Chapter 1: General Information

Service Training Manual CM 765/785

DEFINITION OF SYMBOLS

Hydraulic Symbols Definition

Working line: Any line used to carry

working fluid. This includes suction lines,
pressure lines, and cylinder or motor
connections and return lines.

Pilot line: Pressure used internally or

externally to control valve operation. The
dashed line is used to differentiate pilot
lines from others on a schematic.

Drain line: Drain lines are always

connected to the reservoir and are used for
pump or motor case lines as well as a case
drain connection for certain types of
valves. Drain line pressure should typically
be less than 5 psi (0.34 bar) and be
subjected to minimal spiking of the
pressure.

Enclosure lines: This line will be used on

a schematic around more than one
component symbol. This indicates that all
of the items enclosed on the schematic are
located in a single component on the
machine.

Squares: Squares or combinations of

squares indicate valves.

Circles: Circles indicate pumps, gauges,

or rotary actuators.

Arrows: Arrows indicate variability,

adjustability, or direction of flow.

Spring (An arrow through the spring

indicates an adjustment point.)

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Hydraulic Symbols Definition

Check valve: A valve that allows free flow

in one direction but blocks flow in the
other. They can be equipped with a spring-
loaded poppet that increases the cracking
(opening) pressure of the valve. Some
check valves are pilot operated that means
they can be opened with pilot pressure to
allow reverse flow.

Spring Loaded Check Valve

Gas Charged Accumulator

Diamond: The diamond shape indicates

fluid conditioners.

Relief valve: Relief valves are used to limit

maximum pressure to protect a circuit.
They may be pilot circuit relief valves or full
flow system relief valves. Relief valves
may be direct acting (spring over a poppet
or spool) or pilot operated style (2-stage
type). Pilot operated relief valves are more
stable with high flows or where flows may
vary greatly. The downstream side of any
relief valve must be connected to low
pressure or to the reservoir.

Pressure reducing valve: A valve that

limits pressure at its outlet regardless of
the inlet pressure. Frequently used to
reduce system pressure to a lower PSI to
perform a specific function.

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Hydraulic Symbols Definition

Pressure reducing/relieving valve

Sequence valve: A pressure operated

valve similar to a relief valve, which at its
setting, directs flow to a secondary line
while holding a predetermined minimum
pressure in the primary line. Used in
circuits that use a single directional valve
to operate two functions in sequence.

Directional control valve

Three position four way valves
1. Open Center Closed Port
2. Open Center Open Port
3. Open Center Closed Port
4. Open Center Open Port
5. Closed Center Closed Port
6. Closed Center Open Port

Flow control valve, pressure and

temperature compensated, restrictive
type: A valve that is used to control the
fluid flow through a circuit. The pressure
and temperature compensated designation
mean that the regulated flow rate passed
by the valve will remain constant
regardless of system pressure and fluid
temperature. A restrictive type valve is
used with a variable pump system because
the pump can match its output to the flow
requirements determined by the flow
control valve.
1. Pressure and temperature
compensated
2. Restrictive type flow control with
return check valve

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Hydraulic Symbols Definition

Flow control valve, pressure and

temperature compensated, bypass
type: This valve is also used to control
flow through a circuit. The bypass type
valve is normally used with a fixed
displacement hydraulic pump. Excess flow
is bypassed to the reservoir by the valve.
1. Pressure and temperature
compensated
2. Bypass type flow control with return
check valve

Orifice or restriction: An orifice is a

restriction used for controlling flow (speed).
It can be of fixed size or variable (such as
a needle valve). They are the simplest
forms of flow control device.
1. Fixed
2. Variable

Shuttle valve: A valve used to allow the

higher of two pressure sources to use
downstream to perform a function. An
example could be a hydraulic released
traction brake system. The pressure
developed on the pressure side of the
circuit is used to release the brake via the
shuttle valve.

Cooler or heat exchanger: The diamond

shape with arrows pointing outward
indicates a cooler or heat exchanger. The
symbol can represent a cooler that uses
either air or water as the cooling medium.

