NDSCO1500HP 车载液压系统

用 户 手 册
YZ061-SC

NDSC 2000HP Drilling Rig

Movable HPU
YZ427-SC
April, 2016

四川宏华石油设备有限公司

2012 年 12 月
 Foreword
YZ427.00 movable HPU is one of main supporting devices of NDSC2000HP drilling

rig, it can supply the power and control for steering oil cylinder and pin oil cylinder of

mast trailer.

This manual describes generally the technical parameters, working principle, overall

structure and component structures, installation, operation, maintenance and repair etc of

portable HPU. The operators of the hydraulic system shall read this manual carefully

before starting to install and operate the system.

There is a recommended spare parts list attached to the user manual as a reference for

users ordering spare parts. If the spare parts needed by users are not included in the list,

please refer to the attached drawings in the user manual.

The components for each hydraulic system have ex-works serial numbers, and please

point out their models and ex-works serial numbers when users order spare parts or inquire

related things.
 Important safety statements

The personnel engaged in the use, management, operation, maintenance and repair of

product shall know related contents in this user manual well, follow the normative

procedure about use, management, operation, maintenance and repair, and especially pay

attention to safety warnings and notices mentioned in this user manual, national laws and

regulation, industrial regulations and general knowledge for avoiding human injury and

equipment damage.

This manual may not be able to list all safety warnings information in detail.

Therefore, when choosing any one method to operate the system, first confirm necessarily

that this method neither endangers personal safety nor damages equipment.

To maintain the system correctly is an important way to keep it in reliable and safe

running. The personnel engaged in maintenance shall maintain it as per the methods

introduced in this manual.

Be sure to repair the product properly and replace parts with the parts made by their

manufacturer for the safe and reliable running of the equipment. The users must repair and

replace parts as per the manufacturer-authorized right.

Please read the contents with following titles or marks carefully!

Warning: used in the conditions that personal injury and death may be caused due

to incorrect conformity with operation steps and methods etc.

Notice: used in the conditions that may cause equipment injury or damage due to

imprecise observation of operation steps and methods etc.

 Contents
1. Safety warnings ................................................................................................................. 1

2. System description............................................................................................................. 2

2.1 General ............................................................................................................................ 2

2.2 Actuating mechanism ...................................................................................................... 2

2.3 Pipeline connection.......................................................................................................... 2

2.4 Safety facilities ................................................................................................................ 2

3. Main performance parameters ........................................................................................... 2

4. Schematic diagram of HPU ............................................................................................... 3

5. Installation of movable HPU ............................................................................................. 3

6. Use of movable HPU ......................................................................................................... 4

6.1 Check ............................................................................................................................... 4

6.2 Startup and pressure adjustment of system...................................................................... 5

6.3 Operation of HPU ............................................................................................................ 7

7. Maintenance and troubleshooting...................................................................................... 9

8. Attached drawings ........................................................................................................... 14

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1. Safety warnings

1.1 Only trained and qualified persons can install, operate and maintain the hydraulic

system with qualification certificates.

1.2 Persons on duty shall wear labor protection articles as required.

1.3 Fire is forbidden around the hydraulic system.

1.4 Check the oil level carefully, add oil in time if the level is too low, so as to prevent

the hydraulic components of oil pumps etc from being damaged.

1.5 If there is a warning signal, stop the system operation immediately. It cannot be

started again before the problem is not solved.

1.6 Cut off power supply and release the system pressure before starting maintaining

operation. There shall be a shut-off device for wrong operation and distinct warning board

to avoid the safety accident of human injury and equipment damage.

1.7 Do not wear gloves during maintaining operation. Oil collecting measures shall be

taken to keep the system and environment clean.

1.8 When plugging out the quick release joint, be sure to install the protection cap on

the quick release joint for avoiding pollutant getting inside. Make sure the cleanness of

joints before plugging in.

1.9 Connect quick release joint for correctness and reliability.

1.10 For a new oil cylinder, put the oil cylinder on an empty ground, connect

hydraulic pipelines, and repeatedly stretch and retract them for discharging air.

1.11 Discharge air of oil cylinder by static air discharge or dynamic air discharge

methods. In principle, under dynamic air discharge condition, use it firstly. When dynamic

air discharge condition is unavailable, and big ear rings at two ends of oil cylinder are fixed,

the static air discharge method can be used. .

