Hydraulics on Logging Units

March 2009
 Why Hydraulics
• Transmission of power is very easy and flexible using
Hydraulics. Pumps and Motors are connected by flexible hoses
• It is safe in the sense that it does not have fire or electrical
hazards. Remember we need to switch OFF / Disconnect the
Truck Alternator during Explosive related operations yet the
Winch has to move. Hydraulics can be run from the Unit 12/24
V Battery
• It is relatively maintenance free. Just keep changing Oil &
Filters regularly as scheduled in PM manuals
• Hydraulic operations are smooth and noiseless.
• The ease with which one can control Speed, Torque, Direction
of the winch by operating just one Joy Stick

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Important characteristics of hydraulic circuits
 Transfer of large forces
 Operations may commence from rest under full load.
 Smooth adjustments of the following is easily achieved:
 Speed
 Torque
 Force
 Change of Direction (no engaging reverse gear)
 Simple protection against overloading.
 Suitable for both quick and very slow controlled
sequence of movements.
 Decentralized transformation of mechanical/electrical to
hydraulic and hydraulic to mechanical energy is possible

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 Logging Unit hydraulics
There are 2 Independent* Closed Loop Hydraulic circuits in a
Logging Truck (or Skid)

* These two independent circuits share a common Prime Mover and a

common Hydraulics oil tank

1. Controls direction, Speed and Torque of

the Winch
2. Runs the Alternator at a constant
speed of 1800 rpm under changing load
conditions
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Closed Loop Hydraulic circuit- Electrical analogy

I A

R V
Current
source

V= IR , I = V/R Pressure = Flow*Load

Power = V * I Power = Pressure * Flow , Torque * RPM

The current source feeds power The Pump converts mechanical energy to
while the Resistor dissipates Power hydraulic energy while the Motor converts
hydraulic energy back to mechanical
energy

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 Closed Loop Hydraulic circuit components
Prime Mover (M) Source - Truck/Skid Diesel Engine
Hydraulic Pump (2)
Hydraulic Fluid (1) Pressure Gauge
Hydraulic Motor (4) Fluid Flow
Mechanical energy turns the
Pump, which sucks
hydraulic fluid from a tank
and pushes it out under
pressure. The pressurized
Pump Motor
fluid is taken to the motor in
a hose. The pressurized fluid
turns the motor, looses
energy and returns to tank
Various accessories like Hoses, Filters, Controls, Valves etc.

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 Well, It’s not that simple
What will happen if
Pressure Gauge

Fluid Flow 1. The load on the motor increases

2. How to stop the motor without
stopping the engine
Pump Motor 3. The Hydraulic oil heats up, gets
dirty with metal dust

1. If the load on the motor increases, pressure will increase. It may burst the
hoses, stall the pump and engine, cause mechanical damage
2. Variable Displacement is the answer
3. When hydraulic oil heats up, it might loose its properties and start burning,
spoil the rubber seals and gaskets. Metal dust has to be filtered

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 Case 1 – Safety from High Pressure
Relief Valve – Operates much like a Zener Diode
Pressure Gauge

Fluid Flow

Pump Motor

A simple relief valve may consist of nothing but a ball or poppet held seated in the valve body by the
compressive force of a heavy spring. When the pressure at the inlet is insufficient to overcome the force of
the spring the valve remains closed and hence it is very often referred as a normally closed valve. When the
preset pressure is reached, the ball unseats and allows flow through the outlet to tank. In most of these
valves, an adjusting screw is provided to vary the spring force. Thus the valve can be set to open at any
pressure within the specified range. The pressure at which the valve first opens is called the cracking
pressure. A relief valve should NOT be allowed to operate in Relief mode for long.

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Case 2 – Displacement (just like Gears)
Displacement of a Pump (or Motor) is the amount of fluid
moved per Rotation. Displacement is measured in cc. For
example a Pump could be 90cc (meaning that for each complete
rotation of the Pump shaft 90cc of oil will come out) and a Motor could
be 120cc.
Pressure Gauge In our example let
Fluid Flow Pump = 90 cc
Motor = 120 cc
If the engine rpm (ω1) is
1200 then what is the
Pump Motor rpm of the motor (ω2)?

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 Case 2 – Variable Displacement
Think of Variable Displacement as being able to adjust the angle of a Fan’s
blades. If we make the Blades FLAT (angle=0) then even if the Fan
rotates no flow will take place.
What will happen if the angle is revered?
In a Logging Truck we use
Variable Displacement Pumps
Pressure Gauge

Fluid Flow

Pump 0-90 Motor

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 Case 2 – Changing Direction of the motor
•To change the direction of rotation of the motor the Fluid flow direction MUST
change to reverse. Fluid Flow direction is controlled by Pumps
•Fluid Flow direction can be changed smoothly by Axial Piston design Variable
Displacement Pumps that can achieve this even while turning in the same
direction at the same rpm (much like the Fan example of last slide)

The Displacement of the Pumps

(or motors) can be controlled by
a simple Electrical Joystick Lever.
In Logging Trucks/Skids the
Winchman’s Joystick sends a DC
Current to Solenoid coils
mounted on the Hydraulic Pump.

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 Case 2 – Over center Variable Displacement Pumps

Axial Piston Variable Displacement Pumps can also change the direction of
Fluid Flow. Such pumps are called Over-center pumps
This means on such Pumps there is NO HIGH pressure Port and NO LOW
pressure port. Instead there are 2 ports (A and B) when one is HIGH the
other is LOW.

Notice that Motors can be variable displacement too but displacement can never be zero (or close to zero).
Why?

