UNDERGROUND DRILLING
COMMON / BOOMER DCS
System knowledge and troubleshooting training
5. Hydraulic system
Mining and Rock Excavation Service
FOR INTERNAL USE ONLY
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DISCLAIMER
This material is to be treated as training material only.
Information provided in this training material does not replace instructions or information
provided in Atlas Copco instruction manuals, safety manuals, or vendor manuals.
Part numbers, schematics and specifications such as pressures, measurements, and
weights are to be treated as examples of training purposes only.
Always consult the instruction manual provided with your product for specifications and
maintenance information.
Sub-supplier information is mainly for illustration purposes, always consult the sub-
supplier manuals or sub-supplier webpage for more details.
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5. HYDRAULIC SYSTEM
Course agenda
1. Introduction Questions you should be able to answer after the chapter:
2. Safety
3. Application and operating
What are the main components?
4. Control system Where are the valves located on the machine?
What is the function of the main components?
5. Hydraulic system How to find the schematics for the hydraulic system?
How do you relate the schematics to the hydraulic system?
6. Electric system
How to identify the components in the hydraulic schematics?
How to read the schematics?
7. Air and water
How can different types of oil/lubricants affect the
performance of the hydraulic system?
8. Carrier
What are the typical problems and ways to manage them?
9. Functions
10. Maintenance
11. Analytical troubleshooting
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5. HYDRAULIC SYSTEM
Main components
Hydraulic diagrams
Oil and lubricants
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5. HYDRAULIC SYSTEM
Main components
Hydraulic tank
Oil cooler
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5. HYDRAULIC SYSTEM
Main components – Rear manifold
Y414A/B Cable reel
Y415A/B Water reel
Y162 Water pump
Y171 Compressor
Y410A/B Rear jacks
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5. HYDRAULIC SYSTEM
Main components – Hydraulic pumps, boom 1
Percussion and positioning
Rock drill rotation pump
Damper pressure regulator
Compressor
Rock drill damper
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5. HYDRAULIC SYSTEM
Main components – Hydraulic pumps, boom 2
Percussion and positioning
Rock drill rotation pump
Damper pressure regulator
Water pump
Rock drill damper
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5. HYDRAULIC SYSTEM
Main components – Boom positioning valves – BUT S
Y453 Feed tilt cylinder
Y459 Feed rotation
Y451 Feed extension cylinder
Y452 Boom extension cylinder
Y456 Right boom cylinder
Y455 Left boom cylinder
*Y457 Boom front left
*Y458 Boom front right
* If BUT 29 Elec. Parallel
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5. HYDRAULIC SYSTEM
Main components – Front manifold
Sensors:
– B100 Percussion pressure
– B101 Rotation pressure
– B121 Rock drill return
– B133 Feed pressure
Valves
– Y104 Feed speed
– Y101 Percussion
– Y102 Rotation
– Y103 Feed pressure
– *Y450 Anti parallel
* If BUT29 hyd. parallel
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5. HYDRAULIC SYSTEM
Main components – Front manifold
Y156 Air condtioning
*Y436 Protection roof
Y423 Front jacks slide
Y412 Front jack right
Y411 Front jack left
Y350 Drill steel support
*Canopy only
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5. HYDRAULIC SYSTEM
Main components – Park brake valve
These are valves for:
– Parking brake pressure regulator
– Parking brake pressure sensor
– Parking brake on / off
– Diesel positioning
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5. HYDRAULIC SYSTEM
Main components – Hydraulic pumps connected to engine
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5. HYDRAULIC SYSTEM
Main components – Hydraulic pumps connected to engine
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5. HYDRAULIC SYSTEM
Hose/valve/ component marking related to the schematic
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5. HYDRAULIC SYSTEM
Main components
Hydraulic diagrams
Oil and lubricants
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5. HYDRAULIC SYSTEM
How to find the hydraulic schematics in the documentation
Rig Documentation
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5. HYDRAULIC SYSTEM
How the schematics are built up
• BMH & BMHT Feed
• Front Basic
• Boom Positioning
• Middle Module
• Cabin/Canopy Module
• Power Module
• Rear Module
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5. HYDRAULIC SYSTEM
How the schematics are built up
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5. HYDRAULIC SYSTEM
How the schematics are built up
HYDRAULIC OVERVIEW
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Front block
Pressure manifold
Drilling block Drilling Block
Diesel pos.