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2. System description

2.1 General

YZ427.00 movable HPU is one of main supporting devices of NDSC2000HP drilling

rig, it can supply the power and control for steering oil cylinder and pin oil cylinder of

mast trailer. HPU mainly comprises HPU skeleton, HPU rain shed, operation valve bank,

hydraulic oil tank assembly, diesel engine pump set and pipeline.

Operation valve bank of HPU adopts HLPSL-3 type load sensitive proportional

multiplexing manual reversal valve bank so as to control the direction, pressure and flow

of system and reduce related control components greatly, reduces pipes and system

commissioning work, and achieve the purpose that different loads work simultaneously

under different pressures and flows.

2.2 Actuating mechanism

Actuating mechanism includes steering oil cylinder of mast trailer and pin oil

cylinder.

YZ427 movable HPU supplies hydraulic power and control for above actuating

mechanism.

2.3 Pipeline connection

Connect HPU with actuating elements by hydraulic pipelines as per interface

indicating tag plates, install quick release joint which is convenient to disassemble, thereby

being beneficial to the disassembly and assembly during movement of drilling rig.

2.4 Safety facilities

The HPU comprises pressure display equipment, operation valve bank has Safe

decompression function, and operation box is provided with operation instruction tag plate

and pipeline connector tag plates.

3. Main performance parameters

Technical parameters

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Rated pressure of hydraulic system: 16MPa

Rated flow rate of hydraulic system: 20L/min
Volume of hydraulic oil tank: 100L
Power of diesel engine: 8.8kW

Recommended working medium:

L-HM46 (Mobil DTE25) anti-wear hydraulic oil (summer)
L-HV32 (Mobil DTE13M) low-temperature anti-wear hydraulic oil (winter)
L-HM68 (Mobil DTE26) anti-wear hydraulic oil (extremely hot)
Cleanness of hydraulic system: NAS1638, grade 9

4. Schematic diagram of HPU

Please refer to attached drawing 1.

5. Installation of movable HPU

5.1 Installation of HPU

YZ427 movable HPU is used for supplying power to steering oil cylinder and pin oil

cylinder, HPU is installed on HPU supporting frame of mast trailer, it is shown in

following drawing.

Installation of HPU

5.2 Pipeline connection of all actuating components of HPU

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Connect HPU with actuating elements (steering oil cylinder and pin oil cylinder) by

hydraulic pipelines, and pipeline connections are shown as follows:

Port A of pin oil cylinder—to “port A of pin oil cylinder” of HPU

Port B of pin oil cylinder—to “port B of pin oil cylinder” of HPU

Port A of steering oil cylinder—to “port A of steering oil cylinder” of HPU

Port B of steering oil cylinder—to “port B of steering oil cylinder” of HPU

Interface instruction of HPU

5.3 Check

Check pipeline connection for conformity with schematic diagram and HPU interface

instruction, check all joints for leakage, and check quick release joint for reliable

connection.

6. Use of movable HPU

6.1 Check

6.1.1 Appearance check

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6.1.1.1 Check all components of HPU for appearance damage such as appearance

crash and impact etc.

6.1.1.2 Check all actuating components of hydraulic system and pipelines for correct

connection.

6.1.1.3 Check whether operation control mechanism can be stably maintained at the

neutral position and the backlash is proper or not.

6.1.2 Oil check

6.1.2.1 Check whether the oil level is between the specified scale marks;

6.1.2.2 Check the conformity between the brand of the added oil and the ambient

temperature.

6.1.2.3 Check the oil for muddiness and replace the hydraulic oil if any even through

the replacement period is not reached.

6.1.3 Connection check

6.1.3.1 Check the assembly and connection of all hydraulic actuating mechanisms for

correctness and reliability.

6.1.3.2 Check the connection of the quick release joints of the components for

correctness and reliability.

6.2 Startup and pressure adjustment of system

6.2.1 Startup

6.2.1.1 Check bolts, pipe joints, quick release joints for firm connections.

6.2.1.2 Check liquid levels of HPU;

6.2.1.3 Start diesel engine pump set, run it for 10 min without load, monitor

components and connectors for oil leakage and abnormal phenomena, and stop to check

and repair if any.

