Atlas Copco Drilling Solutions

Aftermarket Technical Service

Hydraulic System - Middle Range and PV270

Latin America School – October 2009
Santiago Chile – Hans Traub
 Middle Range Hydraulic System

Gear Box
Main Pumps
Diesel Engine

Triple Pump

The DM45 is a hydraulic driven, blast hole drill. Power to drive the hydraulic system is supplied by a Diesel Engine
through a 3 – hole gear box. The hydraulic pumps convert the Diesel energy from the Engine to hydraulic energy that can
be used by the various motors and cylinders to perform the necessary drilling and propelling tasks. The result is a simple
and flexible drilling system. We will cover the training in four circuits: Propel, Feed, Rotation and auxiliary functions.

Main Pumps

Triple Pump
 Pumps Drive

On DM45/50/L the main pumps

are mounted underneath of
triple pump. Stroker 9A of the
main pump are face down.

On PV270 series, the main

pumps are mounted on top.
The 5A stroker are face up.
Lube Points For Drive Shaft

Every 8 – 10 Hours or Daily

Main Hydraulic Pumps
Main Hydraulic Pumps
Main Hydraulic Pumps

1 Piston Pump
2 vane Chambers
3 Rotary Servo
4 Servo and Replenishing pump
5 Plug Optional
6 Servo Relief valve
7 Replenishing Relief Valve
8 High Pressure Sequence Valve
9 High pressure Pilot Control
10 Dual relief Valve
11 Replenishing Check Valve
Denison Pumps Test Ports

VA

V
KG

D
DG

VB
G
BG
 GAUGE PRESSURE RANGES: 1. 6000PSI, 68,9 bar gage for A or B port -- V
2. 200 PSI, 13,7 bar gage for case port -- DG
3. 500 PSI, 35 bar gage for replenishment port -- K, KG
4. 1000 PSI, 68,9 bar gage for servo port -- G, H

TYPICAL PRESSURES

Replenishment 180-220 PSI

(12,4-15,0 bar) + case

pressure

Servo: 300 PSI (20,6 bar) +

case pressure
+ 40 PSI (2,8) bar per 1000
PSI (68,9) bar system
pressure

Case: 75 PSI (5,2 bar)

continuous
125 PSI (8,6) bar intermittent
Denison 5A Stroker
 Denison 5A Stroker
Mechanical Null Adjustment
Manual Stroker Shaft
Mechanical Null
Volume stops
Servo Tube

NOTE: The null adjust

screw has a mechanical
stop that limits its rotation in
both directions. Do not
force the screw past its
stops.
2 Pin Electrical Connector

Never turn the manual stroker shaft with servo tube in place when the
engine is running. Shaft or internal damage will occur.
 Denison 5A Stroker
Electric Null Adjustment

Remove Hex cap

and adjust electrical
null with allen
wrench

NOTE: When the engine is started, the tracks (rotation) may creep
even though the pump has been mechanically nulled. The electric part
of the adjustment will correct the creeping.
Denison 9A Stroker
 Denison 9A Stroker
Adjustment Procedure

Insure that the machine is in a safe operating condition. Install Pressure gauges on each work port (AG
and BG). With the control installed and the pump running the adjustments are as follows:
Denison 9A Stroker
Adjustment Procedure

If tracks rotate.

1. Lift machine so that tracks are clear of the

ground.
2. Select Tram mode.
3. Remove wires connected to both coils.
If tracks do not rotate no adjustment is
required.

Mechanical adjustment.

1. Loosen “Null Adjustment” lock nut on

appropriate pump.
2. Turn “Neutral Trim adj. nut clockwise
and note if tracks stop rotating.
3. If tracks speed up stop, turn adj. nut
counter clockwise until tracks stop
rotating. This adjustment must be
done slowly.
 Drill / Propel Manual Override Button

Control Valve
54418116

Consists of:
4 Way Valve 57325623 X 1
Solenoid 57516346 X 1
Manifold 54418108 X 1
Relief Valve 54417993 X 1
Pressure Reducer 57325664 X 1
2 Way Valve 57325649 X 2
ELECTRICAL SYSTEM COMPONENTS

Tier 3

Tier 2
 Drill / Propel Control Valve

On AC
Drillmasters,
“X” port is
always
pressurized
when in the Drill
mode.

