SKS-W

MAINTENANCE TRAINING
TOPIC 8
 BASIC HYDRAULICS

TOPIC 8

HYDRAULICS

2
 PASCALS LAW

3
 PASCALS LAW

4
 PASCALS LAW

5
 FORCE ?

F=PXA
F
P=F/A
P A
A=F/P

Force ( F ) = # LBS. ( Weight )

Pressure ( P ) = P.S.I. ( Pounds Per Square Inch )
Area ( A ) = 10²” ( Square Inches )
6
 FORCE

F
P A

7
 FORCE

F
P A

8
 RESERVOIR

9
 RESERVOIR

10
 CYLINDER SPEED

60 SECONDS

1. If the cylinder with a 2 foot stroke holds 1 gallon…

2. A 1 gpm pump will cause the piston to move

The 2 feet in one minute, a rate of 2 feet/minute.
11
 CYLINDER SPEED

30 SECONDS

3. If pump delivery to the same cylinder is increased to 2 gpm…

4. The piston will travel the distance in ½ minute,

A rate of 4 feet/minute.

12
 FLUID PATH

FLUID CHOOSES PATH

2. It first chooses “A” because only
OF LEAST RESISTANCE 100psi is required. A pressure gauge
At the pump will read 100psi.

1. The oil can choose 3 paths.

Gauge reads 100psi

A

100psi opens valve A

200psi opens valve B

13 300psi opens valve C

 FLUID PATH
FLUID CHOOSES PATH
OF LEAST RESISTANCE 3. If flow is blocked beyond “A”

A
Gauge reads 200psi
100psi opens valve A

200psi opens valve B

300psi opens valve C

4. Oil will flow thru “B” when pressure

14 At the pump reaches 200psi.
 PRESSURE DROP IS ADDITIVE
1, There is no resistance to flow
here, so…
2. This gauge reads zero.
0psi

A
100psi 3. At this point, flow is resisted
by a spring equivalent to 100psi.

4. Therefore, this gauge reads 100psi.

100psi

B
200psi 5. Here, flow is resisted by a 200psi spring
PLUS a 100psi back-pressure from valve A.

6. The two pressures add

300psi and this gauge reads 300psi.

C 7. With a 300psi back pressure here…

300psi
8. And a 300psi spring here…

9. There is 600psi pressure at the pump.

600psi

15
 FLOW THROUGH AN ORIFICE
2. Is equal to the pressure here…

1. If the pressure here…

A 100psi 100psi
3. There is no flow
here.

5. Causes oil to flow through the orifice.

4. An increase in
pressure here… B 500psi 100psi
6. The pressure drop is 500psi to
100psi or 400psi.

7. Here the pressure drop is only

10psi, so flow is much less.

C 110psi 100psi

D 110psi 110psi
8. If flow is blocked beyond the
orifice, flow ceases.

9. Pressure then equalizes on

both sides of the orifice.
16
 FLUID VELOCITY THROUGH A PIPE
1. This pipe is twice the diameter
of the smaller pipe. 2. It would take four pipes this
size to equal. The cross-sectional
area of the larger pipe.

1”

2”

3. If the velocity through this pipe is

5 feet per second… 4. The same gpm will have to go through this
Pipe 4 times as fast or 20 feet per second.

2” 1”

Even if flow in smaller line remains laminar, frictional

Loss will be 16 times more than it is in the larger one.

17
 FLUID VELOCITY THROUGH A PIPE
X 100

1. Microscopic imperfections of the mating

parts are separated…

2. By a film of fluid…

3. Where clearance between the

parts is caused by dynamic forces
and fluid viscosity.

18
 Circles or Partial Circles
Indicate Pumps, Motors or
Rotary Actuators

19
 Bidirectional Variable
Displacement Motor

20
 B Port

P Port T Port

Closed Centre
Open Port
(Motor Spool)

Open Centre
Closed Port

Detented
Lever Actuated

21
 BASIC SYMBOLS

22
 RESERVOIR
BASIC HYDRAULIC TANK
Tank Inspection
Plate

Tank Return and Case Filters

Tank Breather

Tank Level
Sight Gauge

Tank Baffle

23 Suction Pipe
 BASIC SYMBOLS

RELIEF VALVE SYMBOL

24
 PUMPS
Crescent Gear Pump or Motor or gerotor
Female gear rotor
Male gear rotor
Gear Pump

Case

Gear
Inlet Outlet

Case

Vane Pump or Motor

Inlet Outlet

Gear

FIXED DISPLACEMENT PUMP

25 SYMBOL
 PUMPS

FIXED DISPLACEMENT
PUMP SYMBOL

26
 PUMPS

27
 PUMPS

28
 PUMPS

VARIABLE DISPLACEMENT
PUMP SYMBOL

29
 PUMPS

30
 PUMPS

VARIABLE DISPLACEMENT
PUMP SYMBOL

31
 CLOSED LOOP

32
 HYDRAULIC OIL
The correct viscosity of Hydraulic oil is extremely important in providing optimum
performance for the hydraulic components, and for the protection and longevity of the
components. The viscosity is directly related to the oil temperature. The following graph can
be used when selecting the oil viscosity for your area.
Hydraulic oil selection chart

33
 Hydraulics
Hydraulic System
The hydraulic system consists of a hydraulic reservoir / tank that supplies oil to
hydraulic pumps. These hydraulic pumps provide hydraulic pressure to operate all
machine functions outside of the electrical and compressed air circuits. From the
pumps oil is supplied to the levers and control valves which operate hydraulic
motors or cylinders. Another important feature of hydraulic systems is the filters.
All the oil returning to the tank flows through either the return manifold, the drain
manifold, or the case manifold. Oil returning from the return manifold must pass
through the return filter before entering the tank. Oil returning from the drain and
case manifolds is first teed together before passing through the case return filter.
Both these filters have by-pass check valves in case the filters become blocked.
It is important to remember that the pressure in the return, drain, and case
manifolds is different. The pressure in the return manifold is around 35psi, and in
the drain and case manifolds is only <7psi. This is particularly important when
connecting case drains from motors or pumps. If they are connected to the return
manifold the increased pressure will prevent the case drain from draining, which
will result in too much oil in the case and blowing out the shaft / oil seal.
Hydraulic Tank
Tank capacity - 946Lt