6.2.2 Pressure check and adjustment

Warning: during pressure regulation, directly facing position of quick release joint at

outlet of HPU is forbidden to avoid hurting people.

6.2.2.1 Pressure check:

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1) Disconnect pipeline of connector board in stopped state.

2) Check whether all handles of multi-way valve banks are at neutral positions, and

start diesel engine if they are at neutral positions.

3) Operate handle of reversing valve of pin oil cylinder, check whether the pressure of

pressure gauge on operation panel is 12MPa or not, if it is 12MPa, do not adjust.

4) Operate reversing valve handle of steering oil cylinder to “extension” position,

check whether pressure of pressure gauge on operation panel is 11.5MPa, and do not adjust

limit valve at port A of steering oil cylinder if it is 11.5MPa.

5) Operate reversing valve handle of steering oil cylinder to “retraction” position,

check whether pressure of pressure gauge on operation panel is 8.5MPa, and do not adjust

limit valve at port B of steering oil cylinder if it is 8.5MPa.

6) If above three pressure values are meet requirements, do not adjust pressure value

of HPU.

Notice! The pressure of the system has been set properly before delivery and cannot

be adjusted randomly.

6.2.2.2 The pressure regulation is as follows:

Pressure regulation of safety valve of HPU

1) In stopped state, unscrew pressure regulation screw of safety valve of HPU

anticlockwise, and regulate the pressure of the safety valve to smaller pressure position;

2) Disconnect quick release joints at ports A and B at outlet of HPU;

3) Start diesel engine pump set, and check whether it is abnormal after running;

4) Select reversing valve of pin oil cylinder, and then operate its handle to load and

adjust pressure.

5) Screw up pressure regulation screw of safety valve of HPU clockwise slowly,

observe the reading on pressure gauge of HPU, and regulate pressure to 16MPa;

6) In the process of pressure adjustment, if the pressure is not reach to 16MPa and no

more to rise, clockwise screw down secondary pressure limit valve of reversing valve of

pin oil cylinder a little, and adjust alternately until the pressure reaches to 16MPa.

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7) Screw locknut of safety valve of HPU.

6.2.2.2 Pressure adjustment of secondary pressure limit valve

1) In stopped state, unscrew pressure regulation screw of secondary pressure limit

valve anticlockwise, and regulate the pressure of the pressure limit valve to smaller

pressure position;

2) Disconnect quick release joints at port A and port B of valve bank.

3) Start diesel engine pump set, operate the handle of valve bank to check pressure of

pressure gauge.

4) Screw down pressure regulation screw of secondary pressure limit valve slowly,

observe pressure gauge reading, adjust reversing valve pressure of pin oil cylinder to

12MPa, adjust pressure at port A of reversing valve of steering oil cylinder to 11.5MPa and

adjust pressure at port B to 8.5MPa.

5) Screw up the locking nut and protective cap of secondary pressure limit valve of

control valve bank.

Pressure limiting valve at port A of steering cylinder

Control valve of
Pressure limiting valve at
pin oil cylinder
port B of steering cylinder

Pressure limiting valve

Control valve of at port A and port B of
steering cylinder pin oil cylinder

Safety valve

6.3 Operation of HPU

6.3.1 Check

6.3.1.1 Appearance check

6.3.1.1.1 Check all components of hydraulic system for traumatic damage such as

apparent crash and impact etc.

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6.3.1.1.2 Check components of hydraulic system and its hoses and pipelines for

installation.

6.3.1.1.3 Check whether operation control mechanism can be stably maintained at the

neutral position and the backlash is proper or not.

6.3.1.2 Oil check

6.3.1.2.1 Check whether the oil level is between the specified scale marks;

6.3.1.2.2 Check the conformity between the brand of the added oil and the ambient

temperature.

6.3.1.2.3 Check the oil for muddiness and replace the hydraulic oil if any even

through the replacement period is not reached.

6.3.1.3 Connection check

6.3.1.3.1 Check the assembly and connection of all hydraulic actuating mechanisms

for correctness and reliability.

6.3.1.3.2 Check the connection of the quick release joints of the components for

correctness and reliability.

