Atlas Copco Drilling Solutions

Parts & Service DRILLCare

PV235 Training Manual.

Hydraulics.
 Hydraulic Section Rexroth Valve Aux.
Circuit

Fan Circuit

Feed & CS Propel Circuit

Rotation & DCS Propel
Circuit

Apitech Aux.
Circuit

2
 Rotation and Dust collector side propel closed loop circuits.

The PV235 hydraulic circuit is basically divided into four individual circuits. Two main circuits and two auxiliary
circuits
 A closed loop circuit which provides oil flow for the functions of the Rotation Circuit and the Dust Collector
Side (DCS) Propel Circuit.
 A main open loop circuit which provides oil flow for the Feed Circuit and Cab Side (CS) Propel Circuit.
 Two open loop circuits which provides flow for the Auxiliary and the fan/cooling circuits.
These will be described separately.
 Power is delivered by a diesel engine through a pump drive gearbox with a .723:1 speed up ratio.
 Rotation Circuit and Dust Collector Side undercarriage is driven by a Denison P7P (7.25cu/in per rev @ max
stroke) variable displacement pump driven at 2500 RPM delivering 78 GPM and is set at max of 4500
PSI.
 Option 1
Rotation motor is a Direct Drive 2 Speed dual vane motor producing a variable speed of 0 to 100 RPM in low
speed or 0 to 200 RPM in high speed with manual speed selection.
 Torque at 100 RPM is 8500 ft/lbs (11524 Nm) and at 200 RPM is 4250 ft/lbs (5762 Nm).
 Option 2
The 4SV-2-10 rotary head with variable speed 190 @ min displacement and 110 @ max displacement.
Torque is 8200 ft/lbs (11117 Nm) powered with one fixed displacement motor and one variable displacement
motor.

3
 Rotation & Propel Closed Loop Circuits

Diverter Manifold

Control Manifold

Dennison P7P
Pump

4
 Closed Loop Denison P7 Pump

Charge pressure is set at

350 psi for PV235 and not
200 psi as used on other
ADS products to be able to
charge the accumulator

5
 Closed Loop Denison P7 Pump

6
 Closed Loop Denison P7 Pump

7
 Closed Loop Denison P7 Pump

8
 Rotation Circuit
(Showing old style control valve. New valve on next slide)

Rineer 2 Speed
4SV-2-10 Optional
Rotary Head
Rotary Head

Control Valve

Diverter & Hot Oil

Shuttle Valve manifold

Replenishing
Accumulator

Torque
Control

Denison P7
Pump Slow Acting relief Valve

9
 Closed Loop Rotation Circuit

A XB A

X B

B
A

B B B B

A A A A

A B

10
 Old Control Manifold One pressure compensated flow control to
(New manifold on next slide) regulate flow for the air conditioning motor
and a two position two way solenoid.
Three solenoid operated 3
way 2 position valves that Two falling
select tram brake release, characteristic
tram speed select and one proportional relief
for the Drill On Track option. valves. One for fan
speed regulation
and the other for
rotation torque
control. Should
either of these
valves fail they
Two pressure would default to
reducing/relieving valves, high pressure.
one for tram brake
release and tram speed
select Pressure set to
500 psi. the other to
reduce the load sense One variable 0 to
pressure to 225 psi. This 5000 psi pulldown
pressure combined with pressure relief valve.
the P3 pump
compensator setting of
300 psi will maintain 500 Two over pressure valves
psi for the brake release
at all times.

11
 New Control Manifold One flow control to regulate flow for the air
conditioning motor and a two position two
way solenoid.
Two solenoid operated 2 way
3 position valves that select Optional two falling
tram brake release, tram characteristic
speed select and one for the proportional relief
Drill On Track option. valves are installed if
required. Otherwise
blanking plugs are
used. One for fan
Pressure speed regulation and
reducing/relieving the other for rotation
valve set at 500 psi to torque control. If
release the propel brakes installed, should
either of these valves
fail they would default
to high pressure.

One variable 0 to
5000 psi pulldown
pressure relief valve.

 Two over pressure valves

12
 Poppet Valves used in the Speed Selector Manifold and Diverter Manifold

Directional function Poppet Valve.

2-way cartridge valves mainly consist of a control cover (1) and a cartridge element (2). The control cover is
provided with pilot bores and, depending on the required overall function, optionally a stroke limiter, a
hydraulically controlled directional poppet valve or a shuttle valve. Moreover, electrically operated directional
spool valves or directional poppet valves can be mounted onto the control cover. The cartridge consists of a
bushing (3), a ring (4) a valve poppet (5), optionally with damping nose (6) or without damping nose (7) and a
closing spring (8).