10 micron breather

Manual Tank fill pump

Oil level Sight gauge

 Hydraulics
Hydraulic System Case return filter Main return filters
An important part of the
hydraulic system is the filters.
Oil returned to the hydraulic
reservoir passes through two
10-micron filters. These filters
are mounted on the hydraulic Service
tank. Service indicators will Indicators
“pop up” Red if the filters are
contaminated and the
elements require changing.
See Topic 10 for Scheduling RETURN HYDRAULIC FILTERS
of filter and oil changes. MOUNTED ON HYDRAULIC TANK

Note: before working on any part of the hydraulic circuit, the system
must de depressurised.
Return Filter Assembly
The Lower cover O-ring is very easily
dislodged. The filter will bypass if
assembled without the O-ring.
Differential
It is therefore imperative that the O-ring
valve
is checked every time the filter is
removed.
It is recommended that the O-ring be
replaced every time the filter is
Lower Cover
changed. By-pass check
O-ring
There is a differential valve / service valve
indictors and a by-pass check valve
located within the filter assembly. The
differential valve will indicate when the
filters are starting to block. This will be
activated before the filters are blocked
and oil flows through the by-pass check
valve, by-passing the filters. This provides
a small amount of time to get the filters
changed before they become completely
blocked.
 Pump Drive Assembly

Engine
Auxiliary Pump

Fan Pump

Pump Drive Box

L/H Tram R/Hand Tram

and and
Rotation Pump Feed Pump
 Rexroth - AA4VG Main Pump

AA4VG Function AA4VG Disassembly

 Main Pumps
The two main pumps are AA4VG180EP2 Rexroth variable piston pumps. The
left main pump supplies pressure to the left hand tram circuit and the rotation
circuit. The right main pump supplies pressure to the right hand tram and feed
circuits . The circuits are closed loop circuits.
The integral charge pumps built into the back of each pump discharge through the
Fe ports from which the oil is directed through a charge filter for each pump then
back into the Fa ports to supply charge pressure to the piston pumps. The two
charge circuits are teed together after the charge filter and pressure (450 psi) is
controlled by a common charge relief. G ports are also looped together. Joining
the charge circuit enables one side to assist the other so preventing ‘dips’ in the
charge pressure which can cause cavitation and reduced pump life. The charge
pressure is used as pilot pressure on the servo piston to stroke the pump as well
as boosting the piston pump inlet. The standard integral charge relief in each
pump is replaced by an orificed plug which allows a small amount of charge oil to
flush the pump case but the volume is reduced so pump case pressure is reduced
and shaft seal life is increased.
STANDARD A4VG PUMP
Fe Fa

Charge Relief
replaced by
Plug with
orifice
 AA4VG EP PUMP CIRCUIT DIAGRAM
(standard)

NOTE: SKS models have an external charge relief, not

internal as shown
 X4
Pump Port
X4
Labelling
X3

X3

X4

X4
Connections
A, B High pressure ports 11⁄4" SAE 420 bar (6000 psi–Code 62) G Charge pressure gauge port 7⁄8"-14 UNF-2B; 17 deep
T1 Case drain or filling port 15⁄16"-12 UN-2B; 20 deep Ps Control pressure gauge port 3⁄4"-16 UNF-2B; 15 deep
T2 Case drain port 15⁄16"-12 UN-2B; 20 deep Fa Filter Outlet 15⁄16"-12 UN-2B; 18 deep
MA Gauge port–sys. pressure A 7⁄16"-20 UNF-2B; 12 deep Fa1 Filter Outlet (filter assembly) M33 x 2; 18 deep
MB Gauge port–sys. pressure B 7⁄16"-20 UNF-2B; 12 deep Fe Filter Inlet M33 x 2; 18 deep
R Case vent port 9⁄16"-18 UNF-2B; 13 deep Fs Port from filter to suction line (cold start) M33 x 2; 18 deep
S Charge suction port 17⁄8"-12 UN-2B; 20 deep MH Gauge port–high pressure 7⁄16 "-20 UNF-2B; 12 deep
X1, X2 Stroking pressure ports (before orifice) 9⁄16"-18 UNF-2B; 13 deep
X3, X4 Stroking pressure ports (after orifice) 7/16”- 20 UNF-2B; 12 deep
 AA4VG EP2 Control SKS
180CC
 AA4VG Charge Pump
From Charge
filter

‘Fa’

Plug
To charge
filter
‘Fe’
Charge pump
discharge

‘S’
Suction port
 Charge Pressure Cut Off High pressure
pressure in or Override cross over relief

Pilot oil

Orifice

Standard charge
relief, Removed
and replaced with
an orifice plug to
still allow flushing
High pressure of the Case
cross over relief
 AA4VG EP Pump
Control module
Large control
piston

NOTE: Charge Pump is removed from SKF-12.

