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Hydraulic Components & Solutions for Mining Equipment

IC-Fluid Power supports mining applications with proven hydraulic components and engineering support that minimize downtime and serviceability.

Black IC30 hydraulic rotary actuator, commonly used as a replacement for Parker Helac L30 actuators with counterbalance valve and foot mounting.

Hydraulic Components & Solutions for Mining Equipment

Mining applications rely on hydraulic systems for precise control of heavy machinery, high power density in confined spaces, and rugged performance under extreme loads and pressures. These systems are often used in harsh environments that are abrasive and exposed to shock, vibration, debris, and extreme temperatures.

What Common Challenges Do Hydraulics Solve in Mining?

Achieving high torque, high force, and high pressure all in one compact machine
Performing efficiently while exposed to dust, extreme temperatures, and vibration
Preventing premature wear and tear from harsh conditions
Integrating components that minimize maintenance requirements
Finding fast replacements without long lead times
Maintaining equipment with high duty cycles and continuous operation
Improving operational safety and reduced pinch points
Protecting systems against potential failure
Minimizing equipment downtime and simplifying field serviceability

What Are Real-Life Mining Applications?

Boom positioning of drill rigs for blasting applications using hydraulic rotary actuators for precise rotation up to 360°
Rotation of attachments for heavy-duty excavation, tunneling, and material handling using rotary actuators
Clamping and actuation applications that need localized pressure boosting using pressure intensifiers
Pressure intensification of support cylinders and brake circuits using pressure intensifiers
Mobile mining equipment such as loaders, cranes, and excavators needing to prevent backflow and maintain pressures up to 10,000 psi using hydraulic check valves
Mobile mining equipment needing preventative maintenance for fluid loss or system failure using butterfly valves and compensators

What Hydraulic Components Are Used in the Mining Industry?

Silver painted hydraulic rotary model SM4 actuator.

Hydraulic Rotary Actuators

Helical spline rotary actuators deliver high power density and precise rotary motion in an enclosed housing compared to long-stroke cylinders or exposed linkages.

Positioning nozzles in drill rigs and tunneling equipment
Steering tunneling boring machines
Rotating articulated booms, buckets, and grapples
Mobile machinery, such as cranes, excavators, and loaders

Operating pressure:
up to 3,625 psi (250 bar)
Maximum torque:
standard up to 750,000 in-lb (85,000 Nm), custom actuators up to 2,200,000 in-lb (250,000 Nm)
Standard rotation angles: 90°, 180°, 220°, 360° (up to 720° as a custom option)
Flange-mounted design options for direct load attachment
Customize nearly every aspect of the design

silver hydraulic pressure intensifier, MP-T series transparent

Pressure Intensifiers – ScanWill

Hydraulic pressure intensifiers boost existing system pressure to achieve ultra-high output pressures, eliminating the need for costly investments or upgraded pumps.

Hydraulic component pressure boosting like motors, actuators, cylinders
Intensifying clamping and cutting tools
Boosting brake systems
Pressurizing support cylinders to stabilize booms and masts

Output pressure:
up to 58,000 psi (4,000 bar)
Pressure ratios:
many options, up to 16:1
Input pressure:
up to 2,900 psi (200 bar)

hydraulic butterfly valve hydraulic shut off valve easy actuation ball valve alternative hytorc

Butterfly Valves – Hytorc

Hydraulic butterfly valves isolate flow from the pump and tank, helping prevent oil loss and environmental impact if a hose or line fails.

Emergency shutoff devices for mobile vehicles including drill rigs, cranes, excavators, and loaders

Temperature range: -4ºF to 176ºF (-20ºC to 80ºC)
Over pressure:
232 psi (16 bar)
Under pressure:
10 psi (0.7 bar)
Sizes: 1.25 to 5 inches (32 to 125 mm)
Materials: non-corrosive aluminum cage and shifter, NBR sealings
Larger weight and space savings compared to a ball valve of the same size as the diameter of your valve increases (77% shorter and 71% lighter for a 4 in valve)

hydraulic rubber compensator from hytorc absorb vibration and noise

Rubber Compensators – Hytorc

Hydraulic rubber compensators protect mobile equipment from axial and radial stress from vibration due to load changes and machinery operation.

