Service Training Manual ECM 720

Hydraulic symbols
Basic building blocks

Working line

Arrows indicate variability,

adjustability or direction of flow
Pilot line

Drain line Spring--an arrow through the

spring indicates an adjustment
point

Enclosure line
Check valve

Check valve-spring loaded

Squares or combinations
of squares indicate valves
Accumulator-gas charged

Circles indicate pumps, The diamond shape indicates

gauges or rotary actuators fluid conditioners

Chapter 1 Page 1 General Hydraulics

Service Training Manual ECM 720

Hydraulic Symbols

IN IN

Relief Pressure reducing Pressure reducing/

Valve valve relieving valve

Directional Control Valve

Three position four way valves
A B A B A B A B

P T P T T P T P

Open center Open center

Closed port Open port
Open center Open center
Closed port Open port

A B A B

P T P T

Closed center Closed center

Closed port Open port

Fluid conditioners

Flow control valves

IN

Filter w/ bypass Cooler

Fixed Variable

Orifice

Pressure & Pressure &

temperature temperature
compensated compensated

Bypass type flow Restrictive type flow

control with return control with return
check valve check valve

Chapter 1 Page 2 General Hydraulics

Service Training Manual ECM 720

Hydraulic Symbols
Pumps Motors

Fixed displacement Fixed displacement

unidirectional undirectional
(Gear or Vane) (Gear or Vane or piston)

Variable displacement Fixed displacement

unidirectional piston pump bidirectional
Pressure & flow compensated (Gear Vane or Piston
(Load sensing)

Variable displacement
bidirectional
Variable displacement (piston)
bidirectional piston pump
(Hydrastatic pump)

Chapter 1 Page 3 General Hydraulics

Service Training Manual ECM 720

Hydraulic Symbols

Pressurized
Vented reservoir Line to reservoir
Reservoir below fluid level
Line to reservoir
above fluid level

Manual shutoff Pressure switch

Shuttle valve
valve

Pressure gauge Temperature gauge

Double acting cylinder

Valve operators

Pilot operator Solenoid operator

Lever

Spring Cam or roller Valve detents

operator (hash mark indicates nuetral)

Chapter 1 Page 4 General Hydraulics

Service Training Manual ECM 720

DEFINITION OF SYMBOLS

1. Working line: Any line used to carry working fluid. This includes
suction lines, pressure lines, and cylinder or motor connections and
return lines.

2. 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.

3. 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 and be subjected to minimal spiking of the
pressure.

4. 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.

5. 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.

6. 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 utilize a single directional valve to operate two
functions in sequence.

7. 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.

Chapter 1 Page 5 General Hydraulics

Service Training Manual ECM 720

8. 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.

9. 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.

10. 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.

11. Shuttle valve: A valve used to allow the highest of two pressure
sources to used 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.

12. 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.

13. 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.

14. 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.

Chapter 1 Page 6 General Hydraulics

Service Training Manual ECM 720

15. 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.
16. Dual pilot operated check valve: Used as a load holding device
normally with a hydraulic cylinder. Utilizes 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.

17. 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.

Chapter 1 Page 7 General Hydraulics

Service Training Manual ECM 720

HELPFUL INFORMATION

1. Pascal’s Law: Pressure exerted on a confined fluid is transmitted

undiminished in all directions and acts with equal force on all equal
areas and at right angles to them.

2. The force in pounds exerted by a hydraulic cylinder can be

determined by multiplying the piston area in square inches by the
pressure applied (PSI).

3. To determine the volume (cubic inches) required to move a piston

a given distance, multiply the piston area in sq. in. (π r) by the stroke
length required (inches). Volume = Area x Length.

4. The weight of hydraulic fluid will vary with changes in viscosity. 55

to 58 pounds per cubic ft. covers the viscosity range from 150 SUS to
900 SUS at 100 degrees f.

5. Flow through an orifice or restriction will cause a pressure drop

across that restriction. The more flow that attempts to pass through a
given restriction the greater the pressure drop.

6. Hydraulic hoses are designated by their nominal inside diameter.

With some exceptions, a dash number representing the number of
sixteenth inch increments in their inside diameter indicates this.

Example: 1. 8/16 or –8

2. 16/16 or -16

7. One horsepower (HP) = 33,000 ft. lbs. per minute.

One HP =746 watts.

One HP = 42.4 BTU per minute.

Chapter 1 Page 8 General Hydraulics

Service Training Manual ECM 720

8. To find the HP required for a given flow rate at a known pressure

use the formula:

Pump output HP = GPM x PSI x .000583 or,

HP = GPM x PSI ÷ 1714 x Efficiency

Piston pumps in good condition are normally 90% to 95% efficient.

Gear pumps in good condition are normally 80% to 90% efficient.

10. To find the uphole velocity of a drilling application use the

formula:

144 x CFM: H2 - H1 = Up Hole Velocity (ft./ minute).

H2 = hole diameter

H1 = Drill rod or stem diameter

11. To calculate the pressure required to open a pilot operated

counterbalance valve use the formula:

Pilot Pressure = Relief Setting - Load Pressure ÷ Pilot Ratio

12. The relationship between torque and HP is:

Torque (in. lbs.) = 63205 x HP ÷ RPM or,

HP = Torque (in. lbs.) x RPM ÷ 63205

13. To find pump volume when displacement (cu. in.) is known, use
the formula:

Volume = RPM x Displacement ÷ 231

There are 231 cu. in. in one US gallon.

