10/24/2019 When and How to Adjust a Load-sensing Hydraulic Pump
When and How to Adjust a Load-sensing
Hydraulic Pump
Jack Weeks, GPM Hydraulic Consulting
Tags: hydraulics
Variable-displacement pumps are used in hydraulic systems where the flow
requirements vary. This usually means the system has several actuators and,
depending on the current cycle of the machine, the number of actuators moving at
a given time will fluctuate. The most common type of variable-displacement pump
is the pressure-compensating pump.
Pressure-compensating Pumps
Pressure-compensating pumps are designed to deliver only the amount of flow
required by the system to maximize efficiency and avoid heat generation. The
compensator is adjusted to a pressure somewhat higher than that required to move
the system’s heaviest load.
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10/24/2019 When and How to Adjust a Load-sensing Hydraulic Pump
A pressure-compensating pump will
deliver its maximum flow until the
system pressure reaches the
compensator setting. Once the
compensator setting is reached, the
pump will be de-stroked to deliver
only the amount of flow that will
maintain the compensator setting in
the line.
Whenever more flow is demanded
by the system (such as would occur
when an additional actuator begins
to move), the pump will increase its
stroke to meet the new flow
demand. Whenever the system flow
needs to decrease (such as when
one or more actuators are stopped),
the pump stroke is reduced.
When the system is stopped
completely, the pump stroke is
reduced almost to zero. It will stroke
only a very small amount or
whatever is required to maintain the
compensator setting in the line,
overcoming any system bypassing
or leaks. While a pressure-
compensating pump is efficient, the
standby pressure remains high.
Adjusting Pressure-
compensating Pumps
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10/24/2019 When and How to Adjust a Load-sensing Hydraulic Pump
Adjusting a pressure-compensating
pump is quite simple. With all flow
blocked and the system idle, the
compensator valve is adjusted to the desired pressure. However, some pressure-
compensating pumps have two valves mounted on the pump body.
The two adjustments can look nearly identical. This type of pressure-compensating
pump is called a load-sensing pump. The second adjustment is called either a
“load-sensing” valve or “flow-compensator” valve.
A load-sensing pump is designed to reduce its pressure to a much lower standby
level whenever the system is idle. This can conserve energy and reduce heat and
wear in systems that spend a significant amount of time in an idle condition.
The two separate pressure adjustments allow setting the compensator valve to the
required maximum system pressure and the load-sensing adjustment to a much
lower standby pressure.
Whenever the system is moving a
load, the high-pressure adjustment
limits the system pressure. For
instance, as a cylinder is extended,
pressure in the system will build as
necessary to move the load.
Eventually, the cylinder reaches the end of its stroke, and flow is blocked.
When the flow is blocked in this fashion, the system pressure can build no higher
than the setting of the compensator, but until another load is to be moved, there is
no need for the system pressure to be kept so high.
Most load-sensing systems have a pump-loading directional-control valve of some
sort that can place the system in an idle condition until it is necessary to move
another load. When the pump-loading valve is shifted, the system pressure drops
to the much lower load-sensing valve setting.
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10/24/2019 When and How to Adjust a Load-sensing Hydraulic Pump
A load-sensing valve usually is smaller than the compensator valve and typically
mounted directly on top of the compensator. The compensator valve is closer to the
pump. The load-sensing valve is factory preset and normally does not need to be
adjusted during the initial pump setup. In most pumps, the factory preset is
approximately 200-300 pounds per square inch (psi).
The most common reason to adjust a load-sensing valve is because someone
unfamiliar with the pump has mistakenly attempted to set the maximum system
pressure by adjusting the load-sensing valve instead of the compensator. This not
only can result in unstable system pressure but in some cases can also void any
warranty on the pump.
A typical configuration of a pressure-compensating pump is shown in Figure 1. A
pump-loading valve is used to determine whether the system is idle or prepared to
move a load. The pump-loading valve is de-energized whenever the system is idle.
Pilot pressure on the left-hand side of the load-sensing valve is then released to the
tank. The pilot line on the right-hand side of the load-sensing valve is connected to
the pressure line at the pump outlet. System pressure shifts the load-sensing valve
and directs pressure to reduce the pump stroke so that system pressure drops to
the load-sensing setting of 300 psi, as illustrated in Figure 2.
When a load is to be moved, the pump-loading valve is energized. This directs pilot
pressure to the left side of the load-sensing valve, keeping it from shifting. System
pressure shifts the compensator valve to de-stroke the pump exactly the amount
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10/24/2019 When and How to Adjust a Load-sensing Hydraulic Pump
necessary to limit system pressure to the compensator setting, 3,000 psi as shown
in Figure 3.
To make the pressure settings, always adjust the load-sensing valve first. The
pump should be deadheaded by closing the manual hand valve. With the pump-
loading valve de-energized, pressure will build only to the current setting of the
load-sensing valve. Adjust the load-sensing valve to the desired pressure.
Once the load-sensing valve is set, energize the pump-loading valve. System
pressure will then build to the current compensator setting. Adjust the compensator
to the desired setting. Open the manual valve, and the system can be placed back
into service.
There are several variations of this design. Sometimes a throttle valve will be used
to determine if a load is available. The pressure drop that results when oil moves
through the throttle valve signals the need for higher system pressure.
Another common variation is to use the load-sensing valve in conjunction with a
proportional relief valve connected in series. Standby pressure will then be
determined by the sum of the load-sensing pressure and the electronically
controlled setting of the proportional relief.
In more complex arrangements such as this, hand valves should be installed that
can be opened or closed to deadhead the load-sensing valve and also to release
its pressure to the tank to enable setting the pressure.
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