No.

SR150C Rotary Drilling Rig Service Manual-

hydraulic system (upper carriage)

R&D Institute
Beijing Sany Heavy Machinery
July 18, 2015
编制： 审核： 批准：
SANY HEAVY MACHINE CO.,LTD
Rotary Drilling Rig

目 录
1.
1. Introduction
Introduction of
of SR150C
SR150C Hydraulic
Hydraulic System…………………………2
System…………………………2

2.
2. Hydraulic
Hydraulic System
System (Chassis)……………………………………………5
(Chassis)……………………………………………5

3.
3. Hydraulic
Hydraulic System
System (Upper
(Upper carriage)…………………………………6
carriage)…………………………………6

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1.Introduction of SR150C Hydraulic System

The main circuit is Kawasaki double-pump double-circuit and negative flow

control system. The oil of left travel, swing, main winch 1 and rotary drive 1 is
supplied by main pump 1. The oil of right travel, aux. winch, rotary drive 2 and
main winch 2 is supplied by main pump 2.

The aux. circuit is load sensing system. The aux. valve consists of crowd valve
plate, left mast valve plate, right mast valve plate, derricking valve plate and
extending valve plate. The oil is supplied by aux. pump.

Pilot circuit consists of pilot pump, foot valve, pilot handle and several solenoid
switching valves. Pilot circuit controls the flow direction of pilot pump oil to
realize functions such as main/aux. valve switchover and motor brake releasing.
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Diesel engine

Main Driver
oil
circuit
Operation
Main Main Aux. Pilot
pump1 pump2 pump pump
Pilot valve
Main valve CONTROL
CIRCUIT
Aux. valve

Motor: rotary drive,

main/aux. winch,
Cylinder: derricking,
travel, swing
crowding, mast,
extending

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Location diagram of key hydraulic components

Main winch motor Rotary drive motor
Pilot joystick

Main valve

Travel motor
and reducer Pump
Aux. winch motor

Swing motor and reducer Aux. valve

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2. Hydraulic System on Chassis

Please refer to hydraulic system on chassis

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3. Hydraulic System on Upper carriage Crowd cylinder

3.1 Location and working principle of boom

cylinder, mast cylinder and crowd cylinder Crowd cylinder One-way
balance valve
One-way
balance valve
 Location of cylinder and balance
valve

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 Structure of hydraulic cylinder

Hydraulic cylinder transforms hydraulic energy into mechanical energy and applies it on a
movable load to produce work.
Hydraulic cylinder consists of a cylinder block, a movable piston and piston rod used to
connect the piston. The two ends of cylinder are sealed by cylinder caps.
When piston rod moves back and forth, it is guided by a removable guide sleeve.
The end with piston rod is rod port, the other end without piston rod is head port. The inlet
and outlet are located on the end cap of rod port and head port.

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 Balance valve
Sant balance valve is adopted for rotary drilling rig.
Structure: balance valve consists of relief valve and one-way valve. When oil circuit flows from
multi-way valve to balance valve, it enters cylinder through one-way valve; when oil circuit
flows from cylinder to balance valve, it enters multi-way valve through relief valve.

The following figure is the sectional view of balance valve. Oil port V1 and V2 are
connected to multi-way valve; C1 and C2 are connected to cylinder. This sectional view
clearly presents the inner structure and the course of action of balance valve.

Two-way
Two-way balance
balance valve:
valve: sectional
sectional view
view Relief
Relief valve
valve adjusting
adjusting screw
screw

One-way
One-way valve
valve

Pilot
Pilot spool
spool Relief
Relief valve
valve spring
spring

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 One-way balance valve

The structures of one-way balance
valve and two-way balance are
similar. The difference is one-way
balance valve only acts in one
direction.
In pressurized circuit, when
directional valve guides the flow to Relief
the head port of crowd cylinder, the
rotary drive connected to the piston valve
rod will fall out of control and the
pump flow will be vacuumed.
To avoid this, a one-way balance
valve is set on the rod port of crowd
cylinder. When rod port pressure
and pilot pressure is larger than Oil port
balance valve set pressure, the spool V2
will open to connect port 1 and port
2. When crowd cylinder moves Pilot port Pilot port
downward, balance valve will Pi1 Pi1
balance rotary drive weight.
Oil port V2
Check
valve
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The function of balance valve

Locking load: because balance valve is directly
connected to the hydraulic cylinder, the set
pressure of balance valve is higher than the
pressure generated by the maximum load, when
the hose connecting the balance valve and multi-
way valve bursts, the pressure generated by load is
insufficient to make the relief valve of balance
valve open, which can lock cylinder to prevent
accident.
Balancing load: when hydraulic cylinder moves
downward, the spool of balance valve
automatically adjust the opening according to the
load heavy.