Areas A1 and A2 act in the direction of opening. Area A3 and the spring act in the direction of closing. The
effective direction of the force resulting from the opening and closing forces determines the spool position of
the 2-way cartridge valve. The medium can flow through the 2-way cartridge valves from A to B or from B to A.
When area A3 is pressurized due to the pilot oil flow from channel B or external pilot oil supply, channel A is
leak-free closed.
Poppet valve used in our application are 2:1 ratio.

13
 Rotation Circuit Control.

For rotation functions the Denison pump is controlled by PWM 200Hz

OUTPUT signal supplied by a multi function joystick that incorporates a
activation trigger which is part of the handle and is located in the upper
front of the operators left hand pod.
To prevent any unwanted or accidental movement of the joystick the
trigger must be activated to enable the operator to carryout any
function. This is a DIGITAL signal.
With the trigger activated and the lever moved away from the operator
the rod will rotate proportionally counter clockwise in relation to the
output/position of the lever. Likewise the trigger must be depressed to
pull the lever toward the operator for clockwise rotation.
The activation trigger only needs to be held to move lever out of the
neutral position, once out of the neutral position the trigger can be
released and the lever will maintain the position selected by a friction
clutch within.

14
 Rotation Circuit Diverter & Hot Oil Shuttle Valve Manifold
HOT OIL SHUTTLE section. To Rotation motor From Rotation
When drill mode is selected. inlet port outlet port

Flow from the Denison pump “A” port is directed to the “PA” port
in the diverter manifold. Pressurized oil is piloted to the pilot
Diverter
chamber of the “HOT OIL SHUTTLE” valve and shifts the spool valve
to allow a portion of return oil from the rotation motors to return B B B B section
to the cooler and filters. A relief valve is set at 215 PSI +/- 10 A A A A

GPM to maintain a minimum of 150 PSI system pressure.

Diverter Valve section.
The 2 position 4 way valve solenoid is de-energized by default
and allows oil flow from the “PA” port to pressurize the “Poppet
Valve” (PV) pilot chambers of PV101 & PV103 holding them Hot oil
shuttle valve
closed.
section
Because PV102 and PV104 pilot chambers have not been
pressurized the poppet valve is not closed which allows oil flow
from A to B, through channel 102 and into the inlet ports of the
To Pump “B” port
rotation motors. Flow to port 101, propel motor is blocked because From Pump “A” port
PV101 poppet pilot chamber is pressurized and held in the closed position.
Return oil from the rotation motors enters the manifold at port 104 and because PV104 pilot chamber is not
pressurized, this allows oil flow through ports “B” to “A’ in Pv104 to be directed to the “B” port of the pump.
A replenishing accumulator is connected to the “K” port of the pump to assist the charge pump to prevent
cavitation in the return lines.
A slow acting relief valve is connected to the pumps “VA” port to prevent shock load generated by broken
formations or the sudden shock that occurs when breaking rod joints.
A torque control relief valve in the main control valve is connected to the “VA” port of the pump. This is a
“FALLING CHARACTORISTIC” type valve and will default to the closed position and maintain High torque if
there was a fault in the wiring.

15
 Rotation Circuit
Rineer 2 speed manifold.

High Speed Low Torque configuration. A Port B Port

High speed low torque configuration is
considered as being connected in “SERIES”.
With selector valve energized for high speed, C Port D Port
oil flows from the pump “A” port directly to the
“A” port of the top rotation motor. Flow from “B”
port is blocked off at the “PV3” and diverted to
“PV2”, because “PV1” pilot chamber is
pressurized it blocks the oil and routes it to the
“C” port of the bottom rotation motor. B
A x B
Oil flow from “D” port is then returned to the “B” A
port of the pump via the diverter valve as PV3
described on slide 9.
x
B PV2

x
A
PV1 Selector valve

16
 Hydraulic Section Rotation Circuit
Rineer 2 speed manifold.

Low Speed High Torque configuration.

Low Speed High torque configuration is considered A Port B Port
as being connected in “PARRALEL”
Oil flow from the pump “A” port flows to the rotation
motor ports “A” and “C” simultaneously because the
selector valve solenoid is de-energized to the default C Port D Port

mode. This allows pilot oil to pressurize the PV2 pilot

chamber which in turn blocks flow at PV2 “A” port.
PV1 and PV3 pilot chambers are not pressurized
which allows oil to flow from “A to B” ports of the
respective poppet valves.
Oil flow from “B” and “D” port is then returned to the x B A

pump “B” port via the diverter valve as described on xA PV3

B

slide 9. B PV2

A
PV1

17
 Propel Circuit Control
Undercarriage is a Cat or Intertractor and is driven by a Rexroth variable displacement 2 speed bent axis piston
motor with a final drive planetary.
Displacement variable in the sense that selection is either min displacement for high speed/low torque
or max displacement for low speed and high torque.
High torque drawbar pull is 91,000 lbs and max speed of 1.3 MPH.
Low torque drawbar pull is 49,000 lbs and a max speed is 2.42 MPH.

