Hydraulic Training

SERVICE MANUAL
HH200
HH220
HH300
HYDRAULIC TRAINING
Rev. 0 ( 01/2008 )
Drillmec SpA
Drilling Technologies
12, Via 1° Maggio

I-29027 Gariga di Podenzano
PIACENZA (Italy)
Corporate web site: http://www.drillmec.com

Mailbox: [email protected]
CAREFULLY READ THIS MANUAL Ph +39.0523.354211
BEFORE OPERATING THE MACHINE Fx +39.0523.524418
Service Manual
Hydraulic Training
Page 2 - Hydraulic Training
INDEX
1 hydraulic symbols.......................................................................................4
2 CHECK VALVE.....................................................................................................7
2.1 inline check valve ........................................................................................................................................ 7
3 PRESSURE REGULATOR (CONTROL PANEL).................................................8

3.1 pressure relief valve dbdH..................................................................................................................... 8
3.2 PRESSURE REGULATOR OB.1472..................................................................................................................... 9
3.3 pressure relief valve r1e02................................................................................................................... 10
4 remote control..........................................................................................12
4.1 hydraulic proportional remote control valve pcl4 ............................................................... 12
4.2 hydraulic remote control hc-rcv...................................................................................................... 15
5 pressure relief valve (HYDRAULIC POWER UNIT)..............................16

5.1 pressure control r5 with 3 ports . .................................................................................................... 16
5.2 pressure relief valve rpgc ................................................................................................................... 20
6 PRESSURE RELIEF VALVE (MAST-ROPE TENSIONING CYLINDERS)........21

6.1 pressure relief valve dbdS................................................................................................................... 21
7 OVERCENTER VALVE.......................................................................................23
7.1 OVERCENTER VALVE - OUTRIGGER/MAST LIFTING..................................................................................... 23
7.2 OVERCENTER VALVE - power swivel shift............................................................................................. 29
7.3 OVERCENTER VALVE - POWER TONG UP/DOWN.......................................................................................... 35
7.4 OVERCENTER VALVE - jib crane rotation.............................................................................................. 38
7.5 hydraulic cylinder holding valves.................................................................................................... 40
8. PRESSURE REDUCING / RELIEVING VALVE.................................................43

8.1 PRESSURE REDUCING/RELIEVING VALVE ( TOP DRIVE/HANDLING ) PP*B SUN ( pART# 50850964 )... 43
8.2 PRESSURE REDUCING/RELIEVING VALVE ( handling system ) ZDR6DP2 rexroth ( pART#
50850964 )............................................................................................................................................................ 45
8.3 pressure reducing valve OB.1388 OLEOBI ( handling system )................................................... 48
9. flow control valve..................................................................................50

9.1 FLOWRATE CURVES......................................................................................................................................... 51
10. SHUTTLE VALVE............................................................................................52

10.1 SHUTTLE VALVE A10020202 HBS.................................................................................................................. 52
11. sandwich style directional valve section..................................54

11.1 general description................................................................................................................................. 54
11.2 drill pipe handler proportional valve........................................................................................... 55
11.3 service proportional valve.................................................................................................................. 56
11.4 mast raising/ outriggers proportional valve............................................................................. 57
11.5 jib crane proportional valve.............................................................................................................. 58
12. accumulators for hydraulic............................................................59

12.1 charging accumulators......................................................................................................................... 59
12.2 charging procedure................................................................................................................................ 59
13. INTRODUCTION TO LOAD SENSE HYDRAULIC CIRCUITS.......................65

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Hydraulic Training - Page 3
14. AXIAL PISTON PUMP ( FIXED DISPLACEMENT )........................................66

15. axial piston pumps (vARIABL. dISPLACEMENT-PILOT CONTROL )..69
16. hydraulic pump training series........................................................77
16.1 hydraulic pump with all function in neutral pump at minimum output............................. 77
16.2 hydraulic pump with boom function activated pump at required output........................ 78
16.3 hydraulic pump with cylinder pressurized at the end of stroke, pump at minimum ou-
tput..................................................................................................................................................................... 79
16.4 hydraulic pump with bypass valve open, pump at maximum output .................................... 80
17. plumbing to the power unit (hh220/hh200/hh300).........................81

17.1 general description of power unit.................................................................................................. 81
17.2 quick connection from hydraulic power unit to semitrailer.............................................. 83
17.3 filling drilling rig pressure hoses.................................................................................................. 92
17.4 bleeding the hydraulic system........................................................................................................... 92
19.1 PULL-DOWN MAIN BLOCK HH300................................................................................................................. 98
19.2 PULL-DOWN MAIN BLOCK HH200/HH220................................................................................................... 100
20. FLOATING BLOCK ob.2317 (part 50851425)..........................................102

20.1 scheme of floating blocK................................................................................................................... 102
21. OPERATING PROCEDURE for RELIEF VALVE of distributor of

service and mast jib crane..................................................................107
22. OPERATING PROCEDURE TO SETTING ROTARY TABLE.......................108
22.1 HYDRAULIC CIRCUIT DESCRIPTION........................................................................................................... 108
22.2 HYDRAULIC BLOCK DESCRIPTION............................................................................................................. 109
22.3 SETTING OPERATION.................................................................................................................................... 110
23. OPERATING PROCEDURE TO SETTING bit breaker tongs............. 112

23.1 hydraulic circuit description........................................................................................................... 112
23.2 setting procedure.................................................................................................................................. 113
24. OPERATING PROCEDURE TO SETTING mouse hole . ........................ 114

24.2 setting procedures............................................................................................................................... 117
25. SETTING OF TORQUE WRENCH................................................................119

25.2 HYDRAULIC COMPONENT............................................................................................................................ 123
25.3 setting procedure of torque wrench.......................................................................................... 124
26. SETTING PROCEDURE OF POWER TONG................................................127

26.1 HYDRAULIC CIRCUIT DESCRIPTION........................................................................................................... 127
26.2 HYDRAULIC CIRCUIT COMPONENT............................................................................................................ 128
26.3 setting procedure OB.2111 (PART# 50851065)................................................................................... 130
27. PROCEDURE FOR RELEASING OF TORQUE, IF DRILL STRING GETS

TORQUE UP AND STOP.................................................................................131
27.1 TOP DRIVE STALLED AT MAXIMUM TORQUE............................................................................................ 131
27.2 TOP DRIVE STALLED WITH LOWER RESIDUAL TORQUE........................................................................ 132
Service Manual
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1 hydraulic symbols
SHOWING DIN (ISO 1219) SYMBOLS USED ON DRILLMEC SCHEMATICS

NO ATTEMPT HAS BEEN MADE TO SHOW EVERY POSSIBLE COMBINATION.
LINE, WORKING
PUMP, SINGLE
FIXED DISPLACEMENT
LINE, PILOT or SIGNAL
LINE, DRAIN
PUMP, SINGLE
CONNECTOR VARIABLE DISPLACEMENT
HOSE (Shown only when a hose is

necessary as opposed to a pipe or tube)
PUMP, SINGLE
VARIABLE DISPLACEMENT,
SHOWING LOAD SENSING
LINE, JOINING COMPENSATOR
("T" FITTING) (USED ON ALL PROPORTIONAL
SENSING SYSTEM)
LINE, PASSING MOTOR, ROTARY,

FIXED DISPLACEMENT
LINE TO RESERVOIR (TANK)

MOTOR, ROTARY,
(ABOVE FLUID LEVEL)
VARIABLE DISPLACEMENT
(BELOW FLUID LEVEL)
CYLINDER, SINGLE ACTING

LINE, PLUGGED
1.3 1.3 CYLINDER, DOUBLE ACTING

RESTRICTION, FIXED
(orifice, nozzle) OR
CYLINDER,
RESTRICTION, VARIABLE DIFFERENTIAL ROD
(throttle valve or adjustable orifice)
CYLINDER, DOUBLE
MANUAL SHUT-OFF VALVE
(MANITROL VALVE)
END ROD
PRIME MOVER, HH300 PULL-DOWN CYLINDER

M
ELECTRIC MOTOR
PRIME MOVER, C
INTERNAL COMBUSTION ENGINE D
(Diesel shown..."G" if gas.)
B A
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COMPONENT ENCLOSURE QUICK COUPLING
VENTED RESERVOIR
BASIC VALVE ENVELOPE
(TANK)
NORMALLY CLOSED
PRESSURE GAUGE
NORMALLY OPEN
TEMPERATURE GAUGE
PRESSURE RELIEF VALVE
(SAFETY VALVE OR
SAFETY CARTRIDGE) 280 bar
ACCUMULATOR,
GAS CHARGED
PRESSURE RELIEF VALVE
WITH EXTERNAL DRAIN
(SHOWN WITH A NORMALLY
300 bar
OPEN SOLENOID VALVE...
MANY OTHER POSSIBILITIES
ACCUMULATOR,
ARE AVAILABLE).
SPRING LOADED
FILTER OR STRAINER PRESSURE REDUCING VALVE
FILTER WITH INTEGRAL

BYPASS CHECKVALVE PRESSURE REDUCING/RELIEVING
6 bar VALVE
OIL COOLER WITH

ELECTRIC FAN MOTOR M
THROTTLE 1.5
OIL COOLER WITH
HYDRAULIC FAN MOTOR CHECK VALVE
FIXED (size shown) ADJUSTABLE
HYDR. REMOTE CONTROL
PRESSURE SWITCH
CARTRIDGE VALVE
CHECK VALVE (BASIC) FLOW DIRECTION PRESSURE

CONTROL CONTROL
CHECK VALVE, FIXED FORCE A 2.0
(SPRING FORCE INDICATED)
CARTRIDGE VALVE WITH

PROPORTIONAL REMOTE STROKE LIMITER
CONTROL VALVE
HYDRAULICALLY UNLOCKABLE
CHECK VALVE.
PILOT ELECTROVALVE
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BRAKE VALVE OVERCENTER VALVE DIRECTIONAL VALVE, 3 POSITION,

(ONE VALVE USED ON 5 WAY, LOAD SENSING,
EACH SIDE DOUBLE ACTING CYLINDER) CLOSED PRESSURE CENTER,
INFINITE POSITIONING
(PROPORTIONAL)
PROPORTIONAL DIRECTIONAL VALVE, 3 POSITION,

THROTTLE CARTRIDGE 5 WAY, LOAD SENSING,
(USED ON MAIN BLOCK CLOSED CENTER,
LOWERING FUNCTION)
INFINITE POSITIONING
(PROPORTIONAL)
DIRECTIONAL VALVE: METHODS OF OPERATION

OVERCENTER
(WITH BRAKE)
(USED ON RELEASE
JIB CRANE WINCH) PILOT PRESSURE OR
SOLENOID
DOUBLE OVERCENTER VALVE
(COUNTERBALANCE VALVE) SPRING
MANUAL
(HANDLE OR PUSHBUTTON)
SHUTTLE VALVE P P DETENT

A
BALL COCK
(SHUT OFF VALVE,
QUARTER TURN VALVE) HAND LEVER
DIRECTIONAL CONTROL VALVES EXAMPLES OF COMBINATIONS OF METHODS

BASIC VALVE SYMBOL SOLENOID OPERATED,
MULTIPLE FLOW PATHS SPRING RETURN
DIRECTIONAL VALVE
2 POSITION, 3 WAY HAND LEVER OPERATED
WITH DETENT
DIRECTIONAL VALVE
2 POSITION, 4 WAY
HAND LEVER OR
DIRECTIONAL VALVE SOLENOID OPERATED,
3 POSITION, 4 WAY, CLOSED CENTER SPRING CENTERED
DIRECTIONAL VALVE
3 POSITION, 4 WAY, OPEN CENTER SOLENOID CONTROLLED,
PILOT PRESSURE OPERATED,
DIRECTIONAL VALVE SPRING CENTERED,
3 POSITION, 4 WAY WITH HAND LEVER
CLOSED PRESSURE CENTER
DIRECTIONAL VALVE
3 POSITION, 4 WAY, TANDEM CENTER
(REQUIRES A HOLLOW SPOOL)
PUMP,VARIABLE DISPLACEMENT
DIRECTIONAL VALVE
3 POSITION, 6 WAY, CLOSED CENTER (10631) COMPENSATOR + TORQUE
LIMITER CONTORL
DIRECTIONAL VALVE, 3 POSITION,
6 WAY, CLOSED PRESSURE CENTER,
ORIFICED A & B PORTS IN CENTER (10632F)
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2 CHECK VALVE
2.1 inline check valve
2.1.1 VALVE ft257
FT257/6/2 Inline check valve 1/2” Gas 2 bar ( Part# 50851221 )

FT257/6/38 Inline check valve 3/8” Gas 0.35 bar ( Part# 50851223 )
Fig. 2-1.1

Type A B C CH P r e s s u r e Weight (kg)
(bar)
12 1/2” G 15.5 80.5 32 400 0.415
38 3/8” G 12.5 69 27 400 0.260
2.1.2 VALVE rv25
RV25 Inline check valve 1 1/4” Gas ( Part# 50850291 )
Part # 50850291
RV25-1.0 - 1.1/4”
Fig. 2-1.2
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3 PRESSURE REGULATOR (CONTROL PANEL)

3.1 pressure relief valve dbdH
Model DBDH-6 REXROTH (Part# 50850894)
Fig. 3-1.1 Fig. 3-1.2
The DBD pressure relief valve are direct operated poppet valves. They are used to limit the pressure in a hydraulic
system.
The valves mainly consist of sleeve (1), spring (2), poppet with damping spool (3) (pressure stages 25 to 400 bar) or
ball (4) ( pressure stage 630 bar ) and adjustment element (5). The setting of the system pressure if infinitely variable
via the adjustment element (5). The spring (2) pushes the poppet (3) onto the seat. The P channel is connected to
the system. The pressure present in the system is applied to the poppet area ( or ball).
If the pressure in channel P rises above the value set at the spring (2), the poppet (3) or ball (4) opens against the
spring (2). Now pressure fluid flows channel P into channel T. The stroke of the poppet (3) is limited by a pin (6).
In order to mantain a good pressure settings over the entire pressure range the pressure range is split into 7 pressure
stages. One pressure stage corresponds to a certain spring for a maximum operating pressure which may be set
with it.
Fig. 3-1.3
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3.2 PRESSURE REGULATOR OB.1472
Model OB.1472.4 OLEOBI (Part# 50850870)
Fig. 3-2.1
Fig. 3-2.2
1. Frame of valve OB.1472.