Charge Pump is Gear Pump driven by the thru-drive
 AA4VG EP Control
The small shuttle in the control module
is controlled by the electrical
The large control piston proportional solenoids, and in turn
which controls the controls the larger piston
direction of flow within
the pump, this is what is
adjusted during a
mechanical centring
 AA4VG EP Controller
Assembly position
marker EP Hydraulic zero position

Clamping screw

Bleed screw Bleed screw

Unscrew by a
max of 2 turns

The new proportional solenoids must be bled during commissioning. If the air is not removed
from the armature chamber oscillations at the control can occur. On the end of the solenoid,
in the brass component a small set screw M4, 2A/F for bleeding purposes. This can be
unscrewed by a maximum of 2 turns and then after completion of the bleeding tightened to a
maximum of 2 Nm.
 AA4VG EP Controller
Pole tube
Feedback Tightening
Arm torque 19 Nm

Tightening torque 5+1 Nm

26 A/F socket spanner

Clamping screw
Assembly position 6.1 Nm
marker EP Feedback
Spring

Hydraulic
zero point
Eccentric pin

When loosening the clamping screw

Hold the eccentric pin - hydraulic zero point
AA4VG EP Controller
STROKING ORIFICES
0.040” max

The size of these

orifices is is important
because they control
the amount of flow
allowed through the
control piston when
the pump strokes on
and off.
 Main Pump Adjustments
Before the main pumps can be centered or the pressure relief and pressure cut off
settings can be adjusted, a number of things have to be done.
1) Disconnect the tram brake release hose at the tee above the track equalizer
bar. This will fix the brakes on and enable you to perform all main pump
adjustments, and load the pump without the rig moving.
2) If the rig is jacked, the tram lockout over ride must be activated. Therefore the
tram functions will operate enabling you to perform high pressure relief and
pressure cutoff adjustments, in the tram mode.
3) The rotation torque control and feed pressure control needs to be removed from
the pump and the port plugged, this will be in port X3.
4) When mechanically (6) and hydraulically centering (7), solenoid DIN plugs for
the lever controls need to be removed, however when setting the port pressure
reliefs and pressure cut off relief these plugs need to be refitted.
When mechanically or
hydraulically
Mechanical Centering
centering the main
pumps, disconnect both
stroking solenoids and
plug Port X3 (Both
Pumps)
X1
Port X3 X2

Use one gauge, swap

between ports (Pressure
approx. 440 psi)
 Hydraulic Centering

Use one gauge, swap

between ports
(Pressure- approx. 40psi)
***Before setting the high pressure
relief valve***
Pressure cutoff valve
must be adjusted to
maximum, in order to
set main reliefs
 High pressure relief
valve setting Set high pressure reliefs to
5500 psi., do not stroke
pumps on for more than 10
seconds

When stroking the pumps only push the control lever 20% on, just enough to cause
the relief valves to crack, thus preventing all the oil from washing over the relief
valve
Pressure cutoff valve
setting
Set pressure cutoff to
5000psi (must be 500psi.
below main relief setting)
 Charge Circuit
Charge is the pressure that is supplied to the inlet side of a piston pump. The piston pumps
need a positive charge to their inlet or they will cavitate and pump life will be reduced . The
AA4VG180EP2 piston pump has an internal charge pump.
The charge pumps are fixed displacement. Oil comes from the tank in through the charge
pump, and out the Fe port, then goes a charge filter and back into the main piston pump at
port Fa. Both the main pumps are teed together and the charge circuit is regulated with the
one relief valve. This is to ensure there will be a constant pressure supplied to both the main
piston pumps. So if there is a pressure drop in one side, the other side will supply extra to
compensate for it.

2 1
5 Charge Pressure Adjustment
7 1. Install a 600 PSI (41 bar) hydraulic pressure
3
gauge in the test port of relief valve.
2. Bring system up to normal operating
temperature.
6 3. Loosen locknut and adjust pressure to 450
4
PSI (27.6 bar), tighten locknut.

SKS Main Pump Adjustments (L.H. pump shown)

1. Charge Pressure Adjustment 4. High Pressure Adjustment (for. & rev.)
2. Relief Valve Test Port (Install gauge for 5. Pressure Cutoff (POR) Adjustment
Charge Pressure here) 6. Mechanical Zero Adjustment
3. Relief Valve 7. Hydraulic Zero Adjustment
Charge Circuit
 Hydraulic
Charge Filters
These filters are in the ‘charge’
circuit. They filter the oil as it is
supplied to the main pumps. There
are two filters, one mounted either
side of the pumps. The filter inlet
comes from port Fe and the outlet
discharges to port Fa.

These filters play an important role

because this is the only filtration of
oil from the tank to the main
pumps.
The only other filtration on the
main pump circuit is through the
loop filters.

Charge filter
 Charge Filter Assembly
The charge filters have an O-ring that helps seal the filter
bowl. If the bowl is leaking the O-ring is probably
damaged and needs to be replaced. Do not continue to
tighten the bowl up, because this will not stop the leak
and will lead to damage of the bowl and filter assembly.

The O-ring should be changed every time the filter is

changed.

The charge filters have a differential indicator to

indicate when the filter is blocking, and a by-pass check
valve to by-pass oil when the filters are blocked. The
differential indicator will flag red (pop up) before the
filters are blocked, allowing time to change the filters
before they fully block.

See Topic 10 for Scheduling of filter and oil changes.

1. Head Assembly 6. Indicator

2. Bowl 7. O-Ring, Indicator
3. O-Ring, Bowl 8. O-Ring, Indicator
4. Filter Element 9. Bleed Plug
5. O-Ring, Element 10. O-Ring, Bleed Plug
 Loop Filters

Left and right pump, loop filters and

diverter valves
Loop Filter Assembly
The Loop filters are placed on the main
pump circuits. They are between the main
pumps and the diverter valves for the feed
and rotation/tramming circuits. They are
located next to the tower raise cylinder, and
have an O-ring which helps seal the bowl
from leaks. If the bowl is leaking, the O-ring
will need to be replaced. Continued
tightening of the bowl lock-nut will not
prevent the leak and could lead to damage
of the bowl and filter assembly.