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Balance valve pressure setting and adjusting

Pressure setting: the cracking pressure of relief valve can be adjusted by adjusting screw and
it should be larger than the max. load pressure. The cracking pressure should not be set too
large or there will be pressure loss.

Adjusting
Adjusting screw
screw

Two-way
Two-way balance
balance valve:
valve: used
used on
on mast
mast cylinder,
cylinder, boom
boom cylinder
cylinder One-way
One-way balance
balance valve:
valve: used
used on
on crowd
crowd cylinder
cylinder

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2. Main winch motor function and working principle

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 Main winch motor

Motor B port, main

winch lifting
Motor A port Shuttle valve
Main winch lowering Motor Br port, brake oil
outlet
Motor BVD balance
valve Motor Mb port
Motor Ma port Motor S port, feed
port
Main winch motor
Motor relief valve
Motor T port, oil outlet
Main winch free-fall
Reducer brake port solenoid valve oil drain

17D solenoid
valve, main winch
free-wheel

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 Main winch motor working principle

Main winch motor adopts Rexroth A2FE107/61W-
VZL181-K ＋ BVD25W38L. The function of
main winch motor is driving winch drum to lift or
lower Kelly bar. It is the important component of
rotary drilling rig for realizing drilling operation.
Activate main winch brake when lifting or
lowering Kelly bar. Under special circumstances, 11
only when the main winch oil inlet passage and oil
return passage are connected and main winch is in
free-fall status, then operate crowding cylinder to
make Kelly bar perform drilling operation.

1—17D solenoid valve (main winch free-fall)

2—balance valve 3—relief valve
4—hydraulic motor 5—reducer brake hydraulic cylinder
6—one-way valve
7—makeup check valve 8—switching valve
9—reducing valve 10—shuttle valve 1
11—shuttle valve 2
Main winch hydraulic schematic diagram

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 Main winch brake deactivated and oil flow direction

Deactivate brake before operating

main winch.
Oil flow direction: main pump—main
valve (pilot handle switchover) —
main winch motor B port (or A port)
— shuttle 2 — switching valve —
reducing valve — motor Br port —
shuttle 1— brake hydraulic cylinder
(deactivate brake).

Main winch brake deactivated oil

circuit has time delay function to
reduce the wear of friction plate.
Brake deactivated oil pressure:
2.2~2.8MPa 。

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 Oil flow direction during main winch lifting

Main pump—main valve (pilot

handle switchover)—main winch
motor B port—the throttle valve on
the left side of balance valve—
balance valve switchover—motor
movement, oil flows to cylinder
through balance valve, check valve
and motor A port.

Oil inlet
Oil return

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 Oil flow direction during main winch lowering

Main pump—main valve (pilot

handle switchover)—main winch
motor A port—the throttle valve on
the right side of balance valve—
balance valve switchover—motor
movement, oil flows to cylinder
through balance valve, check valve
and motor B port.

Oil inlet
Oil return

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 Main winch free-fall

When drilling bucket is close to the drilling
position, main control valve is in neutral position.
Press free-fall button, winch free-fall solenoid
valve (on chassis pilot quadruple valve block) and
17D solenoid valve are energized. The pilot
pressure enters main winch brake hydraulic
cylinder, main winch brake is deactivated. At the
same time, MA and MB are connected, Kelly bar
free-fall function can be realized under the
external forces.
Only when the drilling tool touches the hole
bottom, free-fall function can be activated. Or the
Kelly bar and drilling tool will fall freely because
of gravity, which will cause damage to drilling
tool or the inner wall of hole. This can also be
severe and then result in hole collapse.

The pressure is from the floating

solenoid valve of chassis pilot
quadruple valve block.
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 Overload protection and oil feed function

Because Kelly bar and drilling tool are too

heavy, if brake suddenly, the inertia will create
great impact on the system. To absorb the
impact and protect system devices, two one-
way relief valves are added to absorb the
impact.

When Kelly bar lowers fast, there will be

insufficient oil in main circuit and this will cause
motor suction and cause damage to main winch
motor. So two makeup check valves are installed
in main winch motor to avoid motor suction.

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 Stable startup and brake function

Main winch motor is equipped with balance valve, which can realize hydraulic buffer by inner
one-way throttle valve to ensure the stable startup and shutdown.

Brake spool of main winch balance valve is reset by spring. After long-term use, if deformation
appears, it will cause spool sensitivity decreasing and Kelly bar slipping will occur.

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 Motor balance valve disassembly

Relief valve

Balance valve end cap

plug

Check valve

Balance valve end cap

Brake shuttle valve connecting port

Balance valve
Brake relief port

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Remove the plug of adjustable mouth of relief valve, you can see the
inner structure of relief valve.