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Case 3 – Cooling and Filtration of Hydraulic Fluid

A A

C B B C

As both ports (A & B) can be HI pressure (though not at the same time), we
must create a separate Port (C) where pressure will always be LOW. This
port is called CASE DRAIN. Some portion of the oil is intentionally leaked out
of the main circuit, collected and sent back into a Tank. But before it reaches
the Tank we cool it in a radiator.

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 Case 3 – Cooling and Filtration
As we have removed
some Oil, we must
replenish the same, else
the hydraulic circuit will
soon starve. This is done
by a separate pump
called Charge Pump and
a Charge circuit.
A Charge Pump sucks
CLEAN, COOLED,
FILTERED Oil from the
tank and pushes it back
into the main circuit by
injecting oil in the low
pressure side.

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 Hydraulics so far….
 Logging Hydraulics systems are closed loop systems.
 There are 2 independent systems (Winch, Alternator)
 Pumps used in both these two circuits are Over center
Variable Displacement Axial Type
 Controls to the Pump and Motors are electrical (12V
DC)
 System pressure is limited to 5500 psi by relief valves
 Charge Pumps are Gear type pumps that are mounted
along with the main pumps. Since we have 2 main
pumps we also have 2 charge pumps
 Hydraulic oil must be filtered and cooled

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 Swash-Plate principle

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 The Bent Axis Principle
The Alternator
Motor Axis angle is
fixed to give 32 cc
displacement

*Decreasing Swivel Angle decreases Displacement (therefore increases RPM)

but Hydraulic Motors cannot have 0 cc displacement of as that would mean
Infinite RPM and Zero Torque
The Winch Motor
displacement depends
on the Axis angle can
vary from a min to
give 25 cc to a max to
give 80cc

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 Hydraulics Diagram of Truck/Skid

DATE 11-Jun-18
SKID ASEP001OH
REG RJ-04EA-0938
CHASSIS NO 605596
ENGINE NO. 09107650AZL
Present HRS 19568
1 Present KM 181017
2 All paper Date Due Date New tyre S/R No R021455-4417
Tax 04-Aug-06 LIFE TIME (RJT PASS) New tyre S/R No R021452-4417
RC 04-Aug-06 03-Aug-21 New tyre S/R No R0064202218

Variable Insurance 13-Jul-17 12-Jul-18

Variable
New tyre S/R No R0064132218
PUC Variable
08-06-2018 07-Dec-18 Reel
Displacement Fitness 22-Dec-18 21-Jan-19 Displacement
3
Displacement
ASEP 500 hrs servicePart 0 no. Last service hrs Next Due Remarks
90cc Pump500 Engine oil (C4 15W40)
C415W40 19566 20066 OK 80cc Motor
hrs
Oil filter 56cc Pump
1R0716 19566 20066 OK
Fuel filter 1R0749 19566 20066 OK
servic Water Seperator 1335673 19566 20066 OK
e Air filter 19566 20066 OK
Winch Pump 4 ASEP monthly checklist
Engine oil level
remark
As "F" marked in gauge
Last checklist date
12-Jun-18
Next Due Remarks
11-Jul-18 Unit PM 1 OK
Winch Motor
Diesel Stearing oil level
Belt condition
To be filled max marked in reservior
Check for any cut
12-Jun-18
12-Jun-18
11-Jul-18
11-Jul-18
Belt tension 1/2 inch press on tension Fixed 12-Jun-18 120V 60Hz
11-Jul-18
Engine Battery water level To be filled max marked in battery
Displacement
12-Jun-18 11-Jul-18
Battery water gravity Min 1220-1250 hydromeater 12-Jun-18 Alternator
11-Jul-18
2 Speed
Battery charging Volt 28Volt while charging 12-Jun-18 11-Jul-18
Brake liner thickness 32cc Motor
Min 6mm required (inspection windo) 12-Jun-18 11-Jul-18
Air bag check 12-Jun-18 11-Jul-18 Planetary
Mont Emergency kill
Cabin lifter air suspension To be filled as marked in gauge
12-Jun-18
12-Jun-18
11-Jul-18
11-Jul-18 Gearbox
hly Cabinlifter air leak Any leak in hyd hose 12-Jun-18 11-Jul-18
check Check exaust brake While running 12-Jun-18 11-Jul-18
Clutch servo travel Mechanical type clutch 12-Jun-18 11-Jul-18
Coolent level To be filled max 12-Jun-18 11-Jul-18
Air tank pressure 8 kg( green indecation ) 12-Jun-18 11-Jul-18
Any fault code from ecm Check display for fault code 12-Jun-18 11-Jul-18
Any oil leak Check for any oil leak(85w90&85w140) 12-Jun-18 11-Jul-18
Exaust smoke Black or white 12-Jun-18 11-Jul-18
Engine oil leak Engine oil leak at any part 12-Jun-18 11-Jul-18
All points greasing Need to do the greasing of all the points 12-Jun-18 11-Jul-18

5 Annual service part no

Case Drain
Under chassis nut/bolt checkAll nut bolt check and tight 12-Jun-18
Last service date/km
11-Jul-18
Next Due
Stearing oil change TQ 5ltr 5-Jun-18 4-Jun-19
Stearing oil filter
Oil Filters
349619 Heat exchanger
5-Jun-18 4-Jun-19
water pump check after every 2 years 5-Jun-18 4-Jun-19
Stearing pipe inspection Any leak or loosen part 5-Jun-18 4-Jun-19
Annu Gear box oil change 85w90 5-Jun-18 4-Jun-19
al at Gear box filter change 5-Jun-18 4-Jun-19
1
Year
or 1
lakh
Km.

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