11.

Hydraulic system
11.1 Introduction:

Hydraulic system is one of the most important systems in DEMU Value Package as it drives cooling system of engine
and engine compartment. It is expected that information provided in this session would serve the purpose of
understanding operational principles, maintenance tips & simple trouble-shooting needed by DEMU users.

What is Hydraulic Drive ?

Hydraulic drive is a means to transmit rotational power to driven shaft from another driving shaft. It is accomplished
without any mechanical drive link, but only by using fluid pressure (P) and flow (V) from driving shaft to driven shaft.
It also gives necessary control to the transfer of power by suitable means or device.

Thus, PXV = W

Where;

P = Hydraulic pressure

V = Flow of hydraulic oil &

W = Work energy / power transmitted.

Please find attached a sketch on next page which illustrates • the operation of most basic hydraulic power transmission.

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 HYDRAULIC POWER TRANSMISSION

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Contents of Typical Hydraulic System :

Any Power transmission hydraulic system comprises of -

• Pump hydraulic

• Motor hydraulic

• Pressure Relief valve

• Tank hydraulic

• Hydraulic Oil cooler

Besides above, several application related items like Return line filter, strainer, check valves etc. are also required fo r
the hydraulic system.

All these items are connected almost in a similar manner in all hydraulic systems. Following Figure shows hydraulic
connections of a typical system :

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Types of Hydraulic Systems in DEMU :
There are three types of hydraulic drive systems required for DEMU application.

1. RMR (Roof Mounted Radiator) Fan Drive system

2. SMR (Side Mounted Radiator) Fan Drive system

3. VFD (Ventilation Fan Drive ) system

Though basic hydraulic is same in all these systems, controls and components used are different. RMR & SMR are
thermatically controlled system; whereas Vent Fan Drive is without any thermatic control. It is a direct reduction speed
(1400/1800:1) drive system.

Please refer page nos. 58, 59 & 60 for hydraulic connections of RMR, SMR and VFD systems respectively.

11.2 Technical Specifications & System Components :

Ref No. Characteristics & Components RMR System SMR System VFD System
1 Hydraulic Tank Capacity 180Lt 180Lt *
2 Hydraulic pump P/N 3878470 3878470 3392006
Pump Speed 1980RPM 1980 RPM 1475 RPM
3 Hydraulic motor P/N 3230038 X 2 3873986 3230038
Hyd. Motor speed 2400 RPM 1750 RPM for 40" & 1400 RPM
1450 RPM for 48 "fan
System Pressure 160 Bar 210 Bar 140 Bar
Pump Outlet Flow 56LPM 56LPM 19LPM
4 Hydraulic oil cooler P/N P/N Not yet released 3877064 (large) *
5 Manifold block 3877039 3392669 3392364
6 PRV 3876068 3876068 3392365
7 Thermatic valve 3876879 3876879 *
8 Return line filter element 3877293 3877293 *
9 Return Line Block 3877181 3877181 3877181
10 Strainer 3876063 3876063 3392706
11 Remote control 3879052 - -
12 Inlet Gate valve 3876065 3876065
13 System Pressure gauge 3879027 - *

* These items are not required for VFD system as they are part of main hydraulic system.

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RMR FAN DRIVE SYSTEM

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 SMR FAN DRIVE SYSTEM

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VENTILATION FAN DRIVE SYSTEM

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11.3 Components of Hydraulic system in DEMU :
Following major components of DEMU Hydraulic Systems are discussed in this section.

11.3.1 Variable Displacement Pump

11.3.2 Thermatic Valve
11.3.3. Hydraulic Motor
11.3.4 Fixed displacement Hydraulic pump (Vent Pump)
11.3.5 Manifold block
11.3.6 Return line filter
11.3.7 Strainer
11.3.8 Pressure Relief Valve (PRV)
11.3.9 Remote pressure control valve (For Remote Control)
11.3.10 Hydraulic Oil Cooler

11.3.1. Variable Displacement Pump :

DEMU main hydraulic drive system (RMR & SMR) is

associated with Variable Displacement type hydraulic
pump. This pump is mounted on the engine & it is directly
driven by engine gear drive with 1.1 :1 drive ratio. It has
a pilot control valve which regulates delivery of liquid
flow of the pump after receiving feed back from remote
position.

Working of Variable Displacement Pump :

Hydraulic pump has nine cylinders whose movements

are obtained from rotation of drive shaft. Cylinders suck
& deliver liquid by their reciprocating motion proportional
to stroke length (displacement) of the cylinders.

These strokes are directly controlled by inclination of

the swash plate whose position is governed by Pilot
control valve (which receives feedback from remote
control).

In DEMU, remote control valve is also called as thermatic

control valve (as it’s feedback is translated on the basis
of rise in engine coolant temperature).

Hydraulic pump has a leakage return line back to

hydraulic tank.