The O-ring should be changed every time the filter

is changed

The filters have a differential indicator and a by-

pass check valve, to indicate when the filter is
blocking, and to by-pass oil when the filters are
blocked. The differential indicator will flag red (pop up)
before filters are blocked, allowing a short period to
change the filters before they fully block.

See Topic 10 for Scheduling of filter and oil changes

Loop Filters
 Rotation Circuit
The rotation circuit is a closed loop circuit. It is fed by the left hand main pump.
The rotation circuit oil comes from the B (forward rotation) or A (reverse rotation)
ports on the pump, through the loop filters, through the diverter valve then onto to
the Rotation motors.
 Rotation Circuit SKS
Left Hand Main Pump Basic Operation

LEFT
TRACK

DIVERTER VALVE
IN DRILL MODE
Rotation
Motors
Pump Drive
LEFT
PUMP
 Diverter Valve

Pilot port Connected to Drill

tram solenoid valve. Charge
pressure (450 psi) applied to
this port in the ‘Drill mode’.
Case pressure (7 psi max.) in
the ‘Tram mode’

Drain port
7 psi max.
 Rotation Motor
Case leakage bypass test
The M6 Denison motor is fitted with a flushing valve (hot oil shuttle) which must be
disenabled before case leakage testing can be performed. The shuttle valve assembly must
be removed and the 2 orifices fitted in A & B ports must be removed and replaced with
blanking plugs (3/8" x 1/2" UNF grubscrews). The shuttle can then be refitted. The case
drain hose should be disconnected from the other motor case port and placed into a bucket.
The machine can be started and rotation engaged. It is usually very evident if the motor is
damaged or worn out as the case drain oil volume will be large. Normal case leakage
volume is 2gpm at 3000psi. Over 4gpm indicates a worn out motor. Repeat for the other
motor.

Flushing valve

Case Drain Port

(Front side of Motor)
 Rotation Motor

Orifice
Flushing valve
Rotation Motors
 Right Hand Main Pump
Basic Operation

PULLDOWN
CYLINDER
RIGHT
TRACK

DIVERTER VALVE
IN DRILL MODE

RIGHT
PUMP

Pulldown Mode
 Feed Circuit
The Feed circuit is a closed loop circuit. It is fed by the right hand main pump. It is a basic
closed loop pump to cylinder circuit. The feed circuit oil comes from the A (feed up) and B
(feed down) ports on the pump, through the loop filters, through the diverter valve then on
into the feed cylinder.
A relief valve in the circuit is connected to the Mb port (common to B) which will de-stroke
the pump when its relief pressure is reached. It sends a signal to the X3 port to push the
large control piston back towards centre, therefore de-stroking the pump. The pressure to
the X3 port is limited to 450psi by a pressure relief valve to prevent the pump stroking into
reverse which would cause the feed to creep up.
 Pulldown Pressure Control
Valve
This valve is mounted on the Operators consol is manually adjustable by the operator to
increase or decrease Pulldown pressures. The valve controls pulldown pressure by relieving
pressure from port Mb (Pulldown Pressure) to port X3 to de-stroke the pump.

Damping
Piston Spring
Valve body
Cone
Ball
Control
Knob

Seal Set Screw

Piston
Seat
Spring Damping
O’Ring (5000psi) Sleeve
 Tram Circuit
The tram circuits are closed loop circuits. The R/H tram pump is dedicated to the
R/H track and the L/H tram/ rotation pump powers the L/H track via a diverter
valve. Each final drive has a integral brake pack which is spring applied and
pressure released. The pilot pressure to release the brake is from the drill/tram
select solenoid valve when the tram mode is selected (solenoid de-energized).
This pilot pressure is supplied from the charge circuit and is discharged from the
Drill Tram solenoid to the brake release ports on the final drives.
Tram Circuit
 Final Drive

Case drain Final drive motor

port
Brake
release A&B Ports
port (Forward
and reverse

Motor
mounting
bolts
 Tram Motor

The tram or final drive

motors are a fixed
displacement motor.
They are A2FE125
 Final Drive Assembly

Brake assembly

Case drain port

 Auxiliary Pump

The Auxiliary pump is a double P330 gear pump. This pump supplies all
auxiliary circuits, which are open loop. The front section supplies the SD16 five
spool valve then onto the SD25 four spool jacks valve.
The rear section supplies the SD8 8-section mast valve, power beyond from the
mast valve supplies the SD25 jacks valve to accelerate jacking.
 Auxiliary Functions
There are a number of different functions that are supplied by the auxiliary pump, these are;

Deck Wrench
HOBO Swing Auxiliary
HOBO Clamp/Rotate Pump
Pipe Positioner
Viewing Hatch
Pipe Rack Lock 30 GPM 17 GPM
Pipe Rack Swing
Pipe Rack Rotate
Basic Auxiliary Circuit

SD8-Mast Valve

SD16-Upper SD25-Lower
Valve Valve

Auxiliary Main Air Right Rear Jack

Pump Mast Lock Front Jacks
Water Injection/Dust Collector Left Rear Jack
Mast Elevate Winch
17 GPM 30 GPM Dust Curtain
Auxiliary Circuit
 Auxiliary Circuit
Mast Valve bank (SD8) - 8 Spool
The Mast valve bank is located on the side of the mast. Flow and pressure are supplied by
the rear section of the auxiliary pump.