“Y” port is
always
pressurized
when in the
Propel mode.
Drill / Propel Control Valve

Solenoid 57516346 X 1
4 Way Valve 57325623 X 1
Manifold 54418108 X 1
Pressure Reducer 57325664 X 1
Relief Valve 54417993 X 1
2 Way Valve 57325649 X 2
 Drill and Propel Manifolds
Located below the main diverter valves

Propel Manifold
Drill Manifold
ON CAB SIDE
ON DCS
Main Diverter Valves
 Main Diverter Valve

Body Shown As Mounted and Back Porting View

Spring under X end cap

DIVERTER VALVE ASSEMBLY WITH LOW
AMBIENT SEALS AND RETAINERS
Main Diverter Valve O-ring Seal Retainers

Thin wall retainers go

into the B, A and T ports.
See previous slides.

Heavy duty rings should

always be placed in the
pressure port
Hot Oil Shuttle Valve
Hot Oil Shuttle Valve
 Hot Oil Shuttle Valve
*Sometimes called loop flushing valve Relief set to 150 PSI
Hoses connect to A and B ports of main pump

Relief Valve

Test Port
OVER PRESSURE
CONTROLS
Two Way Valve - Over Pressure Controls
Two Way Valve - Over Pressure Controls
 Overpressure Control
Valves

Feed pressure is vented until machine weight is fully

supported by the jacks.
Overpressure Control Valve
 Over Pressure System Test
Do not test the Overpressure Control System with drill pipe or drill bit against the ground. Only test the
system with the rotary head against the lower tower stops.

Step One:

Level the drill with the tracks about 1 – 2 inches off the ground. The drill weight must be fully suported by the leveling jacks.

Step Two:

Raise the tower and pin in vertical position.

Step Three:

Feed the rotary head down against the bottom stops of the tower.

Step Four:

Slowly increase pulldown pressure to maximum down pressure.

Step Five:

Slowly lift the cab side leveling jack off the ground. Feed pressure must vent immediately when the jack pad is lifted. The rotary head
will normally travel upwards slightly when pressure vents.
If pressure vents immediately, go on to step six.
If feed pressure does not vent, reduces system pressure with the feed controls, re – level the drill and contact your supervisor for
system repairs immediately.

Step Six:

Repeat steps 4 and 5, this time raising the DCS jack slightly. If pressure vents when jack pad is lifted slightly off the ground, the
system is working.
Holdback Two Way Solenoid Valve

Connects to “R” Port On Regen Valve

Holdback PCV and Two Way Holdback Valve
As mounted on drill for DHD Operation

N.O. N.C.
 Feed
Circuit
CS Hydraulic Main Pump
DR/PR Control Valve-Drill Mode
Feed Circuit
Feed System Control Valve
(Regen Valve) HP Version Shown

Sequence Valve Adjustment

“R” Port

Gauge ports G1 and G2

are for pressure testing
the rod and piston side of
the feed cylinders.
Feed System Control Valve
LP 57448136 Version- Rotary Drilling
HP 57448144 Version- DHD Drilling

R
 Feed System Control Valve
HP 57448144 Version- DHD Drilling LP 57448136 Version- Rotary Drilling

R
Sequence
Valve
Adjustment
“R”
Port

Gauge ports G1 and G2 are

for pressure testing the rod
and piston side of the feed
cylinders.
Drillmaster Feed Cylinders

Regen Valve
PV 275 Feed Cylinders
339” Retracted Length
618” Extended Length
1785 Lbs
Feed Cylinders
Lube Points For Traveling Sheaves
 Feed Circuit
The feed system operator interface and remote controls consist of several
components. They are:

CS Main Pump (electrically actuated)

Drill/Propel Valve (electrically actuated)

Proportional Control Valve (electrically actuated)

Control pressure two way valves (hydraulically actuated)

Overpressure Control valves (manually actuated)

Electrical controller on console (manually operated by driller)

We have already discussed the main pumps, Regen or Feed system control valve,and feed cylinders. Now
we must cover the control devices that function at the command of the operator, as well as the devices
that are independent of the operator and protect the system from overpressure.

