Service and Maintenance

Sun Counterbalance valves Settings and adjustments

INDEX

Section 1
Introduction

Section 2
Making Adjustments

Section 3
Troubleshooting

SECTION

Introduction

1
Figure 1.1

Counterbalance valves with pilot assist combine two valves; a check valve and a relief valve. The check valve allow free flow from the directional valve (port 2) to the load (port 1) while a direct acting, pilot-assisted relief valve controls flow from port 1 to port 2. Pilot assist at port 3 lowers the effective setting of the relief valve at a rate determined by the pilot ratio.

Rating for valve is stamped on hex section of valve in PSI .

The counterbalance valve will be on of the most difficult valves you will have to set on a piece of equipment. It is difficult to determine the setting of the valve while in the circuit in the usual manner. Because of this, the counterbalance valve has to be bench set off the machine with a special block for this purpose. You will need the following items to set the counterbalance valve: (See Figure 2.1 for set-up) - Pressure gauge that is suitable for the pressure involved. - A Sun Hydraulics P/N BCJ/S body with a T-2A cavity (Test Block). - Misc. hoses and fittings. - Hydraulic hand pump.

SECTION

Making Adjustments
Figure 2.1 5000 psi Test Gauge

Line to Tank or Pail Counterbalance Valve

Line from Hand Pump

Adjusting Screw

Test Block Cap on Port Port not Used

Lock-nut

Before removing the counterbalance valve, ensure machines and loads (i.e.Top Drive) are mechanically held in position or at rest. Also make sure that the valve is not under pressure at the time of removal. Remove the counterbalance valve and install into testing block. Loosen lock-nut on counterbalance valve. Insert an allen key into the adjusting screw and turn out (counter-clockwise) to increase the pressure setting or in (clockwise) to reduce the pressure setting. While looking at gauge, pump up test system pressure with hand pump and set valve to relieve at recommended setting (see Figure 3.2 for location of setting on valve) . Repeat several times to ensure the consistency of the setting.

SECTION

Troubleshooting

The most common cause o f failure of a counterbalance valve cartridge is seal failure or contamination in the hydraulic fluid, which can then lodge in the working parts of the cartridge and interfere with their operation. The major symptom of a failed counterbalance valve is creeping in the cylinder. 1. Before removing the counterbalance valve, ensure machines and loads (i.e.Top Drive) are mechanically held in position or at rest. Also make sure that the valve is not under pressure at the time of removal. 2. Remove the cartridge from its Cavity. 3. Inspect the cartridge for visible contaminates, if found, carefully remove any obvious particles. 4. Flush the cartridge in clean mineral spirits and blow dry with clean dry air. 5. Replace any seals that are worn or damaged. 6. Dip the cartridge in clean hydraulic fluid and re-install the cartridge tightening to the specified torque. 7. If this procedure does not eliminate the operational problem, replace the malfunctioning cartridge with a new, factory tested cartridge.