6.3.2 Operating valve bank

Operate valve bank to control steering oil cylinder and pin oil cylinder.

6.3.2.1 Pin oil cylinder

Operate the first valve bank to control pin oil cylinder, operate the handle of the first

control valve to “extension” position, piston rod of pin oil cylinder extends; and operate

the handle of the first control valve to “retraction” position, the piston rod of pin oil

cylinder retracts.

6.3.2.2 Steering oil cylinder

Operate the second valve bank to control steering oil cylinder, operate the handle of

the second control valve to “right turn” position to turn right, and operate the handle of the

second control valve to “left turn” position to turn left.

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Operation marks of valve bank

7. Maintenance and troubleshooting

Warning! Stop system and discharge pressure during maintenance and

troubleshooting.

7.1 Proportional multi-way reversing valve

HLPSL-3 type proportional multi-way reversing valve is used for controlling the

movement direction of hydraulic actuating components and can regulate their movement

speeds in a stepless way and enable many actuating components to work simultaneously at

different pressures and speeds without mutual interference. The control by using HLPSL-3

type proportional multi-way reversing valve is advanced technique in hydraulic field and

has complete functions, good performances, stable quality and high precision etc. But in

practical application, if it is not installed or used as required, some faults may be caused.

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HLPSL-3 proportional multi-way valve

7.1.1 No system pressure

7.1.1.1 When operate one of valves, the system has no pressure, and if other valves

work normally, the valve goes wrong, and remove the troubles by mainly adopting the

following steps:

(1) Firstly check the pipeline and oil cylinder connected to the plate valve for faults.

(2) Check the secondary pressure regulating valves at ports A and B for blockage due

to insufficient cleanness of oil.

(3) Check the two-way regulating valve in valves for blockage.

7.1.1.2 If any of the plate valves works and there is still no pressure, the connecting

block goes wrong, and remove the trouble by adopting the following measures:

(1) Check three-way flow regulating valve for blockage or the damping screw in

valve core for blockage.

(2) Check whether main safety valve is blocked and cannot be closed due to scrap

iron.

7.1.2 Oil cylinder vibrates or crawls in operation.

Air existing in system or serious wear of oil cylinder may cause this phenomenon,

discharge air or replace oil cylinder seal or replace oil cylinder.

7.1.3 Valve lever is operated inflexibly with blockage and non-return phenomena.

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It may be caused as oil is not clean sufficiently, and therefore, the valve lever is worn

or blocked.

7.2. Others

7.2.1 Hydraulic oil

Frequently check level in oil tank and supplement oil in time. When the level in the

oil tank is below the minimal level, the temperature rise, accumulation of insoluble air, and

failure of pump due to cavitation, oil goes bad and system faults are caused. If level

decreases, it indicates that there are places which impregnate and leak oil, check and repair

in time.

Hydraulic oil is divided into oil for summer and winter in principle and replaced once

six months.

7.2.2 Oil temperature

The optimal working temperature of hydraulic oil is 35℃～60℃, oil temperature of

system can not exceed 80℃, and too high temperature can quicken the ageing of the oil

and shorten the service life of sealing members and hoses. The oil temperature in oil tank

must be monitored frequently. Gradual temperature rise shows that there is pollution or

colloid formation or hydraulic pump wear. When oil temperature is raised suddenly, stop

and check machine.

7.2.3 Oil filter

The filter elements of oil suction filter, oil return filter and high pressure filter are

replaced once six months.

Air filter is only used for filtering air coming in and out oil tank when liquid level in

oil tank is raised or lowered. Check, clean or replace filter elements once 3-6 months.

7.2.4. Utilized pump

Detect pump set and maintain pump set in good working status without abnormal

temperature rise and abnormal sound.

7.2.5 Quick release joint

Check for falling, abnormal damage and oil leakage etc.