Adjustment Procedure
Install a 3000 PSI(207 bar) test gauge
in the inlet port or a work port of the Deck Spanner
valve. Start the machine and engage
Hobo Swing
one of the valve functions on the mast
valve to deadhead the pressure.
Hobo Clamp
Correct relief valve pressure is 2250 Rotate
PSI(155 bar). This indicates that the
relief valve is set properly and that the Pipe Positioner
pump will build pressure. To adjust the
relief valve, loosen the jam nut using a Viewing Hatch
13mm wrench. Use a 4mm allen
wrench to adjust relief valve adjusting Carousel Lock
screw. With the pressure deadheaded,
turn the adjusting screw clockwise to Carousel Swing
increase relief pressure, or counter-
clockwise to decrease the pres-sure. Carousel Rotate
Tighten the jam nut while holding the
adjusting screw. Recheck the pressure
setting after the jam nut is tightened, to
be sure 2250 PSI (155bar) is showing
on the gauge.
Mast Valve - 8 Spool
Mast Valve - 8 Spool
Mast Valving
8 Spool
 Mast Valving - 8 Spool
Spools
All eight spools on the mast valve Mast Valve - Motor Spool Diagram (all 8 sections)
are motor spools as shown below:
Mast Valving - 8 Spool
Mast Valving - 8 Spool
H.O.B.O. VALVES

Float valve

Sequence valves
 Rod Handling - HOBO
Setting of Sequence valves for the HOBO
Two people are required for this procedure.
1) Position break out wrench in open or released position.
2) Break out wrench sequence valves are located on dust collector side of mast below
auxiliary valve bank, see previous slide.
3) Loosen and remove cap nut from adjustment screws. Loosen locknut.
4) Screw both adjustments fully in, but not overly firm.
5) Have helper operate break out wrench to undo pipe. Pipe clamp cylinder will operate to
full stroke, but rotate cylinder will not move.
6) Have helper hold valve in ‘ON’ position, adjust screw of the ‘A’ (top) valve slowly outward
until rotate cylinder actuates, adjust screw slightly more so that the cylinder operates
freely. ‘A’ valve is now correctly set. Tighten locknut.
7) Now have helper operate break out to retract, clamp cylinder will release pipe but rotate
cylinder will not move.
8) With helper holding lever to retract, adjust screw on ‘B’ (lower) valve slowly outward until
actuation occurs. Adjust slightly more to achieve free movement.
9) Tighten locknut and install both protection caps.
10) Break out sequencing is now working correctly.

NOTE: this procedure can also be found in Section 7 of the Service Manual.
 Rod Handling components - HOBO

Sequence valves

Adjustment
Screw
Adjustment Screw

To drain
To drain
Rotate cylinder - retract
Rotate cylinder - extend
‘B’ from mast valve
to clamp cylinder - retract ‘B’ Valve
‘A’ from mast valve
to clamp cylinder -
extend ‘A’ Valve
 Pipe positioner
sequence
valves
The positioner is sequenced to
1) swing over onto mast
2) retract inward to centre
pipe. When retreating the
positioner guide will extend
away from the pipe, then
swing outward to park
position.
Auxiliary Circuit Upper and Lower Valves
 Auxiliary Circuit Upper and Lower Valves
There are two control valves that control the auxiliary functions. The upper (SD16)
control valve is a 5 bank valve. Four sections are solenoid operated, and one section
(mast elevate) is hydraulic pilot operated. The upper valve receives oil from the 30 GPM
(114 lpm) gear pump. The power beyond port feeds excess oil to the lower (SD25) 4
bank control valve. The lower 4 bank valve has 3 hydraulic pilot operated sections for the
jack functions, and one solenoid operated section for the service winch. The lower valve
receives oil from the 17GPM (64 lpm) gear pump, and from the power beyond port of the
upper 5 bank valve.
Adjustment Procedure
1. This procedure is best done with two people. With machine running, have a helper in
the cab hold one of the valve functions on the upper (5 bank) valve in the open or closed
position to deadhead the flow. Adjust the relief valve on the upper (5 bank) valve until
pressure on the hydraulic gauge in the cab reads 2750 PSI (190 bar).
2. Repeat this procedure in step 1 for the lower (4 bank) valve. You may have to back out
the relief valve on the lower (4 bank) valve a couple of turns so the pressure will be lower
than 2750 PSI (190 bar). If not, the pressure will relieve at the upper (5 bank) valve
setting. Turn adjustment screw in until pressure on the hydraulic gauge in the cab reads
2750 PSI (190 bar).
 Auxiliary Circuit
5 Spool Valve (SD16)
The auxiliary functions of mast elevate, mast lock, main air, water injection and
dust curtain are all controlled by the 5 spool valve. They are all open loop circuits
which go from the pump, through the auxiliary manifold, and then to the 5 spool
valve. From there the flow goes through which ever control valve has been
actuated (function selected), and on to the appropriate hydraulic cylinder or motor.
From there, flow goes back through the control valve and back to tank via the
return manifold, and the return filters.

Mast Elevate
Mast lock
Main air
Water Injection – Dust Collection
Dust curtain
 Auxiliary Circuit 5-Spool

Control Valve (SD16)

5-Spool
Auxiliary Functions - 5 Spool Valve
Auxiliary Functions - 5 Spool Valve
Water Injection Flow Control

Dust Collector
Circuit

Fan Motor

Flow Control
 Mast Elevating Circuit
The hydraulic circuit of the mast elevating cylinders is protected by three counterbalance
valves. There is one valve at the piston end of each cylinder, as well as, one that is tee'd
into the rod end of both cylinders. The single valve on the rod ends is for controlling the
mast when it breaks over center during setup. This is basically acting as a snubber valve to
prevent the mast from running away when gravity overcomes the pivot support balance.
The two valves on the piston ends are for controlling the descent of the mast when lowering
back to tram position.
 Mast Elevating Circuit
Test and Adjustment
To determine if the valves are functioning correctly, the following procedure should be
utilized:
1.Lower the mast approximately one half of the way down to horizontal. Shut down the
engine. If mast will move with engine shut down, then the valve on either or both piston
ends is leaking by.
2.To adjust the valve, raise the mast back up and lock in position. Loosen the jam nut and
back out (counterclockwise) the adjusting screw in 1/4 turn increments. Tighten the jam nut
and retest. If no difference is noted by the end of one full turn of the adjusting screw, then
the valve must be re-placed. Another indication of a malfunctioning counterbalance valve is
the mast assembly bouncing during the lowering of the assembly. If this is experienced,
then the same adjustment procedure as above applies, except that the adjusting screw
would be turned clockwise in 1/4 turn increments. Again, if no difference is noted by the end
of one full turn, then the valve should be replaced.