2. Regulator valve, pressure range 10-420 bar
3. Handwheel for adjustment of valve
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3.3 pressure relief valve r1e02
Model R1E-02-*5**-A1 DENINSON ( Part# 50850443 )
Fig. 3-3.1
The valve series R1E02 is a direct operated pressure relief valve. It is designed to control system pressure according
to the manual setting of the adjustment device (p-Q- function diagram)
These reliable seat type valves consists mainly of seat, con and pressure spring. Below the setting pressure the valve
is leakage free. A damping spool maintains a stable function ater the setting pressure is reached.
Fig. 3-3.2
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3.3.1 GENERAL TECHNICAL DATA
• Design: Poppet type

• Type of mounting: Panel mounting
• Mounting position: Optional
• Direction of flow: P-T
• Ambient temperature range: -20 °C , +60°C
3.3.1 HYDRAULIC CHARACTERISTICS
• Operating pressure range - Inlet ( Port P) 0-350 bar

• Pressure setting range: 7-350 bar
• Nominal Flow: 3.8 l/min
• Contamination level: Max.Permissible contamination level according to NAS 1638 Class
8 ( Class 9 for 15 micron and smaller ) or ISO 17/14 -18°C+80°C
• Fluid temperature range: -18°C + 80°C
• Viscosity range: 10-650 cSt; optional 30 cSt
Fig. 3-3.3
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4 remote control
4.1 hydraulic proportional remote control valve pcl4
PCL 402-2244/A with block level in neutral position, setting 7-17 bar. (Part# 50670152)
PCL 402-2245/A with block level in neutral position, setting 15-34.2 bar, with step. (Part# 50670153)
PCL 402-02-IT60-005 with block level in neutral and external position, setting 3.5-28.9 bar. (Part# 50670220)
PCL 402-2385/A with block level in neutral and external position, setting A-B 5-25 bar, with step. (Part# 50670166)
Fig. 4-1.1
4.1.1 technical information
Pressures
Supply pressure (pump pressure) max. 100 bar (1450 psi)
Recommended supply pressure 15 bar (218 psi) higher than max. control pressure
Control pressure max. 75 bar 1090 psi)
Breakaway pressure min. 1 bar, (14,5 psi) max. 16 bar (232 psi)
Return-line pressure max. 3 bar (44 psi)
Flow rate
Control flow max. 15 l/min (4 USgpm)
Hysteresis
Hysteresis max. 0.5 bar (7,3 psi)
Filtration
Filtration should be arranged so that the Target Contamination Class 18/16/13 according to ISO 4406 is not excee-
ded.
Temperature
Min. ambient temperature –40 °C (-40 °F)
Max. ambient temperature +60 °C (140 °F)
Min. oil temperature –20 °C (-4 °F)
Max. oil temperature +70 °C (166 °F)
Temperature change max. 100 °C/s. max. 212 °F/s
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WARNING
If the filtration demands are not met, the valve poppets can jam in the open position, with the result that the
valve remains actuated. It is not possible to force back jammed poppets mechanically.
Lever forces
All lever forces stated are applicable at a control pressure of 15 bar (valve not fitted with an extra centring spring).
Pedal forces are applicable when the C2 centring spring is used (see page 9).
Normal force for linear lever, fully actuated 1.2 Nm

Normal force for coordinate lever (joystick)
one function fully actuated 1.8 Nm
two functions fully actuated 2.4 Nm
Connections
Three different types of connection thread are available:
G1/4 for flat seal (type Tredo) according to ISO 228/1 (G version)
9/16-18 UNF-2B (for O-ring) according to SAE J1926/1 (U version)
M14 x 1.5 (metric ISO thread) for flat seal (M version)
Weight
The weight of the unit varies with its configuration. A few examples are given below.
Valve with linear lever approx. 1.6 kg/section
Lever unit
(activating
device)
Bellows
Extra
centring
spring
Lever detent
MD2
P
Mounting plate
T
Tank
connection
Regulator
Spool
Pump A B
connection
Signal ports
Fig. 4-1.2
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4.1.2 control pressure
Control pressure
Control pressure characteristics can be obtained in an almost infinite number of versions. They are classified into
four different groups.
• Straight characteristic
• Straight characteristic with overtravel stroke
• Broken characteristic
• Broken characteristic with overtravel stroke
With the straight characteristic, the control pressure changes proportionally with the lever stroke. With the broken
characteristic, the control pressure changes proportionally with the lever stroke up to a pre-determined breakpoint,
after which the characteristic continues to change proportionally, but with a steeper characteristic. This is useful when
there is a big difference between breakout pressure and final pressure and a need to fine-regulate the beginning of
the stroke.
With the overtravel stroke, the control pressure becomes equal to the supply pressure. This is recommended primarily
for directional valves that have a free flow gallery (CFO). The overtravel stroke serves to ensure full actuation regar-
dless of any return-spring tolerances in the spool actuator of the directional valve.
To calculate a suitable control-pressure characteristic, the following information is needed:
Breakout pressure:
The pressure at which the valve just begins to open.
Selectable between 1 and 16 bar.
Final pressure:
Max. control pressure (fully actuated activating device) or, in case of overtravel stroke, the pressure level
obtained on reaching the overtravel stroke. Selectable between 5.5 and 75 bar.
Breakpoint:
The lever stroke and pressure at which the broken characteristic changes characteristic.
Overtravel stroke:
The part of the activating-device stroke that constitutes overtravel.
Fig. 4-1.3
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4.2 hydraulic remote control hc-rcv
HC.RCV.***.B05. ( Part# 50670213 )

HC.RCV.***.A05. ( Part# 50670135 )
Fig. 4-2.1
Fig. 4-2.2
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5 pressure relief valve (HYDRAULIC POWER UNIT)

5.1 pressure control r5 with 3 ports
R5V12 Pressure controls flanged type, series R5 with 3 ports ( Part# 50851444 )
Fig. 5-1.1
5.1.1 general description
Pressure valves are pilot operated controls consisting of two or three valve sections, either a high flow, poppet type
seat valve section controlled by the low flow, adjustable pilot mounted on top or in the case of the Proportional Pressure
Relief Valve, the proportional section P2 sandwiched between the pilot valve and the main body.
Pressure setting is achieved by means of a knurled knob or, if a tamperproof setting is required, by an acorn nut with
lead seal. A proportional pressure setting is achieved according to the current input by R5V....P2.
5.1.2 PRESSURE RELIEF VALVE
R5V pressure relief valves are used to limit the system pressure of a hydraulic system, in order to control the force
exerted by a hydraulic actuator. The R5V valve may also used to generate a pressure drop in a hydraulic circuit.
Normally the pump is connected to Port A and the tank line to Port B.
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Fig. 5-1.2
5.1.3 curves
Fig. 5-1.3
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5.1.4 code of r5v

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Fig. 5-1.4
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5.2 pressure relief valve rpgc
Model RP*C Relief Cartridge valve SUN ( Part 50851443 )
Fig. 5-2.1
5.2.1 CONTROL VALVE
L Standard Screw Adjustment O-ring seal on adjust screw. Adjust screw positively retained. Overset protection-pilot
spring cannot go solid.
Fig. 5-2.2
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6 PRESSURE RELIEF VALVE (MAST-ROPE TENSIONING CYLINDERS)

6.1 pressure relief valve dbdS
Model DBDS-10 REXROTH ( Part 50850427 )
Fig. 6-1.1
The DBD pressure relief valve are direct operated poppet valves. They are used to limit the pressure in a hydraulic
system.
The valves mainly consist of sleeve (1), spring (2), poppet with damping spool (3) (pressure stages 25 to 400 bar) or
ball (4) ( pressure stage 630 bar ) and adjustment element (5). The setting of the system pressure if infinitely variable
via the adjustment element (5). The spring (2) pushes the poppet (3) onto the seat. The P channel is connected to
the system. The pressure present in the system is applied to the poppet area ( or ball).
If the pressure in channel P rises above the value set at the spring (2), the poppet (3) or ball (4) opens against the
spring (2). Now pressure fluid flows channel P into channel T. The stroke of the poppet (3) is limited by a pin (6).
In order to mantain a good pressure settings over the entire pressure range the pressure range is split into 7 pressure
stages. One pressure stage corresponds to a certain spring for a maximum operating pressure which may be set
with it.
Fig. 6-1.2
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6.1.1 dimension OF VALVE WITH screw
1.1 Adjustment element “S” grub screw for pressure setting and protective cap, internal hexagon (Fig. 6-1.4)
4 Connection port P Optional about the circumference or at the bottom (Fig. 6-1.5)
5 Connection port T optional about the circumference (Fig. 6-1.5)
6 Type code (Fig. 6-1.4)
7 Pressure rating (stamped on) (Fig. 6-1.4)
8 Fitting depth (Fig. 6-1.5)
9 Locknut
10 Space required to remove key
Fig. 6-1.3 Fig. 6-1.4

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7 OVERCENTER VALVE
7.1 OVERCENTER VALVE - OUTRIGGER/MAST LIFTING
7.1.1 overcenter valve ob.1663 (part 50850920)
Fig. 7-1.1
1. HYDRAULIC BLOCK FOR CAVITY T-11A
2. COUNTERBALANCE VALVE CA** , Pressure Range 10-420 bar ( SUN)
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IMAGE FOR EXAMPLE
Fig. 7-1.2
DIMENSION
Fig. 7-1.3
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REGULATION
All Sun counterbalance cartridges are built with a leakproof
adjustment (O-ring seals on the adjusting screw) but are not
designed for frequent adjustment in the field.
Cartridges that are factory pre-set by Sun to a customer specified
pressure setting are available and can be installed directly on a
machine without the need for further adjustment.
Fig. 7-1.4
PERFORMANCE CURVE
- Valves are unaffected by back pressure at

Port 2
- Maximum leakage 5 drops/min at reseat.
Reseat exceeds 85% of set pressure
Fig. 7-1.5
CODE REFERENCE
Fig. 7-1.6
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7.1.2 PILOT OPERATED CHECK VALVE ob.1663.03.00 (part 50850989)
Fig. 7-1.7
1. HYDRAULIC BLOCK FOR CAVITY T-11A 1/2” SAE 6000
2. PILOT OPERATED CHECK VALVE CK** ( SUN)
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IMAGE FOR EXAMPLE
Fig. 7-1.8
DIMENSION
Fig. 7-1.9
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CODE REFERENCE
Fig. 7-1.11
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7.2 OVERCENTER VALVE - power swivel shift
7.2.1 overcenter valve ob.1793.00.01 (part 50850919)
Fig. 7-2.1
1. HYDRAULIC BLOCK FOR CAVITY T-2A
2. COUNTERBALANCE VALVE CA** 5:1, Pressure Range 148-428 bar ( SUN)
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DIMENSION
Fig. 7-2.2
REGULATION
Fig. 7-2.3
PERFORMANCE CURVE

Port 2
Fig. 7-2.4
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CODE REFERENCE
Fig. 7-2.5
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Fig. 7-2.7
2. COUNTERBALANCE VALVE CA** 4,5:1, Pressure Range 140-420 bar ( SUN)
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iMAGE FOR EXAMPLE
Fig. 7-2.8
DIMENSION
Fig. 7-2.9
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REGULATION
Fig. 7-2.10
PERFORMANCE CURVE

Port 2
Fig. 7-2.11
CODE REFERENCE
Fig. 7-2.11
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7.3 OVERCENTER VALVE - POWER TONG UP/DOWN
Fig. 7-3.1
2. COUNTERBALANCE VALVE CA** 3:1, Pressure Range 25-105 bar ( SUN)
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DIMENSION
Fig. 7-3.2
REGULATION
Fig. 7-3.3
PERFORMANCE CURVE

Port 2
Fig. 7-3.4
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CODE REFERENCE
Fig. 7-3.5
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7.4 OVERCENTER VALVE - jib crane rotation
7.4.1 overcenter valve VBS0.DE.NA. - 05.42.25.10.02.35.00 OIL CONTROL (part 50850384)
Fig. 7-4.1
Fig. 7-4.2
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7.4.2 performance curve
Fig. 7-4.3
7.4.3 CODE
Fig. 7-4.4
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7.5 hydraulic cylinder holding valves
Drillmec uses a specially-designed overcenter valve on all hydraulic cylinders which operate jib crane. These valves
seal the hydraulic cylinder to prevent it from creeping or moving until pressure
is applied to it. If too much weight ia applied to a boom section, it also acts as a structural safety valve and relieves
the excess pressure at a controlled rate. A holding valve is installed at both ends of the hydraulic cylinder to prevent
movement and limit pressure in either direction.
JIB CRANE ARM JIB CRANE ARM

CBBL.LJN CBBL.LJN
C V V C
PIL PIL
PIL PIL
C V V C
CBBL.LJN CBBL.LJN
V
PIL
PIL
Fig. 7-5.1
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( PIL )
(V)
(C)
+
-
-
+
Fig. 7-5.2
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- Maximum setting should be 1.3 times the

maximum load induced pressure
- Maximum leakage 5 drops/min. at reseat.
Reseat exceeds 85 % of set pressure.
- Back oressure at Port 2 may adversely
affect operation of valve.
Fig. 7-5.3
7.5.2 CODE
Fig. 7-5.4
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8. PRESSURE REDUCING / RELIEVING VALVE