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Maintenance schedule
Maintenance
No. Check content Requirement
period
Keep the oil level in the scope
1 Liquid level between maximum and minimum
levels.
2 Optimal working oil temperature: 35℃～60℃ Every shift
3 System pressure 16MPa
Running sound and temperature No abnormal noise and high
4
of utilized pump temperature
5 Sealability of oil cylinder No drop leakage
Good sealing without leakage and
6 All pipelines and joints Every day
damage
No leakage, damage and virtual
7 Quick joint
connection
Check and fasten all fixing bolts
8 All fixing bolts Every week
and screws.
9 Oil sample Clean and transparent 6 months
10 Filter element Replace 6 months

7.2.6 Troubleshooting

Some potential fault phenomena, reasons for faults and troubleshooting methods are

given out in the following list for reference in maintenance.

Trouble
Reasons Troubleshooting
phenomena
Blockage of oil supply filter element Replace filter element
Improper
system Too low liquid level in oil tank Fill oil to liquid level line
pressure Pollution of hydraulic oil and dirty Clean oil tank and replace
oil hydraulic oil
Blockage of oil suction filter
Replace filter element
element
Too high oil
Too low liquid level in oil tank Fill oil to liquid level line
temperature
Pollution of hydraulic oil and dirty Clean oil tank and replace
oil hydraulic oil

Too high noise Blockage of oil filter element Replace filter element
or vibration Too low liquid level in oil tank Fill oil to liquid level line

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Air in system due to looseness of oil

Check and fasten
suction and oil return pipe joints
Coupling and pump shaft are not
Re-center and install
aligned with each other.
Looseness of bolt of oil tank support Check and fasten
Check overflow valve and
Too low system pressure
re-regulate pressure
Inflexible Blockage of oil filter element Replace filter element
hydraulic Control valve is blocked or has
operation Check, clean or replace valve
defect or leaks seriously.
Actuating mechanism leaks Check or replace sealing
seriously. members
7.3 Spare parts list of hydraulic system
No. Codes Name Model and spec. Qty. Remarks
Pressure test
1 1300000766 PT-7 1
joint
Pressure test
2 1300024279 HFH2-P1-3-P-1 1
hose
Shockproof
3 1300017700 YN-60-Ⅲ;0-25Mpa 1
pressure gauge
Quick release
4 1300114207 ANV12GASF/M/TMA/TFA 1
joint
5 1300104073 O-ring WF-WD18L 5
6 1300022428 Snap on joint 1CG-26-08 1
7 1300028951 Snap on joint 1CG-26-12 1
7.4 Recommended one-year spare parts list of hydraulic system
No. Codes Name Model and spec. Qty. Remarks
1 1300027842 Ball valve Q11F-16P-G1" 1
2 1300037109 Oil return filter RFB-63×10 1
3 1300016806 Oil suction filter TF-63×100L 1
Liquid level
4 1300009092 YWZ-150T 1
gauge
5 1300005043 Air filter QUQ2-10×2.5 1
PGP505A0100
6 1300118575 Gear pump 1
CA1H2NE5E3B1B1
High-pressure
7 1300118389 ZU-H40×10DLM 1
filter
Pressure test
8 1300000766 PT-7 1
joint

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Miniature high
9 1300024279 HFH2-P1-3-P-1 1
pressure hose
10 1300017700 Pressure gauge YN-60-Ⅲ;0-25MPa 1
Multi-way valve
11 1300118388 PSL42A-YZ427 1
bank
Quick release
12 1300114207 ANV12GASF/M/TMA/TFA 4
joint
13 1300104073 O-ring WF-WD18L 10
14 1300022428 Snap on joint 1CG-26-08 4
15 1300028951 Snap on joint 1CG-26-12 2
16 1300024266 O-ring 60×3.55 2

8. Attached drawings

8.1 Fig.1 Schematic diagram of movable HPU

8.2 Fig.2 General assembly drawing of movable HPU

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Fig.1 Schematic diagram of movable HPU

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Fig.2 General assembly drawing of movable HPU

液压站使用安全警示
Cautions fo r HPU
a) 注意经常检查柴油机燃油、机油及冷却水的液面， 发现缺少时立即补充 。

b) 注 意观察液压油油面位置，发现缺油时立即补充，以免造成油泵等液压元
件的损坏。

c) 在 进行维修保养时，应切断动力源，系统卸压，且应有防止误操作的锁闭
设施和明显的警示标志牌，以防造成人身及设备的安全事故。

d) 在进行维修保养时，必须确保系统和环境的清洁。

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