Boom pos. 1 Boom pos. 2
M M
M
Pressure manifold
Pump Pump Diesel pos.
1 1
2 2
3 3
Hydraulic Motor
4 4
Pumps 1
Rear block Hydraulic
Compressor
Pumps 2
Rear block
Compressor Water pump
Water pump
SECTION DIAGRAM
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Pressure manifold
Diesel pos.
M M
M
Pump Pump
1 1
2 2
3 3
4 4 Front basic
Rear block
Compressor Water pump
SECTION DIAGRAM
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Pressure manifold
Diesel pos.
M M
M
Pump Pump
1 1
2 2
3 3
4 4 Diagram name: BMH&BMHT
(Drilling valve)
Rear block
Compressor Water pump
SECTION DIAGRAM
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Pressure manifold
Diesel pos.
M M
M
Pump Pump
1 1
2 2
3 3
4 4 Diagram name: Boom positioning
Rear block
Compressor Water pump
SECTION DIAGRAM
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Pressure manifold
Diesel pos.
M M
M
Pump Pump
1 1
2 2
3 3
4 4 Diagram name: Front basic
Rear block
Compressor Water pump
SECTION DIAGRAM
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Pressure manifold
Diesel pos.
M M
M
Pump Pump
1 1
2 2
3 3
4 4 Diagram name: Power module
Rear block
Compressor Water pump
SECTION DIAGRAM
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Pressure manifold
Diesel pos.
M M
M
Pump Pump
1 1
2 2
3 3
4 4 Diagram name: Rear Basic
Rear block
Compressor Water pump
SECTION DIAGRAM
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Pressure manifold
Diesel pos.
M M
M
Pump Pump
1 1
2 2
3 3
4 4 Diagram name: Air & Water System
Rear block
Compressor Water pump
Hydraulic pumps, Boom 1&2 29
Power Module
1P/2P goes from the pumps to the drilling valve 31
Hydraulic oil travels to the booms 1&2 drilling
valves along line “1P” and “2P”
Power Module
From pumps to drilling valves 32
Oil from the pumps goes to the booms 1&2
drilling valves along line “1P” and “2P”
BMH & BMHT Feed
1P1/2P continues to the valve block located on the front 33
Oil continues through the drilling valves blocks
to Front Basic
BMH & BMHT Feed
Drilling valves 34
Oil from the pumps goes to the booms 1&2
drilling valve blocks along line “1P” and “2P”
BMH & BMHT Feed
From drilling valves to manifold 35
Oil from left and right drilling valves connects
at the pressure manifold where it spreads
further
Front Basic
From manifold to front manifold valves 36
Oil from the pressure manifold goes to the
front manifold valve
Front Basic
Front manifold 37
Front Basic
Oil continues along 1P2 and 2P2 to the left and right boom pos. valve 38
Front Basic
Oil from pressure manifold continues along 1P2 and 2P2 to the boom pos. valves 39
Boom positioning
Positioning valves 40
Boom positioning
Pilot pressure 41
Boom positioning
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PILOT PRESSURE
High pressure comes into the pilot block
Pressure builds up above 35 bar and will
start to push on the valve
The proportional valve regulates the
pressure to 35 bar by closing/opening
50 proportionally
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PILOT PRESSURE
If the pressure regulating valve should jam
There is a safety valve that will release
the pressure at 50 Bar
50
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PILOT PRESSURE
If the strainer is clogged the pressure will
go through the spring applied non-return valve
50
Pilot pressure 45
Pilot pressure is sent along
P35 to the drilling valve block
Boom positioning
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Pilot pressure continues along
P35 where it goes into the drilling
valve block
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To see how the rest of the system is working
first we have to go back to the front basic
diagram and look at the pressure manifold
Front Basic
Oil goes from pressure manifold along P13 to the diesel positioning block 48
Front Basic
Oil continues along P13 through the diesel pos. block where it travels to the rear 49
Power Module
Diesel positioning block 50
Power Module
The Oil travels along P10 to fed the valve block located on Rear basic 51
Rear Basic
The oil travels along P10 to feed the valve block located on Rear basic 52
Rear Basic
Diesel positioning pump mounted on the transmission 53
Middle Module
Pressure travels from the diesel positioning pump along P12 to the power module 54
Middle Module
Pressure reaches Y203:2 (positioning pressure valve) on the diesel positioning valve block 55
Power Module
Diesel positioning switch ON 56
Power Module
Diesel positioning block 57
Power Module
From diesel pos. block to pressure manifold and rear manifold 58
Front basic
Rear Basic
Compressor and water pump 59
Electric Motor 1 sends Electric Motor 2 sends hydraulic
hydraulic oil to the compressor. oil to the water pump.