2 2
14. Area of a circle A = π r or A = .7845 d

15. Pressure conversions, 1 bar = 100 kPa = 1.02 kg/cm2 = 14.5 PSI

Chapter 1 Page 9 General Hydraulics

Service Training Manual ECM 720

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 at which the valve will open when
subjected to direct pressure. As an 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 which 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.

Chapter 1 Page 10 General Hydraulics

Service Training Manual ECM 720

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 that 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.

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. What this means is that 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 began 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 be safely be trammed 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 thereby allowing
the brake to fully release before the machine is allowed to move.

Chapter 1 Page 11 General Hydraulics

Service Training Manual ECM 720

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.

Chapter 1 Page 12 General Hydraulics

Service Training Manual ECM 720

3000
PSI

Equipped with shuttle valve for brake release

3000
PSI

All counterbalance valve will have a specified pilot ratio.

This determines the pilot pressure required to open the
outlet port of the valve.

Chapter 1 Page 13 General Hydraulics

Service Training Manual ECM 720

LOAD SENSING

The Ingersoll-Rand ECM 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 by Ingersoll-Rand 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, for
example; 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. 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

Chapter 1 Page 14 General Hydraulics

Service Training Manual ECM 720

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 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 began 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. As an 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 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:

Standby
compensator

Pressure
compensator

Chapter 1 Page 15 General Hydraulics

Service Training Manual ECM 720

Notes:

Chapter 1 Page 16 General Hydraulics

Service Training Manual ECM 720

Xb Xa

Load Sensing B

Rotation

"B" Supply to Valve s

Ls

Lx

Stroking B A
Xb Xa
Servo
Destroke
"S" Servo B

"X" or Ls A
"L1"

Feed

Ls

Lx

Chapter 1 Page 17 General Hydraulics

Service Training Manual ECM 720

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 limits 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
will 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 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

Chapter 1 Page 18 General Hydraulics

Service Training Manual ECM 720

pressure is limited by the feed pressure control in the cab. A remote

pilot relief valve controls the hammer pressure.

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.

Chapter 1 Page 19 General Hydraulics

Service Training Manual ECM 720

This orifice is only

used with remote
Remote pressure
pressure control
control connection
feature
used on some valves

Pilot connection

B 1

Lx 2
Ls
Pilot connection

1. Primary shuttle valve

2. Secondary shuttle valve
3. Compensator valve

Chapter 1 Page 20 General Hydraulics

Service Training Manual ECM 720

Typical MP valves.

Port relief valve

Compensator

Primary Shuttle

Secondary shuttle valve

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

circuit relief

Pilot operated MP Style valve equipped with a solid

compensator. This example is fitted with a compensator relief
valve.

Chapter 1 Page 21 General Hydraulics

Service Training Manual ECM 720

Typical MP22 pilot operated valve.

Main valve spool

End Cap
End Cap
Valve compensator section

Remote port

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.

Chapter 1 Page 22 General Hydraulics

Service Training Manual ECM 720

ECM 710/720 System Pressure Settings

Hydraulic System Settings

♦ Hydraulic Pump Compensator 3600 PSI (245 Bar)

(Pump #1)
♦ Load Sense Standby Pressure 300 PSI (20 Bar)
(Pump #1)
♦ Hydraulic Pump Compensator 3600 PSI (245 Bar)
(Pump #2)
♦ Hydraulic Pump Standby Pressure 250 PSI (17 Bar)
(Pump #2)
♦ System Relief Valve Setting 4200 PSI (289 Bar)

♦ Hydraulic Pilot Pressure 400 PSI (27 Bar)

♦ Rod Changer Pressure 2500 PSI (172 Bar)

♦ Dust Collector Pressure 2000 PSI (136 Bar)

♦ Maximum Feed Brake Pressure 300 PSI (20 Bar

♦ Rotation Pressure 1900 PSI (131 Bar

(Rotation pressure in ARC mode) 1500 PSI (103 Barf)

♦ Cooling Fan Motor Speed Variable

(two separate units)

Air System Settings

♦ Main air system pressure Max 150 PSI (10.2 Bar)

♦ Service Air Pressure 100 PSI (7.3 Bar)

♦ Grease Pump Pressure 80 PSI (5.5 Bar

♦ Dust collector Pressure 50-60 PSI (4 Bar)

Chapter 1 Page 23 General Hydraulics

Service Training Manual ECM 720

Fluid Capacities

♦ Hydraulic reservoir* 128 Gallons (485 Liters)

♦ Fuel Tank 155 Gallons (587 Liters)

♦ Cooling System 17 Gallons (64 Liters)

♦ Compressor 10 Gallons (38 Liters)

♦ Tram Final Drive Planetarys 1.8 to 2 Quarts (1.9 Liters)

♦ Engine Oil 29 Quarts (28 Liters)

*The hydraulic reservoir volume does not include refilling the

hydraulic lines on the machine.

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

Chapter 1 Page 24 General Hydraulics