Common
Individual cylinder
cylinder C/B valve
C/B valve
Jacks & Mast Raise

MAST
RAISE JACKS

JACK AND MAST RAISE CONTROLS

Mast Raise and Jacks lever assembly
Auxiliary Circuit 4 Spool - Schematic
Leveling Jack Circuit
 Leveling Jack Cylinders
The function of the dual counterbalance valves in the jack circuit is
two-fold:
1.To prevent the machine from drifting down after the jacks are set.
2.To prevent the jacks from drifting down when they are in the
retracted position.
Adjustment
While the valves are preset at the factory, they may be
adjusted if drifting is encountered. Loosen the jam nut and
back out (counterclockwise) the adjusting screw 1/4 turn
increments, not to exceed one full turn. If drifting is still
encountered, the valve must be replaced. Counterbalance Valve

NOTE: If in the above test, the unit does not start lowering, but does so
during normal operations, then the jack cylinder most likely is bypassing or
leaking internally, and further diagnostics and repair or replacement will be
necessary.
 Jack Leg Cylinder
The jack leg cylinder is a “rod entry” design, with the cylinder rod being hollow
and a transfer tube fitted inside the rod to transfer oil to the bottom side of the
cylinder piston (extend). A gallery outside of the transfer tube but still inside the
hollow cylinder rod is ported to the top side of the piston (retract).

Cylinder Piston Transfer Tube Extend

port

Extend oil Retract oil

port port
Retract
port
 Basic Hydraulic Cooler System

AtAt
Operating
Start-up Temperature
“Cold” Thermal
C
Valve
A
B
Bypass Cooler
Check Valve Manifold

Hydraulic Heat Source

Tank
Motors
Cooler Fan Circuit
Cooler Fan Diagram
 Cooler Circuit
Cooler Fan pump.
The fan pump is a Commercial P365 7.2ci gear pump. Pressure is controlled by manifold
housed relief valves mounted on the pump discharge port. Fan speed is set by starting the rig
with the relief backed off, then adjust the relief to set the fan speed, 1400 rpm is usual
setting, (1700 rpm is maximum for a 40” Multi-wing fan). The pump supplies both of the fan
motors with return oil flowing through the hydraulic cooler before returning through the fan
return filter in the hydraulic tank.

Cooler Fan
Pump
 Cooler Fan Motors
Each motor has a manifold mounted wind down check fitted across A and B ports.
This enables fluid from the return side to circulate back through the motor as it
slows down after the rig is shut down so preventing cavitation.

Wind down check

cartridge zero psi
cracking pressure
Hydraulic oil cooler
Coolers
Hydraulic oil flows from the fan pump through the hydraulic fan motors then through a
thermal by-pass valve then straight back to tank via the return filter until 60’C (140 F) is
reached. The thermostat will then shift and redirect oil through the cooler pack before going
back to tank. If the cooler becomes blocked oil will be redirected straight back to tank via the
by-pass check valve. The by-pass check valve like all check valves is a differential check
valve and opens at 45 psi differential between the secondary and primary lines . The
thermostat by-pass is mounted at the side of the cooler pack. When the engine is shut down,
in order to prevent the inertia from the fan draining the motor pressure line and causing the
motor to cavitate, oil is diverted from the cooler discharge (to tank line) back through the
motor via the wind down check valve, therefore ensuring positive charge on the inlet for the
fan motor.
Hydraulic Thermostatic valve Hydraulic cooler - Thermal valve

From
From Cooler
Manifold B C Hot oil
C B Cold oil
By-pass

A
A
To Hydraulic
Tank
Linde
HPV - 02 Closed Loop
Pump Training
PUMPS

HPV – 02 Functional description

Replacing R/R-AA4V125HD/D
 What is 21-Degree Technology?

118
 Motor to pump comparison

119
 HPV-02

• What does HPV-02 mean?

– “H” = H-Series Unit
– “P” = Pump
– “V” = Variable Displacement Operator Controlled

– Pump size = SKF 135cc/rev, SKSW, SKSS 210 cc/rev

• How does it operate?

– Pump remains at zero displacement until the operator feeds an
electric signal to stroke proportionately to maximum displacement
– Pump is used in closed-loop circuits ONLY

120
 HPV-02

121
 HPV-02

122
 HPV-02

123
 Cross-Section of
Pump

124
 Cross-Section of Pump

125
 Cross-Section of Pump

126
 E1P Controller with POR

127
 Cross-Section of
Controller

128
 Cross-Section of
Controller

129
 Cross-Section of
Controller

130
 Cross-Section of Pump

131
 Combination Crossover Relief
Valve/Make-Up Valve

132
 Combination Crossover Relief
Valve/Make-Up Valve

Relieving

Make-Up

133
 Charge Relief Valve

plug
Ma = 10 Nm

valve body (SW 14)

Ma = 30 +5 Nm
nominal pressure marked

spring
spacers
O - ring
Fig. 1

spool
OUT boost pressure relief valve (10) cold start relief valve (8)

IN

This Valve is replaced by

134
a plug with Orifice
 Basic Charge Circuit

135
 POR Curve

Max.
(R/E)
580 - 725 psi less than
"Max" Relief Valve Pressure
Control Pressure

Main Relief Valve

Pressure Curve

Level Set by
Valve III

11% - 12%

(R/B)
0 Max.
(Relief Valve Pressure)
136
System Pressure
 Electro-Hydraulic Control
(with POR)