Filters: A diamond shape indicates a fluid

conditioning device; the dotted line through
the diamond identifies the device as a
filter. The bypass is shown as either a
spring loaded check valve or a relief valve
around the filter. Not all filters are equipped
with a bypass. (The filter symbol shown
has a bypass.)

Manual Shutoff Valve

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Hydraulic Symbols Definition

Double acting cylinder

Pressure gauge

Temperature gauge

Pressure switch

Vented reservoir

Line to reservoir above fluid level

Pressurized reservoir

Line to reservoir below fluid line

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Hydraulic Symbols Definition

Pumps Pumps and motors: The flow arrow
pointing outward identifies pumps. An
arrow drawn through the circle at an angle
indicates the pump or motor is variable. If
the flow arrow points inward, the
component is a motor.

Pumps:
1. Fixed displacement unidirectional
(gear or vane)
2. Variable displacement
unidirectional piston pump —
pressure and flow compensated
(load sensing)
3. Variable displacement bidirectional
piston pump (hydra static pump)

Motors:
1. Fixed displacement unidirectional
(gear or vane)
Motors 2. Fixed displacement bidirectional
(gear, vane, or piston)
3. Variable displacement bidirectional
(piston)

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Hydraulic Symbols Definition

Lever

Pilot operator

Solenoid operator

Spring

Cam or roller operator

Valve detents (hash mark indicates

neutral)

Dual pilot operated check valve: Used as a load holding device normally with a
hydraulic cylinder. Uses two pilot operated check valves in the same valve housing. Pilot
pressure from the inlet side of the valve is used to open the outlet check valve.

Counterbalance valve: Also a load holding device but a more sophisticated valve than a
pilot operated check valve. Commonly used in a dual configuration so pressure at the
inlet of the valve opens the outlet. When lowering a load using a dual counterbalance
valve, the load cannot free fall. If load attempts to lower faster than the supply of
incoming fluid, the pressure at the inlet of the valve will drop, and the outlet of the valve
will begin to close. This creates hydraulic backpressure and slows the descent of the
load. Counterbalance valves also can function as a relief valve. If the load is great
enough, the valve will open and relieve the excessive pressure.

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DUAL COUNTERBALANCE VALVE

Dual counterbalance (CB) valves are commonly used in load holding or load controlling
applications. They are rated by psi and pilot ratio. Examples might be 3000 psi/10:1
pilot ratio, 5000 psi/3:1 ratio. They are available in many different variations. The
pressure rating of a CB valve is the pressure that the valve will open when subjected to
direct pressure. For example; if an external load is applied to a hydraulic cylinder and
causes the pressure in the cylinder to increase beyond the pressure rating of the CB
valve, the valve will function as a relief valve and relieve the excess pressure to the
return line. For this relief function to work, it is necessary that the valve contain a motor
spool that connects the two working ports to the return line when the valve spool is in
neutral. The pilot ratio determines the pilot pressure required to open the valve.

There is a simple formula for determining pilot pressure:

Pilot pressure = Relief Setting - Load Pressure ÷ Pilot Ratio

If the values are inserted, the formula looks like this:

Pilot Pressure = 3000 psi - 0 psi (no load) ÷ 10 (pilot ratio)

300 = 3000
10

By making this simple calculation, we can determine that 300 psi is the pilot pressure
required to open the valve. In a dual CB valve, the pressure on the inlet side of the valve
is used to pilot the outlet open.

In a tram circuit, for example, the sequence of events to tram the machine occur as
follows:

1. The tram valve lever is moved from the neutral position.

2. The open valve allows fluid to move toward the CB valve and the tram motor.

3. At the same time the pressure created by fluid moving toward the load is
diverted to the load sensing porting in the valve.

4. Pressure begins to build in the load sensing line. This line is connected to the
load sensing connection on the main pump. The pressure signals the main
pump to come "ON STROKE". As the pump comes on stroke, more fluid is
delivered by the pump to the tram valve.

5. At the CB valve, fluid moves through the free flow check valve and toward the
motor. The motor is a positive displacement device, which means that fluid
entering will cause the motor to attempt to rotate. As the motor tries to rotate,
any fluid already in the motor must be expelled, and it must pass through the
counterbalance valve. The outlet side of the CB valve will be closed initially
and must be piloted open by pressure from the inlet side of the circuit.

