Hydraulic Components

How To - Identifying Hydraulic Components

Example Used: Warrior 1400X

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 01/26
Aut: C Mc Namee
 Before You Start
• The information included in this document is intended for experienced
personnel familiar with this type of equipment.
• If there are any questions regarding the information provided or the
application of the provided information, please contact,
aftersales@powerscreen.com.
• Operation and maintenance of the machine must be done in accordance with
the instructions in the operation manual for the machine.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 02/26
Aut: C Mc Namee
 Switch Off, Tag out and Lockout Procedure

• WHEN CARRYING OUT MAINTENANCE OR ADJUSTMENT THE

FOLLOWINGPROCEDURE MUST BE FOLLOWED
• Ensure the plant is empty prior to shut down
• Disengage each machine component (e.g. conveyors etc.) using the control
levers.
• Turning off all machine components at once causes a pressure spike in the
hydraulic circuit. A slight pause between disengaging each component can
prevent this spike taking place.
• Turn components off in the order:
Feeder Conveyor
Main conveyor
Screenbox/Fines Conveyor (Oversize Conveyor on Warrior models)
RH/LH side conveyor
• Switch off engine and remove ignition key. Carry the key with you.
• Engage emergency stop.
• Place appropriate maintenance warning sign.
• Use padlock to secure isolator and prevent restart.
• NEVER WORK ALONE

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012
Aut: C Mc Namee 03/26
 Stay Safe

• High –pressure fluid is present in operational hydraulic systems.

• Fluids under pressure are dangerous and can cause serious injury
or death
• Always consider gravity before carrying out any work on a hydraulic machine.
(stored energy risk)
• Any part of a hydraulic circuit that is supporting a load can remain pressurized
(stored energy risk)
• Even after the system has been shut down, attempting to remove a hydraulic
line or component that is supporting a load can result in a sudden release of
pressure and/or uncontrolled movement of the load, causing serious personal
injury and/or property damage
• Do not make modifications, repairs or adjustments to any hydraulic system
unless you are competent or working under competent supervision.
• If in doubt, consult Powerscreen aftersales department.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012
Aut: C Mc Namee 04/26
 Stay Safe

• ALWAYS use gloves and barrier cream.

• ALWAYS switch off and lockout machine whilst carrying out any work.

• ALWAYS immediately clean up any spilled hydraulic oil with correct absorbent
material.

• NEVER work alone

• NEVER use your hands to check for leaks (skin injection risk)

• REMEMBER: Hydraulic systems use fluids under high pressure which can
cause major injury or death.

• REMEMBER: STAY SAFE, STAY ALIVE

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012
Aut: C Mc Namee 05/26
 Identifying Hydraulic Components

• The hydraulic circuits of Powerscreen units

are made up of various components which
perform different functions.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 06/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Electrically switched valve

block signal has 7 second
delay from sensor on
manually operated hand
valve.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 07/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Flow control valve used to

“slow” the conveyor belt
speed. This is achieved by
using the valve to divert some
or all of the flow back to tank

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 08/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Track Solenoid Block,

Proportional valve block which
is electrically voltage
controlled to give
“proportional” oil flow either
forward or reverse to the track
motors.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 09/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Screenbox Pressure Relief

Block, used to set the
pressure relief on the
screenbox circuit .

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 10/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Hydraulic Oil Return Filter

Housing, contains the return
filter for the hydraulic system.
All return oil via manifolds
return to this point for oil
conditioning. (Filter blockage
gauge also shown)

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 11/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Fixed displacement pump.

In this case Quad (4) pump.
Uses engine flywheel to
operate pumps. Flow rate
dependant on engine RPM

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 12/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Equalisation Valve, also

known as a 50/50 flow divider.
Used to split the flow between
two components, in this case
the flow is divided equally
between to hydraulic cylinders
to ensure that they extend
together at the same time.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 13/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Adjustable Pressure Relief

Block, used to limit the
pressure to a component
(motor) excess pressure is
released back to tank

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 14/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Double Acting Hydraulic

Cylinder (Ram), pressure is
used to both extend and
retract hydraulic cylinder.
Various designs, features two
ports

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 15/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• PTO (side) Pump Hydraulic

pump driven of the PTO gear
of the engine. Used to supply
hydraulic oil to some of the
components.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 16/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Drive Motor, various types

used to turn hydraulic power
into rotary movement (driving
conveyor belts etc.)
• Two main ports (flow and
return) may also have case
drain (bleed) port

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 17/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Gate Vales, also know as

shut off valves (shown main
suction pipes from hydraulic
tank. Used to isolate oil if
major maintenance, e.g. pipe
removal.
• Smaller versions may be used
on the unit to isolate (lock)
hydraulic cylinders in place to
prevent leak back to tank.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 18/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Proportional Control Valve

(manually operated), used to
direct the flow of oil to
particular component e.g.
jacking legs. The amount of
oil flow is proportional to the
amount that the valve to
opened

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 19/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Hydraulic Oil Level Sensor,

although strictly an electrical
component we will discuss it
within this presentation.
• Location: fitted to the hydraulic
reservoir.
• Function: to detect low
hydraulic oil level.
• Also shown Hydraulic
reservoir oil level sight gauge
and filler cap

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 20/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Tipping Grid Solenoid, this

electrically operated valve
block controls the tipping grid
function (not on Warrior)

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 21/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Oil Cooler, this electrically

driven oil cooler draws cool air
across the oil filled matrix to
aid cooling

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 22/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Check Valve, (spring) the

check valve acts as a one way
valve so that oil can flow in
only one direction.
• For example if the cooler gets
blocked then increased oil
pressure overrides spring
tension in the check valve
allowing the valve to open

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 23/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Duel Speed Check Valve, the

purpose of this valve is to
reduce the pressure down to
60 BAR / 870 PSI (reduced
pressure required by track gearbox)
and to send the oil via
electrically operated portion of
the valve to the track motors
for the purpose of changing
the track motor speed

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 24/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Feeder Slide Shut Off Valve,

this is used to prevent oil
leaking back to the tank from
the feeder slide hydraulic
cylinders effectively “locking”
the feeder in position.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 25/26
Aut: C Mc Namee
 Identifying Hydraulic Components

• Track drive Motor, used to

drive tracks. In this example
(warrior 1400x) the track
motors have a variable
displacement and so it is
possible to alter the speed by
moving the swash plate in the
motor allowing more oil to
flow.

Ref #: tdoc00003
Rev: 1.0
Date: 20/11/2012 26/26
Aut: C Mc Namee