As stated earlier, the main pump has a hose connected to the “VA” port. This is the compensator vent
port. This hose is used to connect a remotely located controller for the “A” side of the compensator. The
remote device is the Proportional Pressure control valve. Often called the FEAM valve.
 Proportional Remote Control Valve

(FEMA Valve)

Normally open-
Proportional Remote
Control Valve (Pulldown)
Proportional Remote Control Valve

Cross Section
Pulldown Control Valve
Rotation
Circuit
DCS Hydraulic Main Pump
Rotation Circuit
6” Variable Rotation Motor w/ Motor Control Valve
Rotation Motor - 6” Variable W / Motor Control Valve
Motor Control Valve and Pressure
Reducer

Volume Stop screws

Motor “H” Port

Servo Input
500 PSI Max.
Motor Adjustment Procedure
Change Volume Settings

A DJ U ST M EN T COV ERS

M A X . DI SP. ST OP
M I N . DI SPL . L OCK N U T M A X . DI SPL . L OCK N U T
M I N . DI SP. ST OP
Fixed Displacement - 4 cu.in. Rotation Motor
57209637

140 PSI Atmospheric Relief

Drill/Propel Valve - Torque Limit Control
Torque Limit Control Valve

(FEMA VALVE)

TORQUE LIMIT
 Rotation Torque Limit and Pulldown
FEMA
Proportional Pressure Control Valves

Pulldown FEMA

Torque Limit FEMA

Propel Circuit
 Propel Circuit
Components
The primary components of the propelling circuit are the main hydraulic pumps, propel motors, filters, valves and controls.
Main Pumps
The propel pumps are closed-loop hydrostatic transmission package, piston type pumps. “Closed-loop” means that oil entering
the main pumping element goes directly back to the system without first passing through the system reservoir. Oil is used
repeatedly in a continuous loop.

Motor

Pump
Main Hydraulic Pumps
Propel Circuit
Propel Motor
 Propel Motor

Brake Release Port

Propel Brake
 Propel Final Drive 1. Remove motor to get
access to brake retaining
cover

Brake
disconnect bolts
and cover

Brake assembly
retaining plate

2. Compress Springs

3. Remove snap ring.

PV271 CAT Propel Final Drive
P2 Circuit
Double Pump
Circuits
 Double Pump P1 Circuit

6.10 cu. in. / rev.

53 GPM

P1
Drillmaster Fan Circuit 1
Double Pump P2 Circuit
 Vane Pump Failure
Symptoms of Cavitation

Rippled pattern I cam rings. Erosion of port plates

Triple Pump
Circuits
 2006 Fan Circuit w/Triple Pump

P1 P2 P3

P1 is the pump section closest to the gear box.

Fan Circuit w/Triple Pump
DM45/50/L Cooling Fan Motor
Fixed Displacement Uni-Directional Motor
Cooling Fan Piping

Differential Pressure Relief Valve

65 PSI

Fan Relief

Speed Adj.
 P2 Circuit

P1 P2 P3

The P2 section of the triple pump

provides 23.8 GPM of oil for the
spool valve assemblies, these valves
are used to perform all the necessary
auxiliary functions while drilling.
Auxiliary Functions Circuit
Auxiliary Functions Circuit
Spool Valves VPL
 VPL Six Spool Valve Assembly

NOTE: Speed control of some of the valve functions is done with current
adjustments to the valve coils.
Apitech Pulsar
 VPL Type Valve Cutaway

C1 Work Port Relief

C2 Work Port Pressure Relief

VPL Six Spool Valve Assembly
 VPL Six Spool Valve Assembly

Non adjustable Pilot

pressure reducer/relief. DO
NOT ATTEMPT TO ADJUST.

Main inlet unloader and

Manual Stroker Hex relief valve -Adjust max
relief setting here!
 VPL- Nine Spool Valve Assembly

The inlet section of the assembly contains the pilot pressure–reducing valve and filter
for the 9 spools. The inlet does not have an unloader. This stack sends a signal to the
6–Spool Valve unloader that controls the maximum working pressure for both
assemblies.
VPL- Nine Spool Valve Assembly
 VP 6 Spool

Some items shown are not used by AC

NOTE: Speed control of some of the valve functions is done with current
adjustments to the valve coils.
Original VP 6 Spool Valve Cutaway
Hydraulic Tank Schematic
Hydraulic Tank Schematic
High Pressure Test Station
HPTS
 High Pressure Test Station

Always return to center after used

High Pressure Test Station

Neutral, silver screw on top

High Pressure Test Station DM45
High Pressure Test Station DM45
High Pressure Test Station PV271
High Pressure Test Station PV271
We are committed to your superior
productivity through
interaction and innovation.
107