a moveable cone-shaped structure in the center of the valve that helps break up and divert the flow of liquid or gas in a relief valve. The primary role of a lift head in excavator relief valves is to open or close the valve to release pressurized fluid. The lift head is made from a material that is chemically resistant to both high and low temperatures.
The lift head should be connected to the pressure reducing or relieving source (the cylinder, tank, or block), and it is capable of breaking flow down into smaller pieces. The distance between the bottom of the lift head and the top of the seal determines how big these pieces are.
18. How to install an excavator relief valve?
To install an excavator relief valve, you must need the fitting tool kit at hand to do. The relief valve is installed in the upper housing of the cylinder or engine casing. A place for its mounting is located at the top. You need to mount it with a clamp in its place with the help of a screw bolt.
After installing it in its place, make sure to test if it is operating or functioning appropriately. You can judge according to the following methods for whether excavator cylinder relief valve installation requirements:
- Check the adapter and valve are correctly connected.
- Check the two ends of the hose size clearance.
- Open the relief valve handle, relays slowly to see if smooth operation.
- Close the relief valve handle. The pressure difference between sides should be more significant than 0.3Mpa.
- Open the corresponding valves and check if there is no fluid leakage way out of the hydraulic pressure oil tank.
19. What is the role of the O ring in the excavator relief valve?
O ring in excavator relief valve is the component that connects other hydraulic members and plays a bridge role. It is a mechanical seal of the excavator relief valve, so it has high requirements for its material and geometry to ensure sealing performance. However, what kind of requirements the O ring in the excavator relief valve must meet depends on the type of material it is made.
The most common reasons for the premature failure of pressure-control valves are spring backlash-induced cracks and the deterioration of O rings that help hold the spring. In this respect, the O ring plays a vital role in the excavator relief valve, and its quality can ensure the regular operation of the excavator relief valve.
20. What is the role of the sensing element in excavator relief valves?
The sensing element is fundamental to the relief valve. It detects the pressure in a container or reservoir and causes the relief valve to open when it reaches a pre-set, maximum force. The sensing element is an essential component in the pressure control valve and is used to detect flow status. If you want to sense the open or close status of the relief valve, you should use a voltage-divider pressure sensor with clamp-on mounting.
Then the sensing element should be mounted on the final port of the relief valve. This installation can effectively ensure accurate position sensing for different valves, eliminating nonlinearity and hysteresis under a wide range of temperatures.
21. What is the manufacturing process of the excavator relief valve?
The process of manufacturing the excavator relief valve consists of the following steps:
- Cavity Welding
- Heat Treatment
- Temper Heat Strength Tests
- Measurement Flow Rate Test
- Check Valve Test
- Pressure Test
- Vibration Test
- Wear Resistance
- Corrosion Resistance
- Oil Erosion Resistance
- Product Quality Inspection
A quality relief valve is manufactured from the above-listed steps. After following each step, you will get a relief valve that will last longer and improve the effectiveness and efficiency of your excavator.
22. What are the things to consider before choosing an excavator relief valve?
Before choosing an excavator relief valve, you need to know that:
- Use the right brand,
- Pay attention to the specifications,
- Choose a new valve and not a used one.
Select a relief valve with suitable material, size, and pressure specifications based on the needs. The standard setting for an excavator relief valve is 100 bars. You need to check your excavator before buying a relief valve to ensure it matches the current system’s tank, block, and set requirements.
It would be best if you considered what it needs to do. The most important thing to figure out is the type of gas that will be used. A fuel type is required for reliable performance under pressure. The kind of gas and what it must be able to do are critical areas of consideration.
If the excavator relief valve is in a cold area, you need to check whether it can handle low temperatures or generate issues like icing. It is also essential to consider the high pressure exerted by the excavator relief valve and its ability to resist leakages.
23. Why does my pressure relief valve keep opening?
The pressure relief valve keeps opening again and again because the rubber diaphragm inside it has been damaged, and its function is not normal. Once the rubber diaphragm has been damaged, there may be a leak anywhere in the system, no matter how the power of the hydraulic pump increases. The pressure in the hydraulic cylinder will never exceed above the optimum point in pounds per square inch (psi).
The opened relief valve results in power loss and cannot perform its intended function for your excavator. This leads to the flow will always be high because there is a leak in the system. If you have such problems, you can replace your relief valve with another one.