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11.3.2. Remote Control or Thermatic Valve

Thermatic control valve is mounted on engine’s hot water

outlet which controls movement of plunger with rise in
engine coolant temperature. When engine water
temperature is below 80 Deg. C, liquid from pump pilot
valve freely passes through the valve assembly When
temperature rises above 80 Deg. C., thermal probe
expands and starts moving the plunger to create
restriction to incoming flow and generates back pressure.

This back pressure is treated as feedback by Pilot control

which now starts controlling inclination of swash plate
for more delivery coming out of hydraulic pump. In case
of no feed back ( i.e. when X point is plugged) pump
however, gives full delivery.

11.3.3. Hydraulic Motor:

Hydraulic motor is of bent axis/ swash plate design with

fixed displacement of cylinders where inlet of pressurized
liquid causes development of torque & speed to output
shaft. In case of hydraulic motor output, rotational speed
of the motor is directly proportional to flow going to the
pump and pressure of the liquid is directly proportional
to the torque developed by the shaft.

Hydraulic Motor also has a return line flowing freely back

to tank.

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 11.3.4 Fixed displacement hydraulic pump

Fixed displacement hydraulic pump is used to drive

ventilation fan. The pump is mounted on engine and
driven by belts from left (LB) accessory drive of the
engine. In internal construction, fixed displacement
hydraulic pump is similar to hydraulic motor. Only, the
port plate, which receives & delivers the liquid, is of
different design than hydraulic motor. Pump delivers flow
proportional to rotational speed of the driving shaft. Fixed
displacement pump has a case drain return line, freely
flowing back to the tank.

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11.3.5 Manifold block

Manifold block is a steel solid block which houses several

non return valves (check valves) & pressure relief valve
to encase complicated circuit inside and also to facilitate
hose connections to various points in the system. There
are three types of manifold blocks used in DEMU
hydraulic systems as described in the hydraulic circuits.
(Please refer Page Nos 58, 59 & 60)

All of them contain three cartize type check valves as

shown here. Sometimes, these valves may become un-
operational, if small dirt or foreign material gets entrapped
in their seating area.

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 11.3.6 Return line filter

Return line filter is mounted on hydraulic tank which

cleans the hydraulic oil that may get contaminated due
to poor handling or undesirable entry of dust in the
system. It has a restriction indicator at the top of the
head which starts showing red signal whenever return
back pressure is above 25 Bar. When the filter gets
clogged, element should be removed and cleaned with
good / clean solvent ( like Thinner, diesel or petrol etc ).
First cleaning of filter element after engine
commissioning, must be done within 600 hours of
operation.

Caution :

1. Do not attempt to clean the filter unless

restriction indicator shows red band.

2. Cleaning of the filter element more than twice is

NOT recommended as it may damage the fixing
arrangement of paper in the cartridge.

11.3.7 Strainer

Strainer is a very important component in hydraulic

system as it protects hydraulic pump directly from the
entry of solid material. It should be usually checked &
cleaned at the time of replacing hydraulic oil. It has a by
pass valve which opens in the event of complete clogging
of strainer. Check the operation of the same whenever
strainer is taken for cleaning. Strainer does not need
replacement unless found damaged.

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11.3.8 Pressure Relief Valve (PRV)

Pressure relief valve is always connected in main delivery

pressure line to limit the system pressure to 250 bar.
System pressure acts on the main spool. At the same
time pressure acts, via a pilot line fitted with jets, on pilot
poppet. If system pressure exceeds the value set with
the spring, the pilot poppet opens and pilot oil is allowed
to flow back to the tank. The jet combination causes
sufficient pressure drop across the main spool. The main
spool is lifted from its seat and opens the pressure line
connection to tank while operating pressure is
maintained, as desired.

The spring tension on poppet valve can be adjusted by

Alien screw to any desired pressure, from 0-250 bar.

In RMR & SMR options, the pilot control port should be

unplugged to receive flow for pilot poppet valve.

Please note that while replacing a PRV in field, this

plug should be kept open. Otherwise, PRV becomes
un-operational.

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 11.3.9 Remote pressure control valve

Remote pressure control valve is used only with RMR

option. It gives additional pressure adjustment facility to
the system at the time of installation, testing and
reduction of system pressure from outside radiator
assembly, if required.

This valve is hand knob operated, connected to pilot valve

of main PRV. It indirectly does the same job what is
achieved by screwing in or out of adjustment of main
PRV. Remote pressure control valve is a device by which,
restriction is created to the pilot oil flow coming out of
the main PRV. It has one inlet ( to which it generates
back pressure ), return flow line which goes back to tank
and one pressure point which records system pressure
(adjusted pressure).

In the event of malfunctioning, it may not hold the

pressure of 210 Bar which is the required back pressure
for its effectiveness. In such case, replace the valve.