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In the example used above, the 3000 psi ÷ 10:1 (the pilot ratio), the pressure at the inlet
side of the circuit must be 300 psi to pilot open the outlet. This means if the motor
attempts to rotate faster (as in tramming downhill) than the oil supply coming in at the
inlet side of the CB valve, the pressure will drop. As the pressure drops toward 300 psi,
the outlet side of the valve will begin to close and create a hydraulic restriction against
the motor slowing it down and controlling its speed. This action prevents an overrunning
load condition so the machine can safely tram down hills. In a hydraulic cylinder circuit,
the action described above will prevent free fall of the load as the directional valve is
opened.

In the tram motor circuit, a spring set/hydraulically released static brake is used. The
counterbalance valve is equipped with a shuttle valve that directs pressure from the
working side of the circuit to release the brake. Usually the pressure required to release
the brake is lower than the opening pressure of the CB valve allowing the brake to fully
release before the machine is allowed to move.

To Review

The counterbalance valve has three major functions:

1. It provides load-holding capabilities when the cylinder or motor is in a static

condition.

2. The valve protects the machine from overrunning load conditions and prevents
free fall of hydraulic cylinders or downhill runaway of a machine.

3. The valve also provides for a specified minimum pressure so that external
devices, such as a holding brake, can be released prior to movement of the load.

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1 Equipped with shuttle valve for brake release

All counterbalance valves will have a specified pilot ratio. This determines the pilot pressure
2
required to open the outlet port of the valve.

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OPEN CENTER FIXED FLOW HYDRAULIC SYSTEM

This type of circuit is used with a fixed displacement pump providing the flow. Pump flow
can only be varied by changing the speed of the prime mover. The fixed pump may be
any type of pump (gear, vane, or piston). The directional valves used with a fixed pump
are referred to as open center valves. This means that in the neutral position, the pump
flow is directed back to the tank or to another valve down stream of the first. When a
valve is shifted to activate a function, fluid is directed by the valve to that function.
Depending on the type of spool in the valve, partial flow or full flow is directed to the
function. Circuits using a fixed pump must have a relief valve to protect the circuit from
overpressure. A typical circuit is shown below:

1 Fixed displacement pump

2 The pump could be a gear, vane, or piston type pump
3 Relief valve
4 Actuators
5 Open center valves

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PRESSURE COMPENSATED PUMP CIRCUIT

Another type of pump circuit that is commonly used is the closed center system using a
variable displacement pump. This circuit will normally use closed center type valves.
These valves block pump flow when the valve is in the neutral position. In a circuit of this
kind, the pump will be “off stroke” (swash plate is in the near vertical position relative to
the pump shaft) in this situation. When the valve is shifted to direct flow to a function (we
will use a hydraulic cylinder in this case), the pump will go “on stroke” to deliver flow to
the desired function. It is important to understand that the only control of the pump
swash plate is maintained by the pressure control (compensator) of the pump. This
means that the output of the pump is controlled by outlet pressure. For example, if the
activated valve is held in the shifted position (i.e., deadheading fluid to the cylinder),
pressure will build until it reaches the setting of the compensator. When this occurs, the
compensator (which controls the swash plate) will cause the swash plate to return to its
near vertical position stopping flow but holding pressure on the outlet line. This means
that the pump outlet will always be at the maximum compensator setting when the
system requires no fluid flow.