8.1 PRESSURE REDUCING/RELIEVING VALVE ( TOP DRIVE/HANDLING ) PP*B SUN (
pART# 50850964 )
Fig. 8-1.1
DESCRIPTION
Pilot-operated, pressure reducing/relieving valves reduce a high primary oressure at the inlet ( port 2 ) to a constant
reduced pressure at port 1, with a full-flow relief function port 1 to tank ( port 3 )
TECHNICAL FEATURES
Full reverse flow from reduced pressure (port 1) to inlet (port 2) may cause the main spool to close. If reverse free
flow is required in the circuit, consider adding a separate check valve to the circuit.
If pilot flow consumption is critical, consider using direct acting reducing/relieving valves.
Recommended maximum inlet pressure is determined by the adjustment range. Ranges D, E, N, and Q are tested
with a 2000 psi (140 bar) maximum differential between inlet and reduced pressure. Ranges A, B, and H are tested
with a 3000 psi (200 bar) maximum differential between inlet and reduced pressure. Ranges C and W are tested with
5000 psi (350 bar) of inlet pressure.
Pilot operated valves exhibit exceptionally flat pressure/flow characteristics, are very stable and have low hystere-
sis.
Pressure at port 3 is directly additive to the valve setting at a 1:1 ratio and should not exceed 5000 psi (350 bar).
Pilot operated reducing, reducing/relieving valves by nature are not fast acting valves. For superior dynamic response,
consider direct acting valves.
All three-port pressure reducing and reducing/relieving cartridges are physically interchangeable (i.e. same flow path,
same cavity for a given frame size). When considering mounting configurations, it is sometimes recommended that
a full capacity return line (port 3) be used with reducing/relieving cartridges.
Incorporates the Sun floating style construction to minimize the possibility of internal parts binding due to excessive
installation torque and/or cavity/cartridge machining variations.
Service Manual
Hydraulic Training
REGULATION
All Sun pressure reducing cartridges are built with a leakproof

Fig. 8-1.2
CODE REFERENCE
Fig. 8-1.3
Service Manual
Hydraulic Training
8.2 PRESSURE REDUCING/RELIEVING VALVE ( handling system ) ZDR6DP2

rexroth ( pART# 50850964 )
Fig. 8-2.1
Pressure reducing valves tyoe ZDR 6 D are 3-way direct operated pressure reducing valves of sandwitch plate design
with a pressure relief function on the secondary side. It is used to reduce the system pressure. The pressure reducing
basically consists of the housing (1), the control spool (2), a compression spring (3) and the adjustment element (4)
as well as with an optional check valve.
The secondary pressure is set by the pressure adjustment element (4).
MODEL DP
In model “DP”, the pressure is reduced in port “P1”. The control pressure and the pilot oil is taken internally from port
P1.
Fig. 8-2.2
Service Manual
Hydraulic Training
Fig. 8-2.3
8.2.2 code reference
Fig. 8-2.4
Service Manual
Hydraulic Training
8.2.3 unit dimensions
Fig. 8-2.5
Service Manual
Hydraulic Training
8.3 pressure reducing valve OB.1388 OLEOBI ( handling system )
Override
Button
Pressure Reducing Valve

Pressure Adjustment
A P T B
Fig. 8-3.1
1. Disconnect line at B port of base plate and install a 0-100 bar gauge in the end of the hose.
2. Push override button in all the way.
3. Pressure out high pressure line.
4. Set pressure reducing valve ( see setting chart ).
5. Control the setting of pressure switch
8.3.1 reducing valves
Model: PB*B Sun (Part 50850710)
Fig. 8-3.2
Service Manual
Hydraulic Training
DESCRIPTION
Pilot-operated, pressure reducing valves reduce a high primary pressure at the inlet ( port 2 ) to a constant reduced
pressure at port 1, with a full-flow relief function port 1 to tank ( port 3 )
TECHNICAL FEATURES
Full reverse flow from reduced pressure (port 1) to inlet (port 2) may cause the main spool to close. If reverse free
flow is required in the circuit, consider adding a separate check valve to the circuit.
If pilot flow consumption is critical, consider using direct acting reducing/relieving valves.
Recommended maximum inlet pressure is determined by the adjustment range. Ranges D, E, N, and Q are tested
with a 2000 psi (140 bar) maximum differential between inlet and reduced pressure. Ranges A, B, and H are tested
with a 3000 psi (200 bar) maximum differential between inlet and reduced pressure. Ranges C and W are tested with
5000 psi (350 bar) of inlet pressure.
Pilot operated valves exhibit exceptionally flat pressure/flow characteristics, are very stable and have low hystere-
sis.
Pressure at port 3 is directly additive to the valve setting at a 1:1 ratio and should not exceed 5000 psi (350 bar).
Pilot operated reducing, valves by nature are not fast acting valves. For superior dynamic response, consider direct
acting valves.
All three-port pressure reducing cartridges are physically interchangeable (i.e. same flow path, same cavity for a given
frame size). When considering mounting configurations, it is sometimes recommended that a full capacity return line
(port 3) be used with reducing/relieving cartridges.
Incorporates the Sun floating style construction to minimize the possibility of internal parts binding due to excessive
installation torque and/or cavity/cartridge machining variations.
Fig. 8-3.3
Service Manual
Hydraulic Training
9. flow control valve

Model: FT 257/5 - 1/4” Tognella ( Part 50850137 )
Their function is to control and eventually shut-off the flow in one direction, allowing a free return flow in the opposite
direction. The check valve spring is housed in such a way that it does not close as a pack during opening of the check
valve poppet.
Needle adjustments give:
• full shut off (via metal seat);

• accurate control for a wide range of flowrates.
The valve has a graduated adjustement scale below the handle to indicate accurately the valve position.
There is a locking screw in the handle to allow the handle to be fixed.
(Preventing accidental adjustement or movement due to vibration).
A panel mounting nut (G) can be supplied on request. Opening pressure is 0.35 bar.
On request
• Versions in AISI 316 stainless steel code FT 2257/5
• Viton seals (V)
• NPT threads
• Complete with panel mounting nut (G)
• Handwheel in ABS (mp) - plastic
• Body 9 S Mn Pb 23 - UNI 5105

• Needle 1 C 40 - UNI 8373
• OR Nitrile
• Antiextrusion ring PTFE
• Check Valve 38NiCrMo4-UNI-EN10083
• Spring C72 UNI 3545
• Threaded end-plate 35SMnPb10-UNI5105
• Handwheel GD - AlSi12 - UNI 5706 aluminium
• Handwheel (mp) ABS - plastic
Fig. 9-1.1
Service Manual
Hydraulic Training
9.1 FLOWRATE CURVES
Fig. 9-1.2
Service Manual
Hydraulic Training
10. SHUTTLE VALVE

10.1 SHUTTLE VALVE A10020202 HBS
Model: A10020202.00 HBS ( Part 50850782 )
Shuttle valve is in a position to recognise, between two different fluid flow, the one with the highest pressure.
The valve has two inlet, ports “A” and “C” , and one output port “B”. When either port A or C is pressurized, a ball
automatically seals the other inlet and allows the higher pressure fluid to flow to port “B”.
A C
Fig. 10-1.1
SIZE CONNECTIONS DELIVERY RANGE MAX PRESSURE WEIGHT

REFERENCE
OF CONNECTION TYPE
CODE
Fig. 10-1.2
Service Manual
Hydraulic Training
Fig. 10-1.3
Service Manual
Hydraulic Training
11. sandwich style directional valve section

11.1 general description
The directional spool valves types PSV serve to control both, the direction of movement and the load-independent,
stepless velocity of the hydraulic consumers. In this way several consumers may be moved simultaneously, indepen-
dently from each other at different velocity and pressure ratings, as long as the sum of the partial flows needed for
this is within the total delivery supplied by the pump.
The proportional spool valves of this pamphlet are designed as valve banks and consist of three functional groups:
1. Connection Block: Pump side with ports for pressurized oil inlet P and return R back to the tank as well as
additional control and measurement ports LS, Z, M
• Depending on the nature of the pressurized oil supply either by constant delivery pump (open center) or
variable displacement pump (closed center) / constant pressure system
• Depending on the port size for P and R
• With or without integrated control oil supply
• With or without pressure limiting valve
• With or without arbitrary idle pump circulation (safety circuit)
2. 4/3- and 3/3-way directional spool valve: Add-on valves, up to 12 units may be added laterally to the connection
block, with consumer ports A and B
• Depending on the flow pattern
• Depending on the max. permissible consumer flow at the spool’s max. elevation
• Depending on the additional functions on the secondary side, e.g. pressure limiting valves, functional cut-
off
• Depending on the type of actuation
• Additional functions incorporated in other intermediate plates
3. End plate : As completion of the valve bank

• With internal drain or port T for the return flow of control oil
• With or without additional port LS / pump circulation cut-off
Fig. 11-1.1
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11.2 drill pipe handler proportional valve
Fig. 11-2.1
120 LIT./1'
120 LIT./1'
25 LIT./1'
25 LIT./1'
63 LIT./1'
80 LIT./1'
40 LIT./1'
40 LIT./1'
B A B A B A B A
Ls T
R
U W
Fig. 11-2.2
Service Manual
Hydraulic Training
11.3 service proportional valve
Fig. 11-3.1
40 LIT./1'
40 LIT./1'
16 LIT./1'
63 LIT./1'
63 LIT./1'
63 LIT./1'
40 LIT./1'
120 LIT./1'
120 LIT./1'
40 LIT./1'
160 LIT./1'
80 LIT./1'
P B A B A B A B A B A B A B A
LS T
R
U W U W U W
Fig. 11-3.2
Service Manual
Hydraulic Training
11.4 mast raising/ outriggers proportional valve
Fig. 11-4.1
Fig. 11-4.2
Service Manual
Hydraulic Training
11.5 jib crane proportional valve
Fig. 11-4.1
25 lit/1'
25 lit/1'
80 lit/1'
80 lit/1'
P B A B A
LS T
R
Fig. 11-4.2
Service Manual
Hydraulic Training
12. accumulators for hydraulic

12.1 charging accumulators
Check the accumulator gas charge every 6 months or 1,000 hours. Read all of the instructions before beginning the
job. Accumulators must be charged only with dry nitrogen. Never use compressed air or oxygen (Fig. 12-1.1), as
the oxygen molecules will combine with the hydraulic oil and lower the flash point of the oil to below room tempera-
ture.
You will create a major explosion by using compressed air or oxygen to charge accumulators. People
have died using compressed air or oxygen to charge accumulators. Use dry nitrogen, not liquid nitrogen.
EXPLOSION CAUSED BY
WARNING
IMPROPER ACCUMULATOR
CHARGING CAN RESULT IN
DEATH OR SERIOUS INJURY!
* Follow the charging instructions exactly!
* Use ONLY dry nitrogen to charge the
accumulator!
* NEVER use oxygen or compressed air to
charge the accumulator! explosion warning.eps Fig. 12-1.1
12.2 charging procedure
1. Before you begin, you will need a charging kit (Fig. 12-1.2). Do not attempt to charge the accumulators without
one. You can order the charge valve assembly from Hydac. Hydac Corporation.
2. You must use a high-pressure regulator with the nitrogen bottle. If it was not supplied with the bottle, order one-
before proceeding with this job.
3. Before beginning the charging procedure, stop the engine, remove the key, and put a “Do Not Operate” tag over
the key switch. Put the key in your pocket, so no one can start the engine.
4. Verify zero hydraulic pressure on the proper accumulator gauge before beginning. The accumulators should
dump when the engine is stopped, but you still must verify it. If pressure remains, dump the accumulators using
the manual bleed valve (Fig. 12-1.3 and Fig. 12-1.4) on the manifold.
5. If there are multiple accumulators, charge one accumulator at a time. Leave the valve protection caps (See Fig.
12-1.5) on the accumulators until you actually begin the procedure.
Service Manual
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Tank Regulated High pressure gas

pressure pressure regulator is not
included with the
kit. These are
available from the
nitrogen supplier.
Regulator adjustment
Nitrogen bottle handle
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
0
Hose
Charge valve assy
Accumulator Charging Kit

bladder
accumulator (Includes hose and charge valve assembly)
Fig. 12-1.2
Service Manual
Hydraulic Training
6. Remove the valve protection cap and the valve seal cap from the accumulator that you will charge first. (See Fig.
12-1.5)
100
Valve protection cap
1500
150
50
1000 2000 Pressure
500 2500 gauge
PSI
bar 200 Valve body
Valve seal cap
0
T-handle
Valve stem
O-ring
Gas chuck
accum charge assy.eps

Swivel nut
Gas
valve stem
bladder Bleed valve

accumulator
Fig. 12-1.3 Fig. 12-1.4
7. On the charge valve assembly, locate the T-handle (Fig. 12-1.6) of the gas chuck. Rotate it counterclockwise
(outward) completely before attaching the swivel nut to the accumulator gas valve stem .
8. On the charge valve assembly, close the bleed valve (Fig. 12-1.7) and disconnect the hose from the charge valve
gas valve stem. This step ensures that the initial pressure reading is accurate, and it prevents the gas pressure
from escaping out of the hose.
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
0
Remove hose
charge assy/bleed/hose.eps
bleed valve
Close valve
Fig. 12-1.5
Service Manual
Hydraulic Training
9. Find the swivel nut (Fig. 12-1.8) on the charge valve assembly. Screw the swivel nut onto the accumulator gas
valve. Tighten to 10–15 in./lb.
10. After the swivel nut is attached, screw the T-handle (Fig. 12-1.6) clockwise, all the way in. This presses a pin into
the gas valve and opens it. Read the pressure on the charge valve assembly gauge before you attach the nitrogen
bottle to the charge valve assembly. Depending on the gauge reading, proceed as follows:
• If no adjustment is necessary, skip to step #18.
• If pressure is too high, skip to step #15.
• If pressure must be added, proceed to step #11
Fig. 12-1.6
Service Manual
Hydraulic Training
11. Be sure that the nitrogen bottle supply valve is firmly closed. Attach the high-pressure regulator to the nitrogen
bottle, then attach the hose to the high-pressure regulator. Finally, attach the other end of the hose to the valve
assembly gas valve stem as shown in Fig. 12-1.9. Do not open the nitrogen bottle supply valve yet.
12. Turn the regulated pressure adjustment handle on the high-pressure regulator counter clockwise to its minimum-
setting.
13. Crack open the nitrogen bottle supply valve (Fig. 12-1.10). You will get a reading on the high-pressure gauge side
of the regulator. If there is enough pressure in the nitrogen bottle to do the job, proceed to step #14.
14. Adjust the regulator handle clockwise, raising the regulated pressure. The accumulator will begin to fill. Continue
filling until the charge kit gauge reads the desired pressure. Close the nitrogen bottle supply valve.
15. If you overcharge the nitrogen pressure, proceed as follows:
• Close the nitrogen bottle supply valve.