A multi axis multi function lever in the lower left hand console of the pod sends
the input for the propel function of the “Non Cab Side” (NCS) propel motor.
Note this joy stick also controls' the level cylinder functions.
The joystick incorporates a “Dead man trigger” when released will stop all propel
motion and applies the brakes.
When propel is selected with trigger pressed and the joystick is moved away
from the operator, in the “Y” plane the drill will propel toward the “NON DRILL
END” (NDE) and when pulled back toward the operator in the same plane the
drill will propel toward the “DRILL END” (DE).
When the joystick is moved to the left on the “X” plane the drill will counter rotate
to the “DUST COLLECTOR SIDE” (DCS) and will counter rotate to the “CAB
SIDE” (CS) when moved to the right side.
When propelling and the joystick is moved forward to the 10 o clock or 2 o clock
position the direct the drill in that direction.
Pulling the joystick in the opposite direction and moving it to the 4 or 5 o clock Y
position, will direct the drill in that direction.
See diagram on next slide. X

NOTE:
THESE INSTRUCTIONS ARE BASED ON THE OPERATORS POD FACING
THE NONE DRILL END OF THE DRILL.

18
 Hydraulic Section Propel Joystick Orientation

N
D N N
E D D
E E

NCS CS
NCS CS NCS CS

D
E D D
E E

N N N
D D D
E E E

NCS CS NCS CS NCS CS

D D D
E E E

19
 Closed Loop Propel Circuit

Oil flow in the propel closed loop circuit is identical to

that of the rotation closed loop until it reaches the
diverter valve.
Signal from Main Control Valve
At this point the solenoid valve is energized and now A B

diverts the oil to pressurize the pilot chambers of

PV102 & PV104 blocking the oil at the “A” ports of
these valves. This will now allow oil to flow through
PV101 & PV103 “A” to “B” ports, through the 101
channel then to the “A” port of the DCS propel motor. B
PV102 PV101 PV103 PV104

B
B B

Oil from the motors “B” port returns to the diverter A A A A

manifold, through PV103 “B” to “A” ports and then back

to the pumps “B” port also venting a portion of oil
through the “Hot Oil Shuttle Valve” (HOV) for cooling
and filtration purposes.
The propel speed selector is activated by selecting the
F2 button on the computer display until the appropriate
screen is shown then selecting the tram speed
selector.

20
 Cable tensioning
circuit

Feed circuit
Main with
Open Loop Feed Regeneration

&
Propel Systems.

Propel circuit

Load sense line

Valve spool 2 Valve spool 1

21
 CS Open Loop Feed and Propel Circuit
The “CABSIDE” propel and the feed system are open loop
circuits.
Flow is provided by a Parker P3 load sensing pump through the
pump distribution manifold port 111 to the Parker load-
sensing, pressure-compensated proportional directional control
valve.
It has simultaneous-operating characteristics that enable several
machine functions to be operated responsively at the same time,
regardless of the sizes of individual loads.
The flow rate per spool section is up to 78gpm (225 ltr/min)
Copied load signal - The system permits oil consumption in the
load signal line to the pump, without the signal level being
PARKER P3 145 cc
affected.
Pressure compensation - Pressure compensated spools for
lifting and lowering movements. Separate compensator for
each spool section for excellent pressure compensation.
Feed pressure limiters - Individually adjustable between 30
and 4500 psi (300 bar) for each service port. Reduction can
also be controlled remotely.

Parker K220LS

22
 Open Loop Feed and Propel Circuit
Oil flow for the feed and cable tensioning circuit is
controlled by valve spool one of the parker valve.
Feed (extend) flow is directed via A port of directional
control valve to port 140 of the regeneration valve over
the counter balance valve to the feed cylinder and return
oil flow is channeled back through the Parker directional
control valve, return manifold, HOC inlet manifold then
through the 3 micron filters to the hydraulic tank.
Valve spool two supplies oil flow to the CS variable
displacement two speed propel motor.
Note this is either max or min displacement. It is not
infinitely variable.
Flow from the “B” port of the Parker valve is directed to
the Forward port, through the tram counter balance valve
to the motor.
Pilot pressure from the high pressure side shifts the
3 position 3 way spool of the tram counter balance valve
to allow oil to return the directional control valve “A” port
and back to tank as described above.