1 Fixed displacement pump

2 The pump could be a gear, vane, or piston type pump
3 Relief valve
4 Actuators
5 Open center valves

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LOAD SENSING

The CM series crawler drills are equipped with load sensing hydraulic systems. Load
sensing requires piston pumps that incorporate a dual control system. Dual control
means that the pump can be regulated by either maximum pressure or by load
generated pressure. The pumps used are variable displacement axial piston units. Load
sensing is one of the more efficient means of controlling a hydraulic system. This is
because when no fluid is required to operate a machine function, the pump pressure
drops to the standby mode. The standby pressure will vary with different units. When the
machine is in an operational mode (e.g., drilling), the pump is required to operate at only
the highest pressure required plus the standby pressure

In the load sensing system, valves are used that are proportional. This means that for
any given handle position, there is a corresponding flow rate. The drifter and feed
circuits are equipped with controls that also regulate or limit pressure. All of the valves
on the machine are closed center; this means that when a valve is in the neutral
position, pump flow is blocked. Internally in each individual valve section, there is
porting, which directs load pressure (i.e., actual pressure created by the load) toward the
load sensing port on the pump control. This is frequently referred to as the signal
pressure. The internal signal of each valve section is directed through a series of shuttle
valves so that only the highest signal pressure reaches the pump load sense control.

With the unit running but no hydraulic functions being operated, the pressure present at
the outlet of the pump will be standby pressure. It is also important to know that pressure
on the load sensing line will be 0 psi (0 bar). This is because when the valves are in
neutral, the internal load sensing circuitry is connected to the return or tank side of the
circuit. We will use the rotation circuit to demonstrate circuit operation. If we mentally
slow down the system function for this exercise, it will help to understand the operation
of the circuit. First, the valve lever for the rotation function is operated. This opens a flow
path through the valve toward the rotation motor. When this flow path opens, the first
thing that happens is that the standby pressure being maintained in the high-pressure
side of the circuit begins to drop. The load sensing control on the pump constantly
compares the actual discharge pressure with the pressure signal being received at the
load sensing port. With all valves in neutral, the load sensing line shows 0 psi (0 bar) so
the control only allows the pump to build to standby. The load sense control can be
described as a variable compensator. As stated previously, when the valve is moved,
the load sensing control recognizes that the outlet pressure is starting to drop. The
control responds by causing the pump swash plate to come on stroke (move the swash
plate to an angle so fluid is being moved). At this time fluid moving toward to rotation
motor will begin to generate some pressure. This pressure generates a pressure signal
in the load sense signal line. As long as the pressure differential is less than standby, the
pump control will continue to increase flow until a psi differential equal to the standby
pressure is reached between the pump discharge and the load sense signal port. For
example, let us assume that the rotation valve is limited to 10 gallons per minute; as
soon as the flow reaches 10 GPM, no additional flow is delivered by the pump because
the pressure differential between the pump outlet and the load is equal to the standby
pressure. If the bit were to stall (become jammed), the pressure would began to climb. If
this increase in pressure was allowed to continue unchecked, something would break.
Because the pump is dual controlled, the pressure compensator will override the load
sensing and limit system pressure to the maximum allowed, which is the maximum

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pressure setting of the pump. Each individual circuit works the same as described
above. The feed and drifter circuits have the additional feature of built-in pressure
control. This limits the pressure of these circuits to less than maximum pump pressure.

Load Sensing and Compensator Pump Control

1 Standby Compensator
2 Pressure Compensator

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Simplified Load Sense Circuit

1 Dual Control Pump (Pressure Compensated and Load Sensing)
2 Shuttle Valve

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Load Sensing
1 Stroking Servo
2 Destroke Servo
3 Supply to Values
4 Rotation
5 Feed

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MP 18 and MP 22 DIRECTIONAL VALVES

These valves are load-sensing pressure compensated proportional valves. They control
the volume, direction of flow, and maintain a constant flow regardless of changing load
conditions. A valve may also have a feature that allows the pressure within its circuit to
be limited to less than maximum pump pressure. Individual valves within the system may
have different maximum flow rates. This is determined by the design of the directional
spools as well as the style of compensator spool provided. Different compensator spring
rates also affect maximum flow.