• Slowly open the bleed valve on the charge kit. Close the bleed valve when the correct pressure is rea-
ched.
Note! Never let nitrogen out of the accumulator by pressing the gas valve pin with a foreign object. The high
pressure may rupture the valve seat!
16. Let the nitrogen sit in the accumulator for 10 to 15 minutes. This allows the gas temperature to stabilize.Recheck
the pressure on the charge kit gauge.
17. Add or release nitrogen until the pressure is correct. Be sure that the bleed valve is closed before adding pressure,
and that the nitrogen bottle supply valve is closed before releasing pressure.
18. When the correct pressure is reached, proceed as follows:
High-pressure
regulator
Nitrogen supply
valve
Regulated pressure
adjustment handle Higher
Nitrogen bottle
Lower
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
0
Fig. 12-1.7
Service Manual
Hydraulic Training
• Close the nitrogen bottle supply valve.

• Unscrew the T-handle on the charge kit until it is all the way out. This will close the accumulator gas valve.
• Open the bleed valve, which releases the pressure in the hose, charge valve assembly, and regulator.
• While holding the gas valve on the accumulator, unscrew the charge kit swivel nut.
• Remove the charge kit.
• If you are finished with both accumulators, remove the hose and regulator.
19. Make a bubbly mixture from soap and water. Spread the mixture around the accumulator gas valve to check for
gas leaks. Gas leaks will push the bubbles away from the area of the leak. If you find a leak, replace the accu-
mulator or have it repaired by qualified personnel. Never repair an accumulator yourself.
20. Replace the gas valve seal cap (tighten to 22 ft./lb), and hand-tighten the valve protection cap.
21. Repeat the procedure for any other accumulators.
Crack open
supply valve
Nitrogen Bottle
Cracksupply.eps Fig. 12-1.9
Service Manual
Hydraulic Training
13. INTRODUCTION TO LOAD SENSE HYDRAULIC CIRCUITS

Accumulator:. . . . . . . . . . . . . . . . . . .A component used to store hydraulic energy. Drillmec uses two types
of accumulators. One is a nitrogen gas charged accumulator, the other is a nitrogen gas charged accumulator, piston
type.
Constant: . . . . . . . . . . . . . . . . . . . . .A theoretical factor that is regarded as invariant in specified circumstances. The

constant for calculating hydraulic HP is: 1714 (when psi and gpm are used). The constant for calculating kW is: 600
(when bar and lpm are used).
Delta Pressure
(Delta-P): . . . . . . . . . . . . . . . . The pressure differential between two given points in a hydraulic circuit.
Horsepower (HP): . . . . . . . . . . . . . . .A unit of power in the United States Customary System, equal to 0.7457 kilowatts
(kW). To calculate hydraulic horsepower consumption, use the following formula; HP= Pressure multiplied by
the Volume, divided by a Constant.
Orifice: . . . . . . . . . . . . . . . . . . . . . . .A restriction installed in either a hydraulic or pneumatic passageway to create a

pressure drop. This does not always reduce flow directly, but it may cause enough pressure upstream so that some
of the flow would be diverted or reduced elsewhere.
Q-Maximum
(Q-max):. . . . . . . . . . . . . . . . . The highest volumetric flow rate possible from the hydraulic pump. Adjusted with a
mechanical stop screw. Turn screw inward to decrease and outward to increase.
Q-Minimum
(Q-min): . . . . . . . . . . . . . . . . . The lowest volumetric flow rate possible from the hydraulic pump. Adjusted with a
mechanical stop screw. Turn screw inward to increase and outward to decrease.
Section Compensator: . . . . . . . . . . .A component in the directional control valves that self-adjusts for
supply pressure changes. Also described as a pilot operated
pressure compensating valve.
Load sense hydraulic circuits offer advantages over conventional fixed flow circuits. One advantage is improved effi-
ciency. With the conventional system, a fixed displacement hydraulic pump is used to run hydr. system. This hydraulic
pump must have the capability of displacing enough oil volume to run the largest cylinder on the hydr. system.
However, because the smaller cylinders on the hydr. system require less oil volume, an in-line orifice is used to divert
the excess oil to tank via the relief valve. When no hydr. system function is activated, this fixed volume of oil is routed
through the handvalve and back to the tank. All of the excess oil is converted to wasted horsepower and heat.
With the load sense hydraulic circuit, a variable displacement hydraulic pump is used. This hydraulic pump puts out
only the required volume of oil needed to run any particular function or combination of functions. This pump also de-
strokes to a minimum output when no functions are activated; thus conserving energy and fuel.
When activating a function by remote on a “black & white” system, the handvalve spool is fully activated and a signal
is sent to the hydraulic pump to send the required amount of oil to run that function. When activating a function on a
proportional system, electronics are used to vary the position of the handvalve spool, which in turn varies the speed
of the function. The proportional system allows the operator to move the pipe handler as slow and as fast as desired;
thus increasing controllability for smoother pipe handler movement, and reducing operator effort.
NOTE: The complete hydraulic system on a load sense hydraulic circuit must be kept as clean as possible due to
many of the components used in these circuits contain precision machined metering passages and spools that
could malfunction from contamination.
Service Manual
Hydraulic Training
14. AXIAL PISTON PUMP ( FIXED DISPLACEMENT )
Fig. 14-1.1
Service Manual
Hydraulic Training
1. If you only require 40

liters per minute to
LOAD LOAD this cylinder,
3. by installing an orifice
in line that will allow
40 40 liters per minute to
LITERS flow through at the
100
LITERS specified pressure
drop from 280 Bar.
2. you must send 60

liters per minute over
the relief valve,
280 BAR
(4060 PSI)
5.5
100 LPM BAR
Fig. 14-1.2
Service Manual
Hydraulic Training
LOAD
DELTA P = 180 Bar
280 100
BAR BAR
100
BAR
LPM X BAR
KILOWATTS =
600
60 LPM X 280
= 28 KILOWATTS
600 (Constant) WASTED
(Building Heat)
5.5
BAR
100
LPM 280
BAR
(4060 PSI)
Fig. 14-1.2
Service Manual
Hydraulic Training
15. axial piston pumps (vARIABL. dISPLACEMENT-PILOT CONTROL )
Fig. 15-1.1
Fig. 15-1.2
Service Manual
Hydraulic Training
LOAD SENSE KEY

(series #1) High Pressure
Reduced Pressure
Control Pressure
Low Pressure
1000 LBS
LOAD Zero Pressure
(Tank, or oil at rest)
10 GALLON MAXIMUM
CAPACITY CYLINDER
1 INCH OF AREA ON
CYLINDER PISTON
1000 PSI
10 GPM FIXED
DISPLACEMENT PUMP
Fig. 15-1.3
in this diagram, the cylinder will take exactly 1 minute to extend with a pressure of 1000 psi. When the cylinder rea-
ches the end of the stroke, something will have to break because there is no relief valve and the hydraulic pump is
a fixed displacement.
Service Manual
Hydraulic Training
LOAD SENSE KEY

Reduced Pressure
Control Pressure
Low Pressure
Zero Pressure
10 GPM FLOW
OUTPUT
0 PSI
200 PSI
10 GPM FIXED
DISPLACEMENT PUMP
Fig. 15-1.4
In this diagram, we have a 10 gpm fixed displacement pump, an orifice creating a pressure drop of 200 psi, and then
free-flowing back to tank.
Service Manual
Hydraulic Training
KEY
LOAD SENSE High Pressure
(series #3) Reduced Pressure
Control Pressure
1000 LBS Low Pressure

LOAD Zero Pressure
10 GALLON MAXIMUM
CAPACITY CYLINDER
1 INCH OF AREA ON
CYLINDER PISTON
1000 PSI
ORIFICE
1200 PSI
10 GPM FIXED
DISPLACEMENT PUMP
Fig. 15-1.5
In this diagram, the cylinder will take exactly 1 minute to extend with a pressure of 1000 psi at the cylinder and a
pressure of 1200 psi at the pump due to the orifice that caused a pressure drop. The orifice did not change the flow
rate nor the cylinder speed. when the cylinder reaches the end of the stroke, something will have to break because
there is no relief valve.
Service Manual
Hydraulic Training
LOAD SENSE KEY

Reduced Pressure
1000 LBS Control Pressure
LOAD
10 GALLON MAXIMUM Low Pressure
CAPACITY CYLINDER Zero Pressure
1 INCH OF AREA ON
CYLINDER PISTON
1200 PSI
ORIFICE
1200 PSI
RELIEF ADJUSTED
TO 1200 PSI
10 GPM FIXED
DISPLACEMENT PUMP
Fig. 15-1.6
In this diagram, the cylinder will take exactly 2 minutes to extend with a pressure of 1000 psi at the cylinder and a
pressure of 1200 psi at the pump due to the orifice that caused a pressure drop and the relief valve that opened at
1200 psi venting 5 gpm to the tank. This 5 gpm at 1200 psi is creating heat and is wasting horsepower. that leaves only
5 gpm for the cylinder. the orifice did change the flow rate at the cylinder and the cylinder speed. When the cylinder
reaches the end of the stroke, the pressure in the cylinder will equal 1200 psi and all 10 gpm will be vented to tank
via the relief valve.
Service Manual
Hydraulic Training
LOAD SENSE KEY

1000 LBS
Reduced Pressure
load
10 GALLON MAXIMUM Control Pressure
CAPACITY CYLINDER Low Pressure
Zero Pressure
1 INCH OF AREA ON
CYLINDER PISTON
1000 PSI
P2
ORIFICE
1200 PSI
P1 P
Regulator
200 PSI
Q
10 GPM Q-MAXIMUM
Variable Displacement
Pump
Fig. 15-1.7
In this diagram, the cylinder will take exactly 2 minutes to extend. there will be a pressure of 1000 ps1 at the cylinder
and a pressure of 1200 psi at the pump. the orifice caused a drop in pressure (delta-p). The regulator has been adju-
sted to maintain 200 psi (delta-p). the pump is only supplying the amount of oil required to maintain the (delta-p). in
this case, 5 gpm. If the size of the orifice increases, the flow rate will be increased by the delta-p regulator. that will
increase the speed of the cylinder.
Service Manual
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KEY
High Pressure
LOAD SENSE Reduced Pressure
(series #6) Control Pressure
Low Pressure
1000 LBS
load Zero Pressure
10 GALLON MAXIMUM
CAPACITY CYLINDER
1 INCH OF AREA ON
CYLINDER PISTON
3000 PSI
P2
ORIFICE
P
3000 PSI
3000
P1 PSI
P
Q Regulator
200 PSI
10 GPM Q-MAXIMUM
PUMP
Fig. 15-1.8
In this diagram, the cylinder is at the end of it’s stroke. There will be a pressure of 3000 psi at the cylinder and a
pressure of 3000 psi at the pump. The orifice does not cause a drop in pressure because there is no flow. The re-
gulator has been adjusted to a pressure limit of 3000 psi. The pump is only supplying the amount of oil required to
maintain 3000 psi.
Service Manual
Hydraulic Training
KEY
High Pressure
Load Pressure 3
LOAD SENSE Load Pressure 2
(series #7) Load Pressure 1
Zero Pressure
1000 LBS 2000 LBS 2500 LBS (Tank, or oil at rest)
LOAD LOAD LOAD
10 GALLON MAXIMUM
CAPACITY CYLINDERS
1 INCH OF AREA ON
CYLINDER PISTONS
0 PSI 0 PSI 0 PSI
200 PSI
3000
P1 PSI
P
Regulator
200 PSI
Q 10 GPM Q-MAXIMUM
PUMP
Fig. 15-1.9
In this diagram, no function is being activated. The oil has no place to go. The pump is only putting out enough oil to
mantain 200 psi which is the force of the delta p regulator spring.
Service Manual
Hydraulic Training
16. hydraulic pump training series
16.1 hydraulic pump with all function in neutral pump at minimum output
P
X
T
A
REGULATOR
REGULATOR
PRESSURE
DELTA P

Reduced Pressure
Control Pressure
High Pressure
Zero Pressure
Low Pressure
EMERGENCY STOP
KEY
UP
X3
MAX.
Q
A
MIN.
Q
A1
Fig. 15-2.1
output
A
EMERGENCY STOP
UP
A1
X3
Q
MIN.
Q
MAX.
KEY
High Pressure PRESSURE
Hydraulic Training
Service Manual
REGULATOR
Reduced Pressure
Control Pressure
Low Pressure DELTA P
REGULATOR
Zero Pressure
A T P
16.2 hydraulic pump with boom function activated pump at required
Fig. 15-2.1
EMERGENCY STOP
A UP
A1
pump at minimum output
X3
Q
Service Manual
MIN.
Q
MAX.
Hydraulic Training
KEY
REGULATOR
Reduced Pressure
Control Pressure
REGULATOR
Zero Pressure
A T P
16.3 hydraulic pump with cylinder pressurized at the end of stroke,
Fig. 15-2.3
A
EMERGENCY STOP
PUSHED
A1
X3
Q
MIN.
Q
MAX.
KEY
REGULATOR
Reduced Pressure
Hydraulic Training
Service Manual
Control Pressure

REGULATOR
Zero Pressure
A T P
16.4 hydraulic pump with bypass valve open, pump at maximum output
Fig. 15-2.4
Service Manual
Hydraulic Training
17. plumbing to the power unit (hh220/hh200/hh300)

17.1 general description of power unit
The drilling rig HH runs off the Hydraulic power unit. The hydraulic power unit has two electric motor. There are two
hydraulic unit, one for each motor, each hydraulic unit is composed by four hydraulic pumps. There is a hydraulic
tank inside hydraulic power unit. The drilling rig is connected to hydraulic power unit via flexible hoses with quick
coupler.
The hoses are attached to the power unit by connecting the “quick disconnect fittings” on the end of the hoses lewading
from the drilling rig. The fittings go on only one way so there in no chance of hooking up the hoses improperly.
QUICK CONNECTION OF SEMITRAILER
FIXED CONNECTION OF FLEXIBLE HOSES