Power Module
Compressor and water pump 60
HYDRAULIC OVERVIEW
Front block
Drilling block Drilling block
Boom pos. 1 Boom pos. 2
Front block
Pressure manifold
Drilling block Drilling Block
Diesel pos.
Boom pos. 1 Boom pos. 2
M M
M
Pressure manifold
Pump Pump Diesel pos.
1 1
2 2
3 3
Hydraulic Motor
4 4
Pumps 1
Rear block Hydraulic
Compressor
Pumps 2
Rear block
Compressor Water pump
Water pump
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5. HYDRAULIC SYSTEM
Main components
Hydraulic diagrams
Oil and lubricants
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5. HYDRAULIC SYSTEM
Oil and lubricants
Contaminated
lubricants; 60%
Abnormal wear;
22%
Oil degradation;
12%
Oil properties; 6%
According to the study 78% of all machine problems can be related to contaminated oil / lubricants
Source: The centre for Hazardous Materials Research, Harvard, USA
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5. HYDRAULIC SYSTEM
Oil and lubricants – How can contamination in the oil occur?
Contamination
Internally generated contaminants
• From wear on pumps, actuators and motors
• From condensation
Contaminations in new oil
Solid particles or liquids (water) External contaminations entering the system
• Leakage in hoses and fittings
• Dirty filters
• Design flaws
• Failed parts in the rock drill
• Service environment
• Maintenance activities when parts are removed
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5. HYDRAULIC SYSTEM
Oil and lubricants – Contamination level
ISO4406: What and why
Cleanliness code (4406:1999) to quantify particulate contamination levels per
milliliter of fluid at three sizes: 4 µ[c], 6 µ[c], and 14 µ[c]. (Micrometer)
This ISO code is expressed in 3 numbers: For example 19/17/14. Each number
represents a contaminant level code for the correlating particle size.
The code includes all particles of the specified size and larger.
It is important to note that each time a code increases the quantity range of particles
doubles.
The first step in identifying a target ISO code for a system is to identify the most
sensitive component on an individual system.
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5. HYDRAULIC SYSTEM
Oil and lubricants – Contamination level
ISO4406
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5. HYDRAULIC SYSTEM
Oil and lubricants – Contamination level
ISO4406
A higher number in cleanliness indicates a higher quantity
of particles.
Lower number indicates a lower quantity of particles.
So, 16/14/11 is a cleaner oil then 24/22/19 and the
difference in performance is huge
Assume the following pump performance: 200 L / min,
running 24 hours per day:
– For the cleaner oil 22 kg of contaminants is passing through the
hydraulic pump annually.
– For the oil with more and larger particles, almost 4 000 kg of
contaminants is passing through the pump annually.
The component in the hydraulic system with highest cleanness requirement
determines the cleanliness requirement for the entire system!
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5. HYDRAULIC SYSTEM
Oil and lubricants – Contamination problems
Problems when oil is Description
contaminated
For example, if air filter doesn’t work properly the oil will be contaminated with silica which
Wear will start a wear everywhere and shorten the life, especially for pumps and motors.