11.3.10 Hydraulic Oil Cooler

Hydraulic oil cooler is a double pass air to oil cooling

arrangement. Hydraulic oil passes through copper tubes
(finned with wire bundles) & gets cooled by the ambient
air circulated by cooling fan. Hydraulic oil cooler should
be cleaned by pressurized air / water jet in case of dust
accumulation. Hydraulic oil cooler does not need any
periodic maintenance.

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11.4 Hydraulic Oil Specifications :
The following hydraulic oils are recommended :

1. Indian Oil Corporation : Servo System -68

2. Hindusthan Petroleum : Enklo - 68

3. Bharat Petroleum : Hydrol - 68

11.5 Hydraulic System Maintenance :

Hydraulic oil for hydraulic system is expected to give a very long life, if maintained properly. But, because of several
environmental reasons as mentioned under, its life reduces. One should be careful to monitor these factors, which are
detrimental to oil life.

1. Hydraulic oil temperature should be within the best operation range, i.e. 20 Deg - 70 Deg C. A Variation of 10
Deg. below or above this range reduces the oil life to half of the recommended period.

2. Dirt entry into the system because of poor handling, transportation and gasket leakages in the tank etc. Oil
contamination in the hydraulic tank should not be above 10 micron diameter impurity (100 particles in 100 ml of
fluid). It’s a good habit to check the oil in a suitable laboratory & establish the contamination level over a particular
period of time. Oil should be discarded, once contamination level crosses above limit.

3. Viscosity of the oil should not be outside the range (74.5 to 167 sq. mm/second) measured within 20 to 80
Deg.C. temperature range.

4. Avoid mixing of water with the oil which may occur during rainy season. Check presence of water during every
300 hours of engine maintenance by draining the bottom plug & check if cloudiness observed in the oil. Presence
of water will destroy the lubricating properties of oil & cause fast wear.

5. Avoid foaming of the oil which normally occurs due to heavy churning of oil or suction of air by hydraulic pump.

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Hydraulic System Maintenance Schedule :

System / Component Change Period Remarks

Hydraulic oil 2100 hours or 9 months Oil life can be extended by good
whichever occurs earlier maintenance but oil change period
should not be more than one year.

Return Line Filter Element should be discarded Element should be cleaned only when
during oil change period restriction indicator comes up. Do not
clean the element more than twice.

Strainer To be cleaned at oil change Not to be replaced till any damage is

period observed.

Hoses & O rings To be replaced once in 5000- Use genuine hoses as per Cummins
6500 hours or 2 years whichever Parts Book.
occurs first

11.6 Troubleshooting & Fault finding :

Sr. System/Component Complaint Possible Cause

1 Hydraulic Pump No or insufficient flow Low or No oil in hydraulic tank

from the pump Suction of air - Loose suction hose

Pump Drive Arrangement failure Inlet gate valve

kept in closed position Wear & Tear of internal
components of the pump due to dirt - to be
overhauled. Loss of pilot valve control - open &
check the control passages.

Malfunction of thermatic control - by pass

Thermatic control & check.

Excessive noise Air entering into the suction

Choked suction strainer
Damaged bearings inside the pump
Use of wrong grade oil

Insufficient system Improper setting of PRV

pressure Internal leakage due to worn out components
inside the pump - to be overhauled

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Sr. System/Component
2 Hydraulic Motor
3 Thermatic Valve
4 Pressure Relief Valve
5 Hydraulic hose
6 Return line filter
Complaint Possible Cause
Insufficient speed or Insufficient flow from pump (Ref Point 1)
no rotation of the fan Manifold block check valves are leaking -
Check hydraulic circuit & respective check
valves
PRV (spool) entrapped with dirt - Check & clean
PRV pilot valve not functioning - stuck up with
dirt; clean & replace
Wear & tear of rotary group members inside the
motor - To be overhauled
Unstable fan speed - System not bleeded properly - Open
Surging delivery hoses & bleed out air from pump
to motor line
Fan does not pick up Defective thermatic valve - Check
when coolant temp, operation of thermatic valve in hot water temp.
crosses 85 deg. C bath. It should close hydraulic flow at 90 deg. C.
Caution :
Thermatic valve repair is not recommended.
Do not re-use the valve in case flow
does not seize at 90 deg. C.
No or insufficient Incorrect valve setting - Adjust pressure
system pressure as per the table
Dirt entrapped in the spool or pilot valve
Choked jets with dirt - Clean & replace
Excessive temp, of Choked hydraulic oil cooler - Check &
hydraulic oil (Above Clean
70 deg C) System pressure too high - check PRV
setting as per table
Oil not replaced for long time - Refer system
maintenance section.
Repeated hose Wrong part No. - Check as per Parts book
failure Incorrect handling of hose at the time of
tightening - Carefully align & do not apply force
on the hose for tightening.
Blocked PRV - Check & clean
Repetitive choking System filled with excessive dirt / water -
signal Clean & flush the system
Stuck-up bypass valve in the filter assembly
- Open & check
Wrong filter element - Check & replace as per
CIL Part No.
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