ON TOP ROOF OF HYDRAULIC POWER UNIT
Fig. 17-1.1
Service Manual
Hydraulic Training
DRAINAGE
RETURN TO TANK FLOATING

TOP DRIVE BLOCK LS
ROTARY LS LINE
LS SERVICE LIN
LINE
SERVICES
PILOT PRESSURE
SUPERCHARGING FLOW
LINE FLOW
RETURN TO TANK FLOW
PULL DOWN
EXAMPLE FOR HH300, FOR CORRECT REFERENCE SEE ROTARY TABLE FLOW
HYDRAULIC SCHEME OF PROPER RIG FLOW TOP DRIVE
FLOW
Fig. 17-1.2
WARNING
Clean with ether or a clean rag before installing quick disconnects. Make sure you seat the quick disconnect
fittings all the way tight. Failure to tighten the quick disconnects will stop the flow of oil and will prevent the
drilling from operating.
Service Manual
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17.2 quick connection from

hydraulic power unit to semitrailer
17.2.1 quick connection with sleeve
Valves are designed to automatically open in both the cou-

pler and nipple halves when the unit in connected pemitting
maximum free flow.
Valves are designed to automatically close under normal
usage conditions in both the coupler and nipple halves the
unit is disconnected.
To connect following this procedure:
1. pull back the sleeve

2. insert the nipple into the coupler
3. release the sleeve
To disconnect following this procedure:
1. pull back the sleeve

2. remove the nipple and the halves
3. close with cap Fig. 17-2.1
Exclusive
Ball Bearing U-Packer Seal
Two -Piece Body Postive Ball-Lock Sleeve Lock (Wide choice
Construction Design of seals available)
Jet Stream
Valve Design Hardened Localized Poppet Has Non-Shift Wide Choice
Sleeve Induction Metal-to-Metal Valve of End-Fittings
Hardened Stop
Land
Fig. 17-2.2
WORKING PRESSURES*
Valve & Valve (Double Shut-off) Plain & Plain
Valve & Plain (Single Shut-off) (No Shut-off)
Quick Steel Aluminum Brass Stainless Steel Aluminum Brass Stainless
Disconnect Steel Steel
Size
psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar
1/4" 6500 450 2250 155 2250 155 5000 345 11000 760 4000 280 4000 280 10000 690
3/8" 4500 310 2250 155 2250 155 4000 280 11000 760 4000 280 4000 280 8000 555
1/2" 4000 280 1750 125 2000 140 3750 260 11000 760 4000 280 4000 280 8000 555
3/4" 3500 245 1750 125 2000 140 2000 140 9000 625 3500 245 3500 245 7000 485
1" 2000 140 1500 105 1750 125 2000 140 6000 415 3000 210 3000 210 4000 280
1-1/4" 1750 125 375 30 350 25 1500 105 5000 345 1000 70 1000 70 3000 210
1-1/2" 1500 105 375 30 350 25 1500 105 5000 345 1000 70 1000 70 3000 210
2" 1500 105 300 25 400 30 500 35 4000 280 750 55 750 55 1000 70
2-1/2" 1000 70 300 25 400 30 400 30 1000 70 300 25 400 30 400 30
3" 750 55 200 15 200 15 400 30 750 55 200 15 200 15 400 30
4" 500 35 150 10 150 10 300 25 500 35 150 10 150 10 300 25
PRESSURE LOSS (PSI) PRESSURE LOSS (PSI)

300
4
70
200
2
3
6
10
20
30
40
50
60
80
90
1
5
7
8
9
100
20
4
10
40
3
100
30
90
2
5
6
7
8
200
50
70
300
60
80
1
1 3.79 1 3.79
2 7.57 2 7.57
1/4
1/4
11.36 3 " 11.36
3 "
3/8
15.14 4 " 15.14
4
5 3/8 18.93 5 18.93
" 22.71 6 2 2 .7 1
6
7 26.50 7 26.50
8 30.28 8 30.28
9 1/2 34.07 9
1/2
" 34.07
10 " 37.85 10 37.85
3/4
" 75.70
20
3/4
" 75.70 20
1"
30
1" 113.60 30 113.60
H SERIES
1-1
40 151.40 40 /4" 151.40
50
1-1 189.30 50 1-1 189.30
FLOW RATE (LPM)
/4"
FLOW RATE (LPM)

/2"
FLOW RATE (GPM)

60 227.10
FLOW RATE (GPM)

60 227.10
70 1-1 265.00 70 265.00
80 302.80 80 302.80
(MiL-H-6083 OIL @ 90°F ± 5°F)

/2"
(MiL-H-6083 OIL @ 90°F ± 5°F)

90 340.70 90 340.70
100 378.50 100 378.50
2"
Valved and Plain (Single Shut-off)

Valved and Valved (Double Shut-off)
2"
200 757.00 200 757.00
300 1135.50 300 1135.50
400 1514.00 400 1514.00

Hydraulic Training
Service Manual
500 1892.50 500 1892.50

600 2271.00 600 2271.00
700 2649.50 700 2649.50
800 3028.00 800 3028.00
900 3406.50 900 3406.50
1000 3785.00 1000 3785.00
.14
.21
.27
.41
.48
.62
.07
.34
.55
.69
.48
.07
.62
.27
.41
.55
.21
.34
.69
.14
1.38
3.45
4.14
4.83
5.52
6.21
6.90
2.07
2.76
1.38
4.83
4.14
5.52
6.21
6.90
2.07
3.45
13.79
20.69
2.76
13.79
20.69
PRESSURE LOSS (BAR) PRESSURE LOSS (BAR)

Service Manual
Hydraulic Training
17.2.2 QUICK CONNECTION ( CONNECTION WITH TORQUE VALUES )
Example Model: 75 Series Snap Tite

The hoses attach to the drilling rig by screwing the quick dis-connect couplers on to the proper couplers of the drilling
rig.
To connect, merely thread the nipple into the coupler. To disconnect just unthread, the valves are designed to shut off
automatically under normal conditions in both the coupler and nipple halves when the unit is being disconnected.
Fig. 17-2.3
Please take the following steps when installing the couplers:
1. Turn the power unit OFF.

2. Clean all couplers with a can of ether if available. A clean dry cloth will also work but will require extreme care.
Fittings must be spotless clean.
3. Install couplers by screwing them onto their respective counterparts. Try to avoid crossthreading and maintain a
straight line. Jerk the hose back and forth while turning coupler to aid installation effort. Push hard to get the big
coupler threads started.
4. Make sure fittings are tight. If they are properly cleaned they should run up tight with just a firm hand grip. However,
they should be double checked with a chain wrench.
5. Avoid over-tightening. ( see Fig. 17-2.4 )
6. If near salt water, spray with a light oil to prevent oxidation.
7. Avoid pulling too hard on hoses. Most hose failures are caused by pulling hoses off couplers.
WARNING
Turn the power unit off before installing couplers.
Service Manual
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DIMENSION OF COUPLINGS
SIZE A B C (DIA) D E (DIA) F (DIA) G ACME H

in 4.85 1.87* 2.84 1.75 1.35 3.27 1-3/4˝-8
3/4
mm 123.19 47.50* 72.14 44.45 34.29 83.06
in 6.04 4.25 2.75 3.45 2.25 1.77 4.17 2-1/4˝-6
1
mm 153.32 107.95 69.85 87.63 57.15 44.96 105.92
in 7.76 4.75 3.25 4.40 2.62 2.14 5.36 2-5/8˝-6
1-1/4
mm 197.10 120.65 82.55 111.76 66.55 54.36 136.14
in 8.70 5.75 3.75 5.04 3.24 2.50 5.97 3-1/4˝-4
1-1/2
mm 220.98 146.05 95.25 128.02 82.30 63.50 151.64
in 10.05 6.75 4.75 6.07 4.00 3.25 7.05 4˝-4
2
mm 255.27 171.45 120.65 154.18 101.60 82.55 179.07
in 10.13 8.00 6.00 5.29 5.00 3.38 7.46 5˝-4
2-1/2
mm 257.30 203.20 152.40 134.37 127.00 85.85 189.48
in 10.58 8.50 6.50 5.84 6.00 4.25 8.26 6˝-4
3
mm 268.73 215.90 165.10 148.34 152.40 107.95 209.80
in 12.36 11.00 7.00 7.11 6.63 5.25 9.40 6-5/8˝-4
4
mm 313.94 279.40 177.80 180.59 168.40 133.35 238.76
INTERNAL PRESSURE (bar)

413. 79
275. 86
482. 76
551. 72
344. 83
103. 45
689. 66
137. 93
172. 41
206. 90
620. 69
27. 59
41. 38
34. 48
48. 28
20. 69
62. 07
17. 24
10. 34
55. 17
68. 97
13. 79
6. 90
10000 1130.00
9000 1017.00
8000 904.00
7000 791.00
6000 678.00
5000 565.00
4000 452.00
3000 339.00
TOR QUE ( i nch pounds )
2500 282.50
2"
TOR QUE ( N. m. )
2000 226.00
1-1/2" 1-1/4"
1500 169.50
1"
1000
3/4" 113.00
900 101.70
800 90.40
700 79.10
600 67.80
500 56.50
400 45.20
300 33.90
250 28.25
200 MAXIMUM 22.60
RECOMMENDED
CONNECTING
150 PRESSURE 16.95
100 11.30
1000
400
800
7000
5000
10000
8000
100
4000
300
2500
200
250
500
600
700
900
6000
1500
2000
3000
9000
150
INTERNAL PRESSURE (psig) Fig. 17-2.4

Service Manual
Hydraulic Training
CODE REFERENCE
Part No. 75 C 12 -12 F
Material Series Coupling Coupling End Fitting End Fitting Seals

Half Size Size Type
No letter 75 C 12 = 3/4˝ 12 = 3/4˝ F* Std. Seal
Steel, plated coupler 16 = 1˝ 16 = 1˝ Female is Buna
S N 20 = 1-1/4˝ 20 = 1-1/4˝ NPSF V=Viton
316 nipple 24 = 1-1/2˝ 24 = 1-1/2˝ EF E=
Stainless 32 = 2˝ 32 = 2˝ Female SAE Ethylene
steel 40 = 2-1/2˝ 40 = 2-1/2˝ RP Propylene
48 = 3˝ 48 = 3˝ Female Rubber
64 = 4˝ 64 = 4˝ British
Parallel
BS2779
* For sizes up to 1” NPSF Threads. For sizes over 1” NPT Threads.

Service Manual
Hydraulic Training
17.2.3 QUICK CONNECTION ( CONNECTION WITHout TORQUE VALUES )
Example Model: 78 Series Snap Tite

The hoses attach to the drilling rig by screwing the quick dis-connect couplers on to the proper couplers of the drilling
rig.
To connect, merely thread the nipple into the coupler. To disconnect just unthread, the valves are designed to shut off
automatically under normal conditions in both the coupler and nipple halves when the unit is being disconnected.
Fig. 17-2.6
Please take the following steps when installing the couplers:
1. Turn the power unit OFF.

2. Clean all couplers with a can of ether if available. A clean dry cloth will also work but will require extreme care.
Fittings must be spotless clean.
3. Install couplers by screwing them onto their respective counterparts. Try to avoid crossthreading and maintain a
straight line. Jerk the hose back and forth while turning coupler to aid installation effort. Push hard to get the big
coupler threads started.
4. Make sure fittings are tight. If they are properly cleaned they should run up tight with just a firm hand grip, if ne-
cessary you can use a small hammer. However, they should be double checked with a chain wrench.
5. If near salt water, spray with a light oil to prevent oxidation.
6. Avoid pulling too hard on hoses. Most hose failures are caused by pulling hoses off couplers.
WARNING
Turn the power unit off before installing couplers.
Service Manual
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DIMENSION OF COUPLINGS
A
C B
H2 DIA.
F E D H1
A B C D E F G H1 H2
SIZE
in mm in mm in mm in mm in mm in mm in mm in mm in mm
3/4" 5.02 127.51 1.66 42.26 2.93 74.42 4.10 104.14 1.44 36.58 1.25 31.75 3.11 79.00 2.13 54.10 .201 5.11
1" 5.45 138.43 1.38 35.05 3.44 87.38 4.50 114.30 1.74 44.20 1.57 39.88 3.24 82.30 2.38 60.45 .201 5.11
1-1/4" 6.28 159.51 1.78 45.21 3.92 99.57 5.23 132.84 2.08 52.83 1.89 48.00 3.73 94.74 2.63 66.80 .201 5.11
1-1/2" 6.54 166.12 1.63 46.40 4.09 103.89 5.25 133.35 2.45 62.23 2.18 55.37 4.13 104.90 3.25 82.55 .281 7.14
CODE REFERENCE
PART NO. B 78 H C 12 - 12 F
Material Series Sleeve Configuration* Coupling Half Coupling Size End Fitting Size End Fitting Type Nipple Flange*
B 78 No Letter C 12 = 3/4" 12 = 3/4" F WF
Brass for Wing Nut Coupler 16 = 1" 16 = 1" Female NPTF with flange
H N 20 = 1-1/4" 20 = 1-1/4" RP *Nipple only
Hex Nut Nipple 24 = 1-1/2" 24 = 1-1/2" Female British
*Coupler only Parallel BS2779
Service Manual
Hydraulic Training
17.2.4 QUICK COUPLINGS FOR SMALL CONNECTION
• Double shut-off couplings