Other contamination can cause filter problem. You will then get a dirty system and higher
Filtration problems costs for filter. You may also have pressure failures.
If the oil is degraded of some reason, it can not work properly. If the working temperature is
Accelerated degradation too high and for too long time, the oxidation process will start. Metal surfaces will be
of the oil which affects destroyed and viscosity will increase.
the functions of the
machine
To much foaming can cause the oil film to crack (cavitation) and then you have a metal to
metal situation with wear as a result.
Foaming problem • If overhauled parts have leftovers of detergents used during the cleaning process.
• Oil is contaminated with other incorrect oils
• Leakage in the suction line of a pump
Hydraulic oils could manage to dissolve up to 0,3% of water at normal running temp while
a refined mineral oil with a minimum of additives holds just up to 0,01%. After that the
saturation level is reached an emulsion will be formed and the oil will look cloudy.
Poor water separation Water contaminated oil will cause corrosion on internal components, excessive wear on
bearing, cavitation and could plug up the filters.
To avoid water and damages in the hydraulic system always use a high quality hydraulic oil
and drain of water/condensate regularly after allowing the oil to cool down.
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5. HYDRAULIC SYSTEM 1
Oil and lubricants – Contamination case
Pump leakage
Based on WOL # ARO140783715
Hyd. Pump 2 (3222 9998 78) cracked at outlet fitting.
“Pump cracked at the fitting, usually this can be caused by a restriction in the pressure line before
the relief. the customer said there was no relief problems with this machine.”
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5. HYDRAULIC SYSTEM 1
Oil and lubricants – Contamination case
Internal pump leakage
Supplier analysis:
– High abrasions inside the housing and
on the bushings
– Marks from overload on the bushings
– The elements have had signs of wear
from contaminations
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5. HYDRAULIC SYSTEM 1
Oil and lubricants – Contamination case
Internal pump leakage
Supplier conclusion:
– The pump was damaged from
contaminations in the system
– Contamination particles causing high
wear on the running surfaces in the
pump
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5. HYDRAULIC SYSTEM
Oil and lubricants – Reducing contamination
Reducing contamination Description
Reducing contamination
• Do not mix fluids
Proper fluid selection • Follow the maintenance manual for selecting proper oil. Very hot or very cold operating
environments requires oils adapted for the temperature.
• Kept in sealed containers
Proper fluid handling • Most hydraulic fluids are hygroscopic, meaning they absorb moisture when exposed to
and storage humid air – this could lead to water separating from the oil
• Drain the water from the hydraulic tank
• Use caps and plugs in the couplings when disconnecting and replacing hydraulic
components
• Only use hand pump or electric refill-pump when filling new oil in the tank (if vessles are
used instead – risk for dirt in the vessel)
System maintenance
• Change worn out seals in the rock drill or rotation unit to avoid flushing water entering
the hydraulic system
• When replacing hoses – blow clean hoses with air before installing
• Drain the system completely before replacing the fluid
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5. HYDRAULIC SYSTEM
Oil and lubricants
CONCLUSION
It is crucial to use the correct filters with the right quality
This is why Atlas Copco filters should be used on the Atlas Copco machines
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5. HYDRAULIC SYSTEM
Typical problems
Problem Reason Action to take
Make sure hydraulic cylinders are
Over filling hydraulic oil in
Air breather filter clogged retracted when filling oil or take it in
tank with hydraulic cylinders
from oil consideration and leave room for it
in outer position
in the hydraulic tank.
Sticky valves due to wrong
Boom movements does not type of oil for the
Change hydraulic oil
work properly temperature range or water
in hydraulic oil
Check charging valve, the
Broken accumulator on the
Percussion hose vibrations rock drill
membrane and recharge
accumulator
Lack of attention or damper Adjust damper pressure when the
Wrong damper pressure pressure adjusted with cold hydraulic oil has reached working
oil temperature
Always use the filler pump that
Contaminated hydraulic oil Filling oil directly in to tank pushes oil trough the return filters
in the hydraulic tank
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COMMITTED TO
SUSTAINABLE PRODUCTIVITY.
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