Noise reduction and vibration of skid steers, small graders, mini excavators
Mining equipment with low pressure lines

Sizes:
1 to 4 inches (25 to 100mm)
Pressure:
up to 116 psi (8 bar)
Dampens noise, improving operator comfort and worksite conditions

hydraulic check valve hytorc gray check valve 10,000 psi

Check Valves – Hytorc

Designed to prevent backflow and maintain consistent pressure, hydraulic check valves stablize performance even under fluctuating loads and extreme operating conditions

Backflow prevention of excavators, skid steers, cranes
High-force mining equipment

Handles pressures up to 10,000 psi (700 bar) for high-force tools (compared to the standard max pressure capabilities of 3,000 psi (206 bar))
Compact, low-profile designs for space-constrained installations
Optimized sealing for enhanced performance

3 test points hydraulic pressure points and hose assemblies

Test Points & Hoses – Spradow

Hydraulic test points enable quick, safe pressure checks, diagnostics, and fluid sampling without system shutdown or fluid loss.

Preventative maintenance and troubleshooting of mobile machinery (loaders, drill rigs, excavators, and cranes)
High-force mining equipment

Threads: M16x2
Max Working Pressure: 9,135 psi (629 bar)
Temperature range: -4ºF to 322ºF (-15ºC to 161ºC)
Materials: Carbon steel with zinc chromate (stainless steel optional)
Seals: NBR, 90 durometers (other options available)
Standards: DIN ISO 4042
Interchangeable with other brands, such as Stauff and Minimess®

Why Work With IC-Fluid Power for Mining Applications?

IC-Fluid Power supports the most demanding applications for mining, tunneling, and large-scale industrial machinery. With an in-house team of engineers that work closely with the people manufacturing your components, we ensure that every aspect meets the performance, accuracy, and durability requirements of heavy-duty mining equipment.

What is the IC-Fluid Power Difference?

Deep sourcing expertise across European hydraulic manufacturers
Ability to cross-reference and recommend alternatives that don’t sacrifice performance
Access to drop-in replacements for trusted brands like Helac, SJH, and HKS with fast lead times of 10-26 weeks
Full support for industry standards and safety-critical hydraulic systems used in mining
Responsive lead times and local technical support
Engineering guidance to match flow, pressure, frequency, and force requirements

If you’re designing or maintaining hydraulic systems for mining applications, IC-Fluid Power can help identify the right components for your system requirements.

Contact an engineer today.

Frequently Asked Questions

Mining and tunneling equipment utilizes many different hydraulic components that must work under extreme loads, abrasive environments, and continuous operation. Rotary actuators, pressure intensifiers, check valves, butterfly valves, and test points are used in tandem on mining equipment. Some examples on common uses are…

Rotary actuators control precise boom and attachment positioning on drill rigs and excavators. Pressure intensifiers boost system pressure for brake circuits, cylinders, and other tools without requiring a larger pump for the whole system. Butterfly valves and check valves protect mobile machinery from fluid loss and back flow. Test points facilitate easy pressure diagnostics without lengthy system downtime.

Hydraulic rotary actuators deliver high torque output and precise rotary motion in an enclosed, compact housing. These design features make them particularly well suited for heavy-duty mining and drill rig applications, such as boom positioning and rotation, as well as machine steering. Their size allows them to fit into small, mobile machinery, while their enclosed design allows them to function in harsh environments with dust and debris.

Helical spline designs offered by IC-Fluid Power are capable of standard torque up to 750,000 in-lb (85,000 Nm) at operating pressures up to 3,625 psi, with custom configurations capable of reaching 2,200,000 in-lb (250,000 Nm). Standard rotation angles range from 90° to 360°, with up to 720° available as a custom option for applications requiring extended rotation range.

Yes, by not needing to upgrade your pump or fully redesign your system to provide a local pressure boost in one area.

Pressure intensifiers enable systems to reach ultra-high output pressures (up to 58,000 psi / 4,000 bar) from an existing hydraulic circuit. This eliminates the need to upgrade pumps or invest in redesigning the entire system to handle high-pressure capabilities. With pressure ratios up to 16:1 and input pressures up to 2,900 psi (200 bar), they are used to intensify pressure to brake circuits, pressurize support cylinders on booms and masts, and boost clamping and cutting tool performance. This makes them a cost-effective solution for applications where local, task-specific high pressure is needed in a standard hydraulic system.