• Locking by screwing the socket sleeve-nut on to the male-threaded plug. This gives the coupling resistance to
heavy mechanical demands (ram loads, hydraulic shocks, severe pulsating pressures, etc.).
• Can be connected against residual pressure
• Dust caps and plugs
Fig. 17-2.7
8
1 Socket body
7
5 6 4
2 Retainer 3 4
2
3 Valve spring 1
4 Valve
5 Valve seal
6 O-ring
7 Sleeve
8 Plug body
9 Back-up ring 2
3
10 Circlips 5
10 9
Fig. 17-2.8
SIZE Nominal Diameter (mm) Spillage per connection (ml)
1/4” 5.7 1.1
3/8” 7.6 1.9
1/2” 10.3 2.8
3/4” 14.2 5.8
1” 16.5 10.9
1 1/4” 20.5 26.9
1 1/2” 25.8 37.5
2” 34.7 81
Service Manual
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Coupleur femelle / Socket Coupleur mâle / Plug
Fig. 17-2.8
taille DN / ND adaptation (F) coupleur femelle / socket coupleur mâle / plug longueur / length
size (mm) connection (F) L1 ø1 L2 ø2 connecté (ed)
1/4” 5,7 1/4 (G & NPT) 53 35 32 19 144 35 15 19 71 64

3/8” 7,6 3/8 (G & NPT) 65 38 35 23 217 42 19 23 104 77
1/2” 10,3 1/2 (G / NPT / Mét.) 74 45 41 27 320 50 22 27 165 92
3/4” 14,2 3/4 (G & NPT) 91 55 50 35 600 63 29 35 382 116
1” 16,5 1 (G / NPT / Mét.) 103 69 63 41 1092 71 36 41 585 130
1”1/4 20,5 1 1/4 (G & NPT) 145 89 77 55 2780 97 50,9 55 1460 180
1”1/2 25,8 1 1/2 (G & NPT) 173 100 88 63 4200 109 56,9 63 2040 202
2” 34,7 2 (G & NPT) 205 117 105 71 6640 129 69,4 71 3200 236
Service Manual
Hydraulic Training
17.3 filling drilling rig pressure hoses
The Drilling Rig is shipped with the hoses filled with oil. However, if the unit has been sitting for a long period of time
or if a damaged hose has been replaced with a new one, then the hoses must be filled.
Hook up all the hoses to the power unit. Start the power unit and let it run for ten minutes before running the drilling
rig. The hoses will fill up by themselves in ten minutes even if the drilling rig is not in the drilling mode.
17.4 bleeding the hydraulic system
17.4.1 bleeding the service cylinders
If the opening and closing of the cylinders seems spongy or slow, it may be a result of air in the cylinders. Normally
there is no need to worry about bleeding the cylinders lines because the unit is shipped fully tested. However, should
the drilling rig sit for a long period of time, if a new attachment is being installed or if a damaged cylinders hose has
been replaced, then the system may require bleeding to remove unwanted air in the system. To bleed the cylinders
system, follow the following steps:
1. Shut Power Unit OFF.

2. Make sure the line quick dis-connects are coupled to the power unit.
3. Start the power unit
4. Loosen the lines at the hydraulic cylinder by backing the fittings off just a little.
5. Wait for oil to flow from the fittings. WATCH FOR AIR BUBBLES. When air bubbles have stopped then quickly
re-tighten the fittings.
6. Repeat the same procedure for “OPEN” side.
7. Operate the cylinder. If they are still a bit spongy then repeat bleeding steps once more.
17.4.2 bleeding main hydraulic CYLINDERS ( mast raising)
If using the cylinder seems spongy or slow, it may be a result of air in the cylinders. To bleed the cylinders of mast
raising, you must use the dedicated bleed on cylinders. To bleed the cylinder system, follow the following steps:
1. Loosen the screw of bleed ( without remove the screw )

2. WATCH FOR AIR BUBBLES. When air bubbles have stopped then quickly re-tighten the fittings.
WARNING
Bleeding operation of these cylinders, it must be made before every lowering of mast, to avoid jerk during
lowering
BLEED
Fig. 17-4.1
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17.4.3 BLEEDING main HYDRAULIC CYLINDER - pull down
If using the cylinder seems spongy or slow, it may be a result of air in the cylinders. To bleeding the cylinders, you can
move in and out the cylinder up to limits, after some operations the air should be out from hydraulic cylinder. However,
you could use bleeding of cylinder with mast in lower position. (See Fig. 17-4.2)
BLEED
Fig. 17-4.2
Service Manual
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18. FLOW COMPENSATOR

C3: Flow compensator for rotary pumps
C4: Flow compensator for pull down pumps
L2: Pressure regulator for swivel torque
L3: Pressure regulator for tripping pull limit
Y1: Electrovalve - Thrust limitation
Y2: Electrovalve - Pump summation
Y3: LS Rotary (HPU 1-2) activation
Y4: LS Pull down activation
Y5: Electrovalve drilling operation
Y6: Electrovalve LS Rotary-Cut-Off
Y3
L2
L3
C3
C4
Y6
Y6
C3
C4
Y1
Y3
Y3
Y1
L3
Y6
Y2
Y1
Y4
Fig. 18-1.1
Service Manual
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P-P1: 1.1/2” SAE 6000

P2-P3: 1.1/2” SAE 6000
Y: 1.1/2” BSP
LS-X-L-L1-LG-PIL: 3./8” BSP
ML-MP-MP1-MP2-MP3-ML-ML1-MX-MX1: 1/4” BSP
Fig. 18-1.2
Service Manual
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ROTARY PUMPS
C3
Y4
ROTARY
PULL DOWN PUMPS
C4
PULL DOWN
Y5
Y3
Y1
Y6
Y2
Fig. 18-1.3
Service Manual
Hydraulic Training
FROM PUMP
SUMMATION BLOCK
LS LS
Fig. 18-1.3
PILOT LINE FROM
PULL/DOWN REMOTE CONTROL
PILOT FROM PILOT FROM

ELECTROVALVE Y 53 A ELECTROVALVE Y 53 A SUPERCHARGING LINE
19. PULL DOWN MAIN BLOCK
19.1 PULL-DOWN MAIN BLOCK HH300
FROM FLOATING BLOCK THRUST PILOT FROM

PUMP INLET FLOW ELECTROVALVE Y 53 C
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Service Manual
FROM FLOATING BLOCK PULL

PILOT FROM
ELECTROVALVE Y 53 B
Fig. 19-1-1
Service Manual
Hydraulic Training
FROM Y53A
FROM Y53B FROM Y53C

Fig. 19-1-2
CONTROL DESCRIPTION
8: Valve controlling flow from chamber “B”
11(1): Max pressure relief valve for chamber “C”
11: Max pressure relief valve for chamber “A”
16(1): Pilot operated check valve for floating operation - Chamber “B”
16(2): Pilot operated check valve for floating operation - Chamber “A”
16(3): Pilot operated check valve for floating operation - Chamber “C”
12-13: Cartridge Valve with manual stroke limiter for chamber “C”
19: Valve for descent - controlling flow to tank of chamber “C”
20-21: Valves for descent - controlling flow to tank of chamber “A”
14-15: Cartridge valve with manual stroke limiter for chamber “A”
DIMENSIONS OF CONNECTION
D: Thread 3/8 BSPP, from pull down remote control
PP: Thread 3/8 BSPP, from pilot system 60 bar
PIL: Thread 3/8 BSPP, from electrovalve Y53A
P: Flange 4” CETOP 400, pump flow inlet
T: Flange 3” SAE 3000, to tank
PS: Flange 5” SAE 3000, supercharging line
DR: Thread 3/4” BSPP, to tank
SP: Flange 1.1/4” SAE 6000, from floating block-thrust
GL: Flange 1.1/2” SAE 6000, from floating block-pull
S: Flange 1.1/2” SAE 6000, to tank
TO 17 (2) DISTRIBUTOR 12
TO WEIGHT INDICATOR TO TANK

14 15
FROM PULL-DOWN REMOTE PRESSURE COMPENSATOR 3

PILOT LINE TO C2
FROM PILOT SYSTEM C2
CONTROL (DOWN) MB ( DOWN REMOTE CONTROL)
60 bar (PA) C3 PILOT LINE TO E1
PORT A1 ( UP REMOTE CONTROL)
FROM ROTARY BLOCK “ T ” PORT TO TANK
2"sae3000 2"sae3000
T1
CONTROL
B1 VALVE 10 OPEN
16
PA
E1 18.1
T
B
B
B
B
18.2 MT
E1
T
T
T
T
P
P
P
P
PUMP INLETO 35.4 DR
A
A
A
A
FLOW
A1
DR1 P1 MB
C1
MP
CONTROL
C
3
VALVE 10 CLOSE
P 2
FROM PULL MA
A A 1
D
DOWN REMOTE
Z1.24
CONTROL
X6
X24 Z2.24
A B
P
X5
B
TO WEIGHT
INDICATOR A1
162
PILOT LINE TO B1
26
4.1 10 10 7 9 9.1 13
8 30
5 5.1 5.2 5.3 11
19.2 PULL-DOWN MAIN BLOCK HH200/HH220
FROM FLOATING BLOCK

“ THRUST ”
FROM FLOATING BLOCK
“PULL”
35
PILOT LINE FROM B1

Hydraulic Training
Service Manual
2"sae3000
32
14 15
Fig. 19-2.1
Service Manual
Hydraulic Training
REGENERATIVE COMAND
FLOATING OPERATION
COMAND
FLOATING BLOCK
PILOT SYSTEM AUX. PUMP

60 BAR
PULL DOWN REMOTE

CONTROL
(UP)
PULL DOWN REMOTE

CONTROL
(DOWN)
Fig. 19-2.2
CONTROL DESCRIPTION
4.1-5-5.1-5.2-5.3: Cartridge valve - cover- hydr.oper.distributor for regenerative circuit.
8: Valve controlling flow to tank from chamber “B”.
10-11: Check valve with manual stroke limiter for chamber “A”
18(1): Regenerative circuit command
12: Max pressure relief valves chamber “A” (350 bar)
18(2): Floating operation command
7: Max pressure relief valve chamber “B” (350 bar)
9-9(1): Anti-cavitation cartridge valve
13: Pilot operated check valves for floating operation
14-15: Overcenter valves (chamber “A”) pressure controlled throttle valve wich
controls in the metering out line the negative loads on cylinder
DIMENSION OF CONNECTION
P: Flange 3.1/2” CETOP 6000. Pump inlet flow
T: Flange 4” SAE 3000. To tank
T1 (blind): Flange 2.1/2” SAE 3000.
A-B: Block interface.
DR1: Thread 3/8” BSPP. Blind connection
DR: Thread 3/4” BSPP. To tank
C Thread 1 1/4” BSPP. From floating block
D Thread 1” BSPP. From floating block
C1 Thread 1/2” BSPP. From pull down remote control
C3 Thread 1/2” BSPP. From pull down remote control
PA: Thread 3/8” BSPP. From pilot system 60 bar
Service Manual
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20. FLOATING BLOCK ob.2317 (part 50851425)

20.1 scheme of floating blocK
11-SETTING TO MINIMUM + 1/4 TURN

9- SETTING TO MINIMUM + 1/4 TURN
10- SETTING ≈ 150 bar
TO MAIN PULL-DOWN BLOCK
SETTING WITH MINIMUM VALUE

LEAST 10 bar.
Fig. 20-1.1
Service Manual
Hydraulic Training
MS
Ø1.2
X Z MG1 MS1 X Z Y
MS
B B B B
XM 11
A A
MG G
Ø2
S
TIRO SPINTA
X1
9
Ø8x1.5
X
10
x
MG
X1
Z
A
B
A
Y1
Z2
Ø0.6
T
Ø1.2
P
X2
B
Ø1.8
X
X
Ø0,8
A B B
Z
X
A B a
P T
B
a
P T
LS T Y P MP
MP
Fig. 20-1.2
9: RP*C RELIEF VALVE ( SUN)
10: RAR06 PRESSURE REDUCER VALVE (DENISON)
11: RAV06 PRESSURE RELIEF VALVE (DENISON)
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20.1.1 RP*C RELIEV VALVE
Fig. 20-1.3
20.1.2 RAR06 PRESSURE REDUCER VALVE
ADJUSTMENT
Manual handwheel
Rotation 3,75 rev
Operating torque 0,72 Nm
Fig. 20-1.4
Service Manual
Hydraulic Training
20.1.3 R4V06 PRESSURE RELIEF VALVE
ADJUSTMENT
Manual handwheel
Rotation 3,75 rev
Operating torque 0,72 Nm
Fig. 20-1.5
20.2 SETTING PROCEDURE OF FLOATINGF BLOCK
Test without loads, verify max pressure of pull down:

1. Turn on floating control. S1
2. Adjust top drive pushing regulator to minimum, R5.
Gradually increase the pulling force of top drive by
regulator, R10. You will see top drive raise.
3. Bring top drive up to upper limit. With this condition of
rig, increase pulling force of top drive to max value by
regulator, R10. S1
4. Connect a pressure gauges ( range 0 - 400 bar ) with
outlets MP, MG and MS. Reading pressure gauges:
MP = 350 bar
MG = 350 bar
MS = 10 bar
Fig. 20-1.6
5. Reduce pulling force of top drive by regulator R10, and
increase pushing force by regulator R5, you will see
top drive lowering
6. Bring top drive up to lower limit. With this condition of
rig, increase top drive pushing force to max value by
regulator R5. Reading pressure gauges:
MP = 170 bar
MG = 10 bar R5
MS = 150 bar
IMPORTANT
The setting values indicated, it’s a instance. For detai-
led on values, see hydraulic scheme of your rig R10
Fig. 20-1.6
Service Manual
Hydraulic Training
PRESSURE GAUGE
EXAMPLE OF OPERATION CONDITION
MG MS MP
Begining of drilling operation with light string, therefore it’s need to 70 bar
push, with low speed that it derives from ROP (example),
• Pulling regulator to minimum add 20
10 bar 50 bar
• Pushing regulator to 50 bar (example), pressure gauge MS bar to MS
(example) (example)
for load
sensing of
pumps
When drill string has the same weight of weight on bit
10 bar 10 bar 30 bar
• Pulling regulator to minimum
(example) (example) (example)
• Pushing regulator to minimum
Drill string with heavy, therefore it’s need to pull part of weight (
floating )
200 bar 25 bar 220 bar
• Pulling regulator to 200 bar (example), pressure gauge MG
• Pushing regulator to minimum + 1 turn ( example 25 bar )
Back-reaming upward out with heavy string assembly.
Example: floating pressure of string assembly.
It’s need to lift quickly. 220 bar 25 bar 240 bar
• Pulling force regulator to 20 bar (example)
• Pushing regulator to 25 bar (example)
Back-reaming downward out with heavy string assembly.
Example: floating pressure of string assembly.
It’s need to go down quickly. 150 bar 25 bar 170 bar
• Pulling force regulator to 150 bar (example)
• Pushing force regulator to 25 bar (example)
Service Manual
Hydraulic Training
21. OPERATING PROCEDURE for RELIEF VALVE of distributor of

service and mast jib crane
Model OB.1472.4 Relief Valve RP*C (Part# 50850870)