Inner structure of
relief valve

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Inner structure of relief valve

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Disassembly of balance valve spool: first remove the bolts on the end
caps of both sides of the balance valve.

Remove the Remove the

four bolts four bolts

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After removing four bolts,

remove the spool.

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spool

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Inner structure of balance valve spool, use a hand vice to clamp it.

Damping hole

Damping spool

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Damping spool

Unscrew with socket head cap screw

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The disassembled damping valve spool

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3.Aux. winch motor function and working principle

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 Schematic diagram of aux. winch motor

Motor Br port, brake release port

Motor balance valve

Motor B port

Motor S port

Motor A port
Motor relief valve

Motor T port, oil drain port

Reducer brake deactivated port

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 Aux. winch motor function and working principle

Rexroth A2FE63/61W-VZL181-K ＋ BVD20W17
is adopted.
The function of aux. winch motor is driving aux.
winch drum to lift drilling tool or other load.

Aux. winch circuit is similar to main winch

circuit. The difference is that aux. winch do not
have free-fall function.
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Note:
Aux. winch rotates faster, operate the handle
evenly. Avoid suddenly shifting the lever, failure
to do so will cause damage to motor reducer.

1—balance valve 2—relief valve 3—hydraulic motor 4

—reducer brake hydraulic cylinder 5—check valve Aux. winch hydraulic schematic diagram
6—oil feed check valve 7—switching valve
8—reducing valve 9—shuttle valve

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3.Rotary drive motor and working principle

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 Rotary drive motor schematic diagram

Motor A port
Motor B port Motor X port
Motor T port,
Rotary drive motor 1 oil drain port

Rotary drive motor 2

Rotary drive
motor oil feed,
relief valve

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 Rotary drive motor and working principle

During drilling operation, the rotation
speed of rotary drive must change
frequently to meet different working
conditions. So a variable motor is
needed to realize this function of rotary
drive.

Rexroth variable motor is adopted and

the mode is A6VM107HA2T/63W-
VAB010A. The main function of
rotary drive motor is driving Kelly bar
to rotate. It is the most important part
in drilling operation. During drilling
operation, load torque is transmitted to
rotary drive motor directly.

The structure of rotary drive motor is shown as the right 1—drive shaft 2—plunger 3—cylinder
figure. The pressure oil enters plunger through valve plate, 4—valve plate 5—groove 6—control block
pushes the plunger to move forward and backward. This
action is transformed into rotational motion by the ball
joint of plunger shaft. Cylinder rotates with the plunger and
generates torque.
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 The variable function of rotary drive Hydraulic

motor
Rotary drive motor can automatically
adjust motor displacement according to
system pressure. The maximum
displacement is 107cm³ and the minimum
displacement is 40cm³ 。
When the system pressure is low, variable
control valve is in the left position,
pressure oil pushes cylinder move
rightward, motor displacement is
reduced. When system pressure reaches
the preset pressure of variable control
valve, the valve is reversed. The pressure
oil enters the big cavity of hydraulic
cylinder through one-way throttle valve.
Because of the big space of this cavity,
the oil will push the cylinder piston to
move leftward, and the maximum
displacement is achieved.
Control Hydraulic
The motor displacement is automatically
valve Spring cylinder
adjusted based on the pressure difference
of system pressure and spring pressure.
Rotary drive motor hydraulic schematic diagram

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Hydraulic
 Rotary drive motor low speed high torque motor

When rotary drive is in low speed

high torque mode, the T control
solenoid valve of pilot quadruple
valve block is energized. Pressure oil
enters the left cavity of variable
control valve through this solenoid
valve and motor X port to make
control valve reverse. The pressure oil
in working circuit enters the big
cavity of hydraulic cylinder through
one-way throttle valve. Because of
the big space of this cavity, the oil
will push the cylinder piston to move
left, and the maximum displacement
is achieved. In this mode, rotary drive
Hydraulic
motor is working under the maximum Control
valve Spring cylinder
displacement and rotary drive is in
low speed high torque mode.
Rotary drive motor hydraulic schematic diagram

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 Rotary drive motor make-up relief valve (on A

rotary drive oil bracket)
When rotary drive stops suddenly,
this will create a great impact on the
system because of the inertia. The B
relief valve on rotary drive return
circuit can absorb the impact when
rotary drive stops suddenly.

When drilling from hard formation S make-up port

to soft formation, drilling speed will
be accelerated instantaneously. In Relief valve
this condition, the accelerated motor
will cause motor suction, so the Make-up
make-up circuit is added to the motor check valve
circuit to prevent vacuum occurring.
When rotary drive motor is about to
be vacuumed, the oil in make-up
circuit will enter working circuit
through check valve to realize oil
make-up to prevent motor vacuum.
Rotary drive motor make-up relief valve

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THANKS

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