• CW (Right-Hand) Rotation
• Solenoid “My” = Workport “P”
• Solenoid “Mz” = Workport “S”

137
 Electro-Hydraulic Control
(with POR)

138
 SKSW with LINDE HPV-02
Schematic, Pump only

139
 Control Signal Characteristics

N/A
N/A

N/A N/A

N/A

140
 Displacement relative to Control
Current

Bucyrus Rotary Drill Configuration

141
PUMPS

HPV – 02 Closed Loop

Set up Instructions
 Oil Selection and Viscosity
Recommendations
Suitable hydraulic oils are mineral oil HLP to DIN 51524, biodegradable fluids upon
request, or other pressure fluids upon request

Linde recommends only using hydraulic oils which are confirmed by the producer as
suitable for use in high pressure hydraulic installations. The hydraulic oil chosen
must allow the working viscosity to be within the optimum viscosity range (as
shown below).

Due to pressure and speed influences, the temperature of the leakage fluid is
always higher than the circuit temperature. The temperature must not exceed 194°F
(90°C) in any part of the system.

· Recommended viscosity range for optimum performance: 15 cSt to

30 cSt
· Maximum allowable working viscosity range: 10 cSt to 80 cSt
· Viscosity limitations: 6 cSt minimum viscosity
1000 cSt maximum viscosity (Intermittent for cold starts)
· Oil temperature limitations: (-4)°F to 194°F / (-20) °C to 90°C

143
 Setting Linde HPV-02 Main pumps-
Neutral Setting

1. Warm oil, all hydraulic settings should be set with 50ْc oil
temp
2. Shutdown machine, remove break interlock valve coil (this
will stall final drives).
3. Remove and plug hose from Y1 on pump. Cap Y1.
4. Fit test points to MS, MP, Y & Z ports.
5. Start machine, jack machine so tracks are clear of the
ground, turn to tram mode. Override tram interlock.
6. Test that final drives don’t drive thru breaks. If so stop and
repair breaks.
7. Bring engine up to full speed 2100rpm.
8. Check Hydraulic Neutral Using 0-600psi gauge check MS,
then using the same gauge check MP. If the maximum
difference between the readings is below 29psi (2bar) no •Y1 •Z1
hydraulic neutral is required. IF DIFFERENCE OF MORE
THAN 29PSI (2bar) IS RECORDED HYDRAULIC NEUTRAL •Y •Z
IS REQUIRED.
9. Loosen spanner nut with hammer and punch
10. Using 16mm wrench and digital calipers adjust the hydraulic
Neutral Adjustment 14.75 as illustrated in sketch
11. Repeat step 7 & 8. Continue to make small adjustments to
the Hydraulic Neutral Adjustment until the pressure difference
between MS and MP is less than 29psi
12. Secure the Spanner Nut once settings are final.

IF HYDRAULIC NEUTRAL IS NOT ACHIVEABLE CONTACT

BUCYRUS PRODUCT SUPPORT
144
 Setting Linde HPV-02 Main pumps-
Pressure Settings
1. Warm oil, all hydraulic settings should be set with 50ْc oil
temp
2. Shutdown machine, remove break interlock valve coil (this
will stall final drives).
3. Remove and plug hose from Y1 on pump. Cap Y1.
4. Fit test points to MS,& MP ports.
5. Start machine, jack machine so tracks are clear of the Y1
ground, turn to tram mode. Override tram interlock.
6. Test that final drives don’t drive thru breaks. If so stop and
repair breaks.
7. Loosen Valve III about 2 full turns. Loosen complete
cartridge, do not alter adjustment
8. With motor stalled out against the brake, gradually increase
mA signal to proportional solenoid (gradually move tram lever
for pump) . System pressure will rise proportionally with the
mA signal until it reaches the pressure compensator setting,
at which point it will start to fluctuate (hunt). 0-6000psi gauge
at Mp
9. If the pressure compensator setting is incorrect (should be
5000psi), reduce the mA signal, adjust the pressure
compensator, recheck the setting as per paragraph 8.
10. Repeat 9& 10 swapping Gauge to Ms
11. Once pressure compensator adjustment is completed, screw
Valve III back in all the way
12. Again gradually increase mA signal. The system pressure will
now rise to the cross line relief valve setting.(5550psi)
13. Record pressures on all gauges at each test.

145
 Setting Linde HPV-02 Main pumps
Pre-setup Checks

•ENSURE LINE RELIEFS ARE

SECURE 125ft-lb (170N-m)

•ENSURE BOTH MAX FLOW

10mm ADJUSTMENTS ARE
IDENTICAL AS ILLISTRATED

146
 Adjustment of Drill and
Tram Controllers
•To set the minimum and maximum output for both the drill and tram controllers, remove wire A or B
from the controller terminal. Place multimeter in series between the controller and the coil on the
pump. Turn the ignition on and hold the override switch on. Deflect the lever in the direction that gives
a reading on the multimeter, the Min (100mA) must be set first.
•To set the minimum output (threshold) deflect the lever until the Micro Switch “clicks” on, at this point
set the threshold screw pot to give 100mA. To adjust the maximum output, fully deflect the lever and
turn the screw pot MAX clockwise to increase or anti-clockwise These pumps are Electro-proportional,
the pump strokes on proportionally from 100mA input to 600mA
•to decrease until 600mA is reached. This procedure only needs to be done to one side of each
controller as the output for A and B are always the same. After setting Max re-check the threshold then
re-check Max
•NOTE: Auto pulldown must be switched off. To set tram controllers, tram override will need to
be activated in tram mode. Engine must be off with the ignition on. The ramp adjustment will
delay the action of the pump so the ramp should be adjusted several times anticlockwise to disenable
it on feed and rotation joysticks, and only minimal ramp should be applied to tram. This method should
be repeated for all 4 pump controllers (2xtram, rotation & feed).