DIMENSION
Fig. 21-1.1
REGULATION
L Standard Screw Adjustment O-ring seal on adjust screw. Adjust
screw positively retained. Overset protection-pilot spring cannot
go solid.
Fig. 21-1.2
CODE REFERENCE
Fig. 21-1.3
Service Manual
Hydraulic Training
22. OPERATING PROCEDURE TO SETTING ROTARY TABLE

22.1 HYDRAULIC CIRCUIT DESCRIPTION
ROTARY TABLE
60 RPM
i=6.57
380 RPM
OMV315 OMV315
1.1/4" 1.1/4"
1/2"
MB A B MA
A B
C1 C2
P T
Ø1.2
X
OB.2122
250 bar
MP P T
Rotation 5-25 bar

230 lit/1'
CW/CCW C28 ROTARY TABLE

TORQUE
Remote control
(with detent)
5-25 bar R8
RPM Regulator
R15
A7
Fig. 22-1.1
Service Manual
Hydraulic Training
22.2 HYDRAULIC BLOCK DESCRIPTION
22.2.1 hydraulc block ob.2122 (part 50851060)
TO REMOTE CONTORL
ROTATION
TO REMOTE PRESSURE/TORQUE
CONTROL
PUMP INLET FLOW
SETTING 250 bar
TO TANK
Fig. 22-2.1
Service Manual
Hydraulic Training
22.2.2 compensator valve 3 port , r5p ( deninson)
A7 R8
Tank
IN A
B
Fig. 22-2.2
The 3-port pressure compensator R5P in combination with a variable orifice (e.g. distributor as show in the hydraulic
scheme ) constitutes a 3-way flow control valve, that generates a pressure compensated variable flow.
3-way flow control valves have an additional tank port. The loss of energy due to the oil volume going to tank is based
only on the load pressure and not on the system relief valve setting.
• Max setting by R5P handknob: 250 bar

• External (remote) setting by pressure regulator on control panel: increase value from minimum, up to get the
steady speed rotation
22.3 SETTING OPERATION
To setting hydraulic circuit of rotary table:

1. Block rotary table with mechanical system, see Fig. A7
22-3.3
2. Unscrew the handknob pressure adjuster on R5p valve
(position 2 ) of hydraulic block OB.2122 (Fig. 22-2.1
and Fig. 22-2.2)
3. Bring up to maximum the pressure regulator R8 on
main control panel ( clockwise )
4. With control C28, try to rotate, it won’t rotate because
it’s inserted mechanical block. Reading on main control
panel pressure of gauge A7
5. Gradually increase setting of R5P valve by handknob, Fig. 22-3.1
up to, pressure gauge A7 indicates 250 bar
6. Block the setting of valve R5P, with jam nut of hand-
knob.
IMPORTANT R8
The setting values indicated, it’s a instance. For detailed
on values, see hydraulic scheme of your rig
C28
Fig. 22-3.2
Service Manual
Hydraulic Training
Section B-B
Section C-C
D
B
B
E
Section E-E
Rotaty table block
Section A-A
Rotaty table block
Section C-C Fig. 22-3.3

Service Manual
Hydraulic Training
23. OPERATING PROCEDURE TO SETTING bit breaker tongs

23.1 hydraulic circuit description
BIT BREAKER TONG
DBD Pressure Relief Valve

DBD Pressure Relief Valve
B A B A B A B A
U W U W U W
S18
S16 Fig. 23-1.1
Service Manual
Hydraulic Training
23.2 setting procedure
IMPORTANT
The manual tong used, it’s a Blohm+Voss type BV-55.
This tong doesn’t must be used for value of torque
upper to 9000 kgm.
Pressure limits of actuating hydraulic cylinder, they
115 bar
105 bar
132 bar
are the following: 90 bar
MAKE-UP 9000 daNm - 132 bar

BREAK-OUT 9000 daNm - 105 bar
To have more safety on max pressure values, we advise

to setting the relief valves, installed on: rod side and
piston side. Max torque of 8000 daNm.
MAKE-UP 8000 daNm - 115 bar Fig. 23-2.1

BREAK-OUT 8000 daNm - 90 bar
To set these values, follow this procedure:

• Adjust torque control R50 ( on main control panel) up A10
to max. ( clockwise rotation ) R50
• With control S16, active hydraulic cylinder for MAKE-
UP ( rod side ), to bring up to end stroke. (hydraulic S16
cylinder closed )
• Read hydraulic pressure on gauge A50, unscrew jam
nut on relief valve on rod side, modify setting of relief
valve up to that the pressure gauge indicate 115 bar
• Block setting value with jam nut
• With control S16, active hydraulic cylinder for BREAK-
OUT ( piston side ), to bring up to end stroke (hydraulic Fig. 23-2.1
cylinder open)
• Read hydraulic pressure on gauge A50, unscrew jam
nut on relief valve on piston side, modify setting of relief
IMPORTANT
valve up to that the pressure gauge indicate 90 bar
The setting values indicated, it’s a instance. For de-
• Block setting value with jam nut
tailed on values, see hydraulic scheme of your rig
ROD SIDE
PISTON SIDE
Tongs for 9000 kgm ( max pressure on piston full section 105 bar,
max pressure on annulus section rod side, section 132 bar) Fig. 23-2.3
Service Manual
Hydraulic Training
24. OPERATING PROCEDURE TO SETTING mouse hole

MOUSE HOLE CLAMP
170x130xC.105
5:1
32
3:1
34
48
49
B A B A B A B A B A
40 LIT./1'
40 LIT./1'
Y62
Y59
Y60
Y61
U W U W U W
A51
R51
MOUSE HOLE
CLAMP REGULATOR
Fig. 24-1.1
Service Manual
Hydraulic Training
24.1.1 hydraulic components
PILOT OPERATED REDUCING
Fig. 24-1.2
SEQUENCE VALVE- DIRECT ACTING WITH CHECK
Fig. 24-1.3
Service Manual
Hydraulic Training
COUNTERBALANCE VALVES - ATMOSPHERICALLY REFERENCED, 3 PORT CAVITY
Fig. 24-1.4
Service Manual
Hydraulic Training
24.2 setting procedures
24.2.1 setting of reducing valve pos. 49 (

pb*b, sun)
Pressure setting: 20-25 bar ( for more details see hydraulic

scheme of rig )
• Install pressure gauge after reducing valve. ( centralizer

hydraulic cylinder, piston side )
• With control C12, close mouse hole clamps
• Verify pressure setting of valve 49 (PB*B), reading
pressure gauge Scale Bar Fig. 24-2.1
• Return to neutral position of control C12
• Adjust reducing valve 49 (PB*B), to obtain the correct
value.
C12 R51
IMPORTANT
Usually, the setting of reducing valve, it’s obtained
unscrewing completly (counter-clockwise) and after
screwing of 1/2 turn
24.2.2 setting of sequence valve pos. 48 (

SC*A, sun)
Pressure setting: 40-45 bar ( for more details see hydraulic

Fig. 24-2.2
scheme of rig )
• With control C12, closed mouse hole clamps

• Verify that centralizers are closed before mouse hole
clamps
IMPORTANT
Usually, the setting of reducing valve, it’s obtained
unscrewing completly (counter-clockwise) and after A51
screwing of 1/4 turn
24.2.3 setting of accumulator pressure

pos. 34
Fig. 24-2.3
Usually, the accumulator is supplied with nitrogen pressure
of 110 bar. For this application is advised to set accumu-
CLAMPS
lator at 65-70 bar. To procede with accumulator charging
operation see Section 12.
24.2.4 setting of overcenter valve pos.32

(CA**, SUN)
The hydraulic block Pos. 32, it’s composed from two valves,
one check valve without setting and an overcenter valve
with setting at 140 bar. To set overcenter valve, it need full
clockwise rotation to minimum setting of valve is 140 bar.
CENTRALIZER Fig. 24-2.4
Service Manual
Hydraulic Training
24.2.5 Setting of clamping force for mouse hole
The regulator R51 adjust clamping force.
IMPORTANT
The setting values indicated, it’s a instance. For detailed on values, see hydraulic scheme of your rig
•
IMPORTANT
• The minimum clamping force will be with pressure of 50 bar ( 11000 daN )
• Accumulator with charge pressure of 65 bar, it begins to be efficacious with least 90 bar of pressure on
mouse hole clamps.
• Accumulator with charge pressure of 110 bar, it begins to be efficacious with least 140 bar of pressure
on mouse hole clamps.
Service Manual
Hydraulic Training
25. SETTING OF TORQUE WRENCH
Hydraulic block OB.1907.00.00 (Part# 50850956)

Hydraulic block OB.1906.01.00 (Part# 50851485)
25.1.1 HYDRAULIC BLOCK OB.1907.00.00 (Part# 50850956)
MP MH MP1
TO TANK
BREAK-OUT
MAKE-UP
MAKE-UP
MANOMETER
PILOT PRESSURE INLET

FOR AUTOMATIC RETURN
OPERATION
PILOT / PRESSURE
HIGH PRESSURE TO CLAMP BLOCK
FROM CLAMP BLOCK
Fig. 25-1.1
Service Manual
Hydraulic Training
Fig. 25-1.2
Service Manual
Hydraulic Training
COMPONENT DESCRIPTION
4: h.P. SEQUENCE VALVE

8: RETURN SEQUENCE VALVE
3: MAKE-UP REGULATOR
2: MAKE-UP / BREAK-OUT SELECTOR
9: DAMPENING SEQUENCE VALVE
HYDRAULIC CONNECTIONS
T: 1” BSP
P-P1-P1A: 3/4” BSP
G-H: 1/2” BSP
Y: 3/8” BSP
X-X1-MP: 1/4” BSP
Service Manual
Hydraulic Training
25.1.2 HYDRAULIC BLOCK OB.1906.00.00 (Part# 50851485)
TO TANK
MANOMETER
HIGH PRESSURE
PILOT PRESSURE INLET
FROM TORQUE BLOCK
CLAMP OPENING
UPPER CLAMP
CLAMP
LOWER CLAMP
UPPER CLAMP
SEQUENCE VALVE
HIGH PRESSURE
TO TORQUE BLOCK
CLAMP OPENING
Fig. 25-1.3
C1 C2 D E F
F
44
F
P1A
MP P
T P
Fig. 25-1.4
Service Manual
Hydraulic Training
COMPONENT DESCRIPTION
4: UPPER CLAMP SEQUENCE VALVE
HYDRAULIC CONNECTIONS
P-P1A: 3/4” BSP

C-1-C2-D-E: 1/2” BSP
T-F: 3/8” BSP
25.2 HYDRAULIC COMPONENT
25.2.1 sequence valve - direct acting with check
Fig. 25-2.1
Service Manual
Hydraulic Training
25.3 setting procedure of torque

wrench
25.3.1 setting sequence valve for upper

clamps (ob.1907, pos 4)
Usually, pressure setting of this valve is 100 bar.
To setting this valve following this procedure:

• Rotate screw regulation( counter-clockwise rotation C54
) up to minimum setting, after rotate of 1 1/2 turn.(
clockwise rotation ).
• Start automatic sequence with control C54, verify clo-
sing of lower clamp before of upper clamp.
• Connect a pressure gauge on outlet MP and verify that
upper clamps start to close with pressure of 100 bar.
• If necessary adjust pressure with upper clamp sequen-
ce valve ( POS 4 ).
25.3.2 setting sequence valve for clamps Fig. 25-3.1

rotation ( OB.1906, POS 4)
This is used for MAKE-UP and BREAK-OUT operation.
Usually, pressure setting of this valve is 210 bar ( max

pressure of sequence valve SCGA-LAN)
To setting this valve following this procedure:

• Rotate screw regulation ( clockwise rotation )up to max
limit, after to block setting with jam nut
S9
25.3.3 setting sequence valve “dampening”
(ob.1906, pos. 9)
Fig. 25-3.2
Usually, pressure setting of this valve is 35 bar.
To setting this value following this procedure:

• Rotate screw regulation ( counter-clockwise rotation )
up to minimum setting..
• Start automatic sequence with control C54. After lea-
ving control, verify that automatic sequence of return,
happen without vibration
IMPORTANT
The setting values indicated, it’s a instance. For detailed
on values, see hydraulic scheme of your rig
Service Manual
Hydraulic Training
25.3.4 SETTING SEQUENCE OF MAKE-UP REGULATOR (ob.1906, POS. 3)
TORQUE WRENCH TORQUE
300 300
250 10330 14677 250
TOOL JOINT DIAMETER (mm)

HYDR. PRESSURE (bar)
200 200
150 150
BREAK-OUT
MAKE-UP
100 100
50 50
0 0 0
0 2000 4000 6000 8000 10000 12000 14000 16000
TORQUE (daNm)
MAKE-UP BREAK-OUT
Fig. 25-3.2
The setting of MAKE-UP derive from type of pipe and thread
that you must tighten.
To set torque value of MAKE-UP, you must refer to diagram A81
Fig. 25-3.2.
• Establish the torque value that you need