Each valve section contains a compensator spool and spring, a primary shuttle valve,
and a secondary shuttle valve as well as the directional spool. These valves may be
manually controlled, electrically controlled, or pilot controlled. The valves used for the
ECM 720 are pilot controlled. The compensator spool in each valve section regulates the
flow. With the main spool in neutral, both the primary and secondary shuttle valves are
vented to the return or tank. At the same time, standby pressure from the pump is
directed to the bottom of the compensating spool and shifts the spool to the closed
position. When the main directional valve spool is operated, the pressure generated by
the load is directed via the primary shuttle to the spring end of the pressure-
compensating spool. The compensating spool begins to move to the open position.
Dependent on the pressure drop between the section compensator and directional spool
opening, a specific volume now flows to the function being metered by the compensator
spool. The load signal also simultaneously communicates to the secondary shuttle and
on to the load-sensing valve on the pump causing the pump to come on stroke to deliver
the flow required to satisfy the directional spool opening. Shifting the directional spool
open to different positions creates an orifice of different size requiring more or less flow
from the pump.

The pressure limiting feature of the valve is used to control hammer pressure, feed
pressure, and rotation pressure during rod changing. The valve compensator section
can be used as a pressure-limiting device when connected to a pilot relief valve. This
allows an individual valve section to operate at a limited pressure level less than the
main pump compensator. In the case of the feed circuit the pressure is limited by the
feed pressure control in the cab. A remote pilot relief valve controls the hammer
pressure.

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1 Port “B” Pressure Connection

2 Port “B” Drifter Return
3 Port “A” Drifter Pressure
4 Port “A” Pilot Pressure Connection

Drawing above is a typical MP style valve. The color coding indicates the various internal
passages. This valve is equipped with a solid compensator and a motor spool. The valve
is also pilot operated.

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1 Pilot Connection
2 This orifice is only used with remote pressure control feature.
3 Remote pressure control connection used on some valves.
4 Primary Shuttle Valve
5 Pilot Connection
6 Secondary Shuttle Valve
7 Compensator Valve

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Typical MP valves

1 Port B
2 Port A
Pressure
Load Sense
Neutral
Tank

Manual MP style valve equipped with a hollow compensator — Note the location of the
shuttle valve.

Pilot operated MP style valve equipped with a solid compensator — This example is
fitted with a compensator relief valve.

1 Port B
2 Port A

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Typical MP22 pilot operated valve

3
1
5

1 End Cap
2 Remote Port
3 Main Valve Spool
4 Valve Compensator Section
5 End Cap

The inlet and outlet ports are located on the backside of the valve. The “LS” load sense
port is on the same section as the inlet and outlet ports.

The “A” and “B” (working) ports are on top of the valve.

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CM 765/785 SYSTEM PRESSURE SETTINGS

Hydraulic System Settings

♦ Hydraulic Pump Compensator 3600 psi (248.2 bar) (Pump #1)

♦ Load Sense Standby Pressure 250 psi (17.2 bar) (Pump #1)

♦ Hydraulic Pump Compensator 3600 psi (248.2 bar) (Pump #2)

♦ Hydraulic Pump Standby Pressure 250 psi (17.2 bar) (Pump #2)

♦ System Relief Valve Setting 4200 psi (289.5 bar)

♦ Hydraulic Pilot Pressure 400 psi (27.5 bar)

♦ Rod Changer Pressure 2000 psi (137.8 bar)

♦ Rotation Pressure forward 2500 psi (172.3 bar)

♦ Rotation pressure in reverse 3600 psi (248.2 bar)

♦ Cooling Fan Motor Speed Two separate units High or Low speed

Air System Settings

♦ Main air system pressure Max 350 psi (24.1 bar)

Low 250 psi (17.2 bar)
♦ Service Air Pressure 110 psi (7.6 bar)

♦ Grease Pump Pressure 80 psi (5.5 bar)

♦ Dust collector Pressure 50-60 psi (3.4-4.1 bar)

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Fluid Capacities

♦ Hydraulic reservoir∗ 150 gallons (567.8 liters)

♦ Fuel Tank 155 gallons (586.7 liters)

♦ Cooling System 17 gallons (64.3 liters)

♦ Compressor 30 gallons (113.5 liters)

♦ Tram Planetary Final Drives 2 quarts (1.9 liters)

♦ Engine Oil 10 quarts (9.5 liters)

All the remainder of the capacities listed is for a complete refill.

∗
The hydraulic reservoir volume does not include refilling the hydraulic lines on the machine.

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