147
 Maximum Flow Adjustment

148
 Changing Response Orifices

149
HPR – 02 – AUX - Open Loop
Functional Description
 What is 21-Degree Technology?

151
 Motor to pump comparison

152
 HPR-02
• What does HPR-02 mean?
– “H” = H-Series Unit
– “P” = Pump
– “R” = Variable Displacement System Controlled

• What are my options?

– Pump with load sense and pressure compensator control
– Both controls directly interchangeable with each other – The same
controls are used on ALL pump sizes
– Pump size 55, 75, 105, 135, 105D, 210 cc/rev
– Rotary Machines CW Rotation
– SCH5000 CCW Rotation

• How does it operate?

– Load sense feature instructs pump to only supply the flow
demanded at the pressure demanded; The pressure compensator
limits the maximum pump pressure before it de-strokes fully
– Pump is used in open-loop circuit ONLY
153
 HPR-02 Pump Cross Section

154
 HPR-02 Pump Cross Section

155
 HPR-02 Pump Cross Section

156
 HPR-02 Pump Porting and Adjustment

157
PUMPS

HPR -02
Inner components
 Cross-Section of Single Pump

159
 Cross-Section of Single Pump

160
 Slipper Details

161
 Cross-Section of Single Pump

162
HPR -02
Control function/ schematic
Agenda

1. Overview
1.1 nxonxonxo xnox
1.2 xxx
2. xxxx
3. Summary
 LP Regulator

LS (Load
G Port Sense) Ports

Standby (Load
Sense) Pressure
Adjustment

Pressure
Compensator
Adjustment

X Port
165
 LP Characteristic Curve

166
 Pump Operation

Load Sense &

Pressure
Compensation
Control

167
 “Standby”
Operation

168
 “Standby”
Operation

169
 “Standby”
Operation

170
 “Load Sense”
Operation

171
 “Load Sense”
Operation

172
 “Load Sense”
Operation

173
 “Load Sense”
Operation

174
 “Pressure
Compensation”
Operation

Example A: Stalled
Function

175
 “Pressure
Compensation”
Operation

Example A: Stalled
Function

176
 “Pressure
Compensation”
Operation

Example A: Stalled
Function

177
 “Pressure
Compensation”
Operation

Example A: Stalled
Function

178
 “Pressure
Compensation”
Operation

Example B: Function
Demands Pressure Greater
than Comp. Setting

179
 “Pressure
Compensation”
Operation

Example B: Function
Demands Pressure Greater
than Comp. Setting

180
 “Pressure
Compensation”
Operation

Example B: Function
Demands Pressure Greater
than Comp. Setting

181
PUMPS

HPR -02
Control / Load Sensing
 “Load Sense” Operation

183
 “Load Sense” Operation

184
 “Load Sense” Operation

185
 “Load Sense” Operation

186
PUMPS

HPR -02
Control / Compensation
 “Pressure Compensation”
Operation
188
 “Pressure Compensation”
Operation
189
 “Pressure Compensation”
Operation
190
 “Pressure Compensation”
Operation
191
Agenda

HPR -02
Start-up & Adjustments
 Pump Start-Up Procedure
Oil Selection and Viscosity Recommendations:

Suitable hydraulic oils are mineral oil HLP to DIN 51524, biodegradable fluids upon
request, or other pressure fluids upon request

Linde recommends only using hydraulic oils which are confirmed by the producer as
suitable for use in high pressure hydraulic installations. The hydraulic oil chosen
must allow the working viscosity to be within the optimum viscosity range (as
shown below).

Due to pressure and speed influences, the temperature of the leakage fluid is always
higher than the circuit temperature. The temperature must not exceed 194°F (90°C) in any
part of the system.

· Recommended viscosity range for optimum performance: 15 cSt to

30 cSt
· Maximum allowable working viscosity range: 10 cSt to 80 cSt
· Viscosity limitations: 6 cSt minimum viscosity
1000 cSt maximum viscosity (Intermittent for cold starts)
· Oil temperature limitations: (-4)°F to 194°F / (-20) °C to 90°C

193
 Pump Start-Up Procedure

Guidelines for Using HPR-02 Pumps Without Suction Screens:

Provided that proper contamination control is designed into the system and practice
during operation, a suction screen is NOT required for the application of the HPR-02
pumps. Proper contamination control guidelines are considered to be:

a. Oil cleanliness control and proper flushing during system manufacturing

must be exercised.

b. Assurance that no contaminants are present in the reservoir or lines

upon initial start-up is essential.

c. The HPR-02 must be protected from system contaminants during

operation, either by incorporating return-line filtration or off-line filtration
with return-line screens.

d. Discipline must be exercised during operational maintenance to insure

contaminants are not introduced into the system or pump.

194
 Pump Standby Pressure

“HPR-STANDBY”

195
 LP Regulator

LS (Load
G Port Sense) Ports

Standby (Load
Sense) Pressure
Adjustment

Pressure
Compensator
Adjustment

X Port
196
 Load Sense Adjustment

“HPR-LSDA”

(For Load Sense & Pressure Compensator Control)

197
 Pressure Compensator Adjustment

“HPR-LSDA”

198
 Minimum Displacement Adjustment

“HPR-MIN”

199
 Maximum Displacement Adjustment

“HPR-MAX”

200
 Maximum Displacement Adjustment
“HPR-MAX”

Change in "Maximum"
Pump Size,
Displacement per 1 turn of
(cc/rev)
Adjustment Stud, (cc/rev)

55-02 TBD

75-02 5.1

105-02 6.5

135-02 7.4

201