• Draw vertical line in correspondence of torque value,
from X axle, go up to MAKE-UP line, from this point you
go to Y axle, and read pressure.
• Begin automatic sequence of torque wrench with con-
trol C54, go up to end stroke of hydraulic cylinder for
R81
rotation clamps, MAKE-UP rotation.
• Maintain torque wrench on to limit of rotation , read
hydraulic pressure on gauge ( positioned on torque Fig. 25-3.3
wrench ). Adjust pressure regulator up to you obtain
needed pressure. You block setting with jam nut
• The BREAK-OUT operation hasn’t adjustement of torque. In this operation the torque wrench gives the max
torque, that it derives from: tool joint diameter and friction from tool joint and jaw. Indication of torque, during
BREAK-OUT operation, it’s gave from diagram, Fig. 25-3.2. To read diagram with BREAK-OUT condition, you
can follow this procedure:
• Reading on right side, the diameter of tool joint.
• Drawing a horizontal line up to BREAK-OUT straight
• From last point, draw a vertical line up to torque value. This value is approximate
•
IMPORTANT
The torques, that you obtain from BREAK-OUT line, they are calculated with friction value of 0.7 ( between
tool joint and jaw)
Service Manual
Hydraulic Training
25.3.5 SETTING OF SEQUENCE VALVE, FOR AUTOMATIC RETURN (OB.1906, POS 8)
When you leave the lever control of torque wrench, it comes back with automatic sequence, on beginning position,
this sequence happens by means the pilot pressure on inlet P1. ( 60-70 bar ).
Sequence of return is composed from these step:
• contemporary release of the lower and upper clamps
• rotation up to original piston.
To respect the above sequence, for return sequence, it’s need adjust the valve at 35 bar ( Pos. 8, block OB.1906).
For adjust, follow this procedure:
• Rotate the screw regulation up to limit ( counter-clockwise ), it was brought at minimum setting. After, rotate for
3/4 turn, on clockwise
• Connect a pressure gauge on outlet MP1. Begin automatic sequence of MAKE-UP or BREAK-OUT, by means
control C54. Leave the lever C54, to start return sequence. Verify that return sequence shall be respected and
the clamps begin to rotate with pressure of 35 bar.
• If necessary, adjust screw regulation of sequence valve.
IMPORTANT
The setting values indicated, it’s a instance. For detailed on values, see hydraulic scheme of your rig
Service Manual
Hydraulic Training
26. SETTING PROCEDURE OF POWER TONG

26.1 HYDRAULIC CIRCUIT DESCRIPTION
LOWER CLAMP
MORSA INFERIORE UPPER CLAMP
MORSA SUPERIORE
200X150X100 R=1:2.28 200X150X100 R=1:2.28
1/2"BSP 3/4"BSP
3/4"BSP
3/4"BSP 3/4"BSP
3/4"BSP
A B C1 C2 C3 C4 D1 D2 F E
MAKE-UP/BREAK-OUT
350 Bar CYLINDER
X6
X3
Y Y 1/4"BSP
350 Bar
A A
B B 350 Bar
120 Bar 280 Bar
MA
1/8"BSP A B
A B
LS X
P T
Y
P T
Y 125X70X190
1/4"BSP 4D03.3.051
R=1:1.45
3/8"BSP
3
A B
1 180 Bar
2
X P T Y
D.9 mm 4D03.3.008
1/8"BSP
X P T X2 X4 X5
X1 MB 1/4"BSP
1/4"BSP
1.1/4"BSP
AUT. SEQUENCE
1/4"BSP
1"BSP
RETURN
1/4"BSP
1/2"
3/8"
3/8" 3/8"
3/8" 3/8"
1.1/4" 1.1/2"
3/8" 3/8"
3/8"
LS
TO T.D. X1 X1 X X5 X2
LOWER CLAMP
MAKE-UP
CLAMPING FORCE
REGULATOR
BRAKE-OUT
RETURN
RETURN
RETURN
MAKE UP TORQUE
REGULATOR
Fig. 26-1.1
Service Manual
Hydraulic Training
26.2 HYDRAULIC CIRCUIT COMPONENT
26.2.1 hydraulic block OB.2111 (part# 50851065)
AUTOMATIC SEQUENCE
RETURN PILOT PRESSURE

TO MAKE-UP / BREAK-OUT
CYLINDERS
CLAMPS OPENING
TO UPPER CLAMP CLOSING

TO LOAD SENSING LINE
BREAK-OUT / RETURN
TO LOWER CLAMP CLOSING TO CHECK MAKE-UP/BREAK-OUT
PILOT PRESSURE
SEQUENCE. MANOMETER
TO CHECK RETURN
SEQUENCE. MANOMETER
TO MAKE-UP REGULATOR PILOT PRESSURE FOR ONLY
R4R06 LOWER CLAMP
TO TANK PUMP INLET FLOW
DRAIN
TO CLAMPING FORCE
REGULATOR. RAR06
Fig. 26-2.1
7: H.P: Sequence valve for upper clamp. ( RSHC)

8: H.P. Sequence valve for MAKE-UP / BREAK-OUT (RSHC)
4-4.1-4.2: Pressure reducing valve- remote pilot operated (clamps) (R4R06)
6: Pilot pressure for only lower clamp closing
11: Return sequence valve. (SC*A )
Service Manual
Hydraulic Training
A B C1 C2 C3 C4 D1 D2 F E
X6
4.1
10/420 bar
7/210 bar
X3 4.2
Y Y
7 8
3 4 A A
B B
A B
MA
A B P T
6
LS P T
A B
P T
2 A B
a b
P X Y T
P T
Y
A B 3
11
1
P T
2
P X Y T
35/210 bar
Ø9
P X X1 T X2 MB X4 X5
Fig. 26-2.2
P: 1” BSP
T: 1 1/4” BSP
A-B-E-F-D1-D2: 3/4” BSP
C1-C2-C3-C4: 1/2” BSP
Y: 3/8” BSP
X-X1-X2-X3-X4-X5-X6-LS: 1/4” BSP
Service Manual
Hydraulic Training
26.3 setting procedure OB.2111 (PART#

50851065)
A1 Clamping force indicator

A2 Power tong torque indicator
R7 Power tong make up torque regulator
R3 Power tong clamping force regulator A1
C7 Torque break out/return R3
C7 Torque make up/return

26.3.1 REDUCING VALVE (pos. 4-4.1-4.2)
Usually the reducing valves are already setting at 350

bar.
Rotate the regulation screw complettly up to limit (clockwise
rotation), so that local setting shall be 350 bar. These valves
are remote controlled, by means a piloting and regulator Fig. 26-3.1
on control panel. The regulator on control panel gives the
effective pressure regulation from 10 to 350 bar.
The valves on Pos. 4 and 4.1, they adjust the clamping
force for upper and lower (see control R3 and clamping
force indicator A1). R7
The valve on Pos. 4.2 adjusts the MAKE-UP torque ( see
control R7 and torque indicator A2)
26.3.2 sequence valve for upper clamps C7A C7

(POS. 7)
Usually, setting of this valves is of 120 bar.
Adjust valve with following procedure: Fig. 26-3.2

• Rotate the screw of regulation completly, with counter-
26.3.4 SEQUENCE VALVE FOR AUTOMATIC
clockwise rotation, then rotate the same screw, with
RETURN (POS. 11)
clockwise rotation, for 3 turns.
• Connect pressure gauge on outlet MA. Begin automatic
Usually setting of this valve is 180 bar.
sequence of power tong. Verify that lower clamps are
closed before than upper clamps
Adjust valve with following procedure:
• If needed, you can adjust the screw regulation to more
• Rotate the screw of regulation completly, with counter-
or less, until the sequence will be respected, at this point
clockwise rotation (minimum setting). Then rotate,
with correct setting, you must tightening the jam nut.
with clockwise rotation for 3 1/2 turns
• Connect pressure gauge on outlet MB.
26.3.3 sequence valve for rotating of
• Begin automatic sequence for automatic return. Verify
clamps, make-up / break-out (pos.8)
that sequence of return is composed from these steps:
contemporary release of the lower and upper clamps
Usually setting of this valve is 280 bar.
then rotation with a hydraulic pressure of 180 bar.
• If needed, you can adjust the screw regulation to
Adjust valve with following procedure:
more or less, until the sequence will be respected,
• Rotate the regulation screw completly, with clockwise
at this point with correct setting, you must tightening
rotation (maximum setting). Then rotate, with counter-
the jam nut.
clockwise rotation for 1 3/4 turns
• Connect pressure gauge on outlet MA. Begin automatic
sequence of power tong. Verify that that lower clamp is
closed before than upper clamps. Then verify that the IMPORTANT
upper clamps begin to rotate with a hydraulic pressure The setting values indicated, it’s a instance. For detai-
of 280 bar. led on values, see hydraulic scheme of your rig
• If needed, you can adjust the screw regulation to more
or less, until the sequence will be respected, at this point
with correct setting, you must tightening the jam nut.
Service Manual
Hydraulic Training
27. PROCEDURE FOR RELEASING

OF TORQUE, IF DRILL STRING GETS
TORQUE UP AND STOP
The purpose of the following procedure is to guide all the
operators working safely. This procedure is applicable on
drilling rigs HH200/HH220/HH300.
It is strongly recommended to follow the below procedu-
re.
HAZARD
We remind to all operators, that not following the sug- SR6 Fig. 27-1.1
gested procedure could damaging the top-drive motors
and also compromising the crew safety

R11
WARNING
Every time that the string get stucked in the well, it is
strongly recommended to all drillers to keep full control
on top drive. To get this, put Top Drive on lower speed,
first ratio, by means of selector S5. C8
27.1 TOP DRIVE STALLED AT MAXIMUM

TORQUE
If the string gets stuck and the torque is reaching the maxi- Fig. 27-1.2
mum torque applicable on the pipe, try to work the torque
out from the string as follow:
1 – Put rotation joystick C8 on neutral position.
2 - Release the torque using regulator R11, Than rotating

it clockwise very slowly, the torque of Top Drive will lower A3
up to zero.
For assure that the torque is released completely, see re-
sidual pressure on gauge A3.
WARNING
Keep Top-Drive speed in first gear, by means of selector Fig. 27-1.3
S5 and never switch gears
WARNING
The switch brakes by means of selector S6, can not be H1
used as a torque release, so it can not be switched on/ S6
off for releasing residual torque.
When H1 lamp is lighted, it indicates that brake is
active
S5
Fig. 27-1.4
Service Manual
Hydraulic Training
WARNING
Do not use Power Tongs or Torque Wrench (where installed) to release the residual torque.
OPTION
27.2 TOP DRIVE STALLED WITH LOWER RESIDUAL TORQUE
If the string gets stuck and the torque is lower than the maximum applicable on the pipe, try to work the string raising
and lowering the torque, in a range of 20% up and down, using SR6 control valve slowly, watching out gauge A3 and
letting enough time for pump reaction .
Keep the joystick C8 inserted. Do not try to release torque up to zero using SR6.
If it is required, apply procedure item 27.1
IMPORTANT
The control R11 “Pipe torque discharge” must be positioned fully CCW, when you are on normal drilling operations.
.

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SERVICE MANUAL

12, Via 1° Maggio

Corporate web site: http://www.drillmec.com

Page 2 - Hydraulic Training

3 PRESSURE REGULATOR (CONTROL PANEL).................................................8

5 pressure relief valve (HYDRAULIC POWER UNIT)..............................16

6 PRESSURE RELIEF VALVE (MAST-ROPE TENSIONING CYLINDERS)........21

8. PRESSURE REDUCING / RELIEVING VALVE.................................................43

9. flow control valve..................................................................................50

10. SHUTTLE VALVE............................................................................................52

11. sandwich style directional valve section..................................54

12. accumulators for hydraulic............................................................59

13. INTRODUCTION TO LOAD SENSE HYDRAULIC CIRCUITS.......................65

Hydraulic Training - Page 3

14. AXIAL PISTON PUMP ( FIXED DISPLACEMENT )........................................66

17. plumbing to the power unit (hh220/hh200/hh300).........................81

20. FLOATING BLOCK ob.2317 (part 50851425)..........................................102

21. OPERATING PROCEDURE for RELIEF VALVE of distributor of

23. OPERATING PROCEDURE TO SETTING bit breaker tongs............. 112

24. OPERATING PROCEDURE TO SETTING mouse hole . ........................ 114

25. SETTING OF TORQUE WRENCH................................................................119

26. SETTING PROCEDURE OF POWER TONG................................................127

27. PROCEDURE FOR RELEASING OF TORQUE, IF DRILL STRING GETS

Page 4 - Hydraulic Training

SHOWING DIN (ISO 1219) SYMBOLS USED ON DRILLMEC SCHEMATICS

HOSE (Shown only when a hose is

LINE, PASSING MOTOR, ROTARY,

LINE TO RESERVOIR (TANK)

CYLINDER, SINGLE ACTING

1.3 1.3 CYLINDER, DOUBLE ACTING

PRIME MOVER, HH300 PULL-DOWN CYLINDER

Hydraulic Training - Page 5

COMPONENT ENCLOSURE QUICK COUPLING

FILTER OR STRAINER PRESSURE REDUCING VALVE

FILTER WITH INTEGRAL

OIL COOLER WITH

FIXED (size shown) ADJUSTABLE

HYDR. REMOTE CONTROL

CHECK VALVE (BASIC) FLOW DIRECTION PRESSURE

CARTRIDGE VALVE WITH

Page 6 - Hydraulic Training

BRAKE VALVE OVERCENTER VALVE DIRECTIONAL VALVE, 3 POSITION,

PROPORTIONAL DIRECTIONAL VALVE, 3 POSITION,

DIRECTIONAL VALVE: METHODS OF OPERATION

SHUTTLE VALVE P P DETENT

DIRECTIONAL CONTROL VALVES EXAMPLES OF COMBINATIONS OF METHODS

Hydraulic Training - Page 7

2.1.1 VALVE ft257

FT257/6/2 Inline check valve 1/2” Gas 2 bar ( Part# 50851221 )

2.1.2 VALVE rv25

RV25 Inline check valve 1 1/4” Gas ( Part# 50850291 )

Page 8 - Hydraulic Training

3 PRESSURE REGULATOR (CONTROL PANEL)

Model DBDH-6 REXROTH (Part# 50850894)

Fig. 3-1.1 Fig. 3-1.2

Hydraulic Training - Page 9