Load sense line

Valve spool 2 Valve spool 1

23
 Open Loop Feed Circuit
2-Spool Parker proportional control valve.

RETRACT
Flow enters the P port in line 111A and is Flow compensator

EXTEND
directed to the pressure reducing valve set
at 500 psi to regulate the pilot pressure.
Main system safety relief set at 5000 PSI.
Individual port limiting valves for the feed
system set at 4100 psi for extend (feed To main control
valve load
down) and 4500 psi. for retract. sense port 203
Main flow is directed to the individual flow
compensators. When the compensators see
Pressure
more than 100 PSID across the valve spool, reducing valve
the sensing line will begin to close the
compensator valve reducing the flow without
loss of pressure and will maintain the load Main relief valve
(Safety )
sensing pressure back to the pump which in
turn will de-stroke the pump and reduce flow
accordingly.
Port relief valves
Remote pressure (RP) line 311 is directed to
the Control Manifold allowing the operator to
regulate feed pressure as required.
When either of the over pressure valves are
activated load sense pressure is through Electro Hydraulic
port 311 in the directional control valve, Proportional Controls

through the control manifold port 203 & 201

to the pump.

24
 Open Loop Feed
Feed down with high speed regeneration

DTH
Regen CB valve. Solenoid
Flow is directed through the extend 5 :1 pilot ratio valve

counterbalance valve to the piston side of the

feed cylinder.
Pilot oil through the N/O DTH solenoid opens Retract holding valve. Vent valve
the REGEN CB valve and re-directs oil flow 2:1 pilot ratio 5:1 pilot ratio

from the rod end over the regen check valve

back to the piston end of the cylinder to
increase the speed of the cylinder.
Extend CB valve
Rod end volume plus pump delivery added to 2:1 pilot ratio
piston side of feed cylinder.
Note Regen CBV is open and holding valve is
not open although pilot pressure is available.
Why??

25
 Open Loop Feed
Feed down with high speed regeneration

Regen Check
Valve

26
 Open Loop Feed Circuit
Cylinder Ø 6.5"
Regen CBV
Rod Ø 5.0"
Set at
Pressure sensed in line “A” is +/- 72.46 psi of both the holding and 1400 psi

regen valves.
1000 lbs
A
If the preset valve to open the regen valve is 1400 psi, pressure WEIGHT
5:1 ratio

required to open the valve would be 1400 psi – load pressure 72.46 = Holding Valve A
1188 psi / 5 (5:1 ratio) = 265 psi. Set at
2:1 ratio
Holding valve works on the same principle. 6000 psi

6000 – 72.46 (load) / 2 (2:1) = 2946 psi

Holding weight
LOAD PRESSURE
Area = r^2 * pi (6.5” cylinder Ø minus 5.0” Rod Ø) 10 ” Ø cylinder A 30” Ø Cylinder B
33.44 sq/ins - 19.63 sq/ins = 13.80 sq/ins.
1000 lbs load divided by 13.80 = 72.46 psi on pilot line A
Note: The above numbers are approxamate. Other elements like 1000 PSI
backpressure, flow resistances and pressure drops have not been taken
into concideration. ? ?

Force Cyl A = Area X Pressure = 31415 lbs/force.

Force Cyl B = Area X Pressure = 94247 lbs/force.

27
 Open Loop Feed Circuit
Drill mode Parker P3
Load sensing
pump

DTH
Solenoid
Regen CB valve.
In drill mode flow is directed as 5 :1 pilot ratio
valve

described in fast feed mode with the

exception that the increased resistance
will now open the load holding valve
Load holding valve. Vent valve
and the higher pressure on the 2:1 pilot ratio 5:1 pilot ratio
pressure side of the regen check valve
will be held closed against its seat.
Return flow will be directed back to the Remote
Extend CB valve feed pressure
directional control valve and back to 2:1 pilot ratio control valve
tank as previously explained. Load sense
line from
Feed/pulldown pressure is controlled Apitech valve
remotely from the operators cab.
Depending on ground conditions, can
be infinitely variable from 0 to 65,000
lbs/force.

Control Manifold

Over
pressure
valves

28
 Open Loop Feed Circuit (New control manifold)
Drill mode Regen CB valve.
1 :1 pilot ratio

DTH
In drill mode flow is directed Solenoid
valve
as described in fast feed mode
with the exception that the
increased resistance will now
open the load holding valve Vent valve
and the higher pressure on 5:1 pilot ratio
the pressure side of the regen
check valve will be held closed Load holding valve.
against its seat. 2:1 pilot ratio

Return flow will be directed Extend CB valve

2:1 pilot ratio
back to the directional control
valve and back to tank as
previously explained.
Feed/pulldown pressure is
controlled remotely from the
operators cab. Depending on
ground conditions, can be
infinitely variable from 0 to
65,000 lbs/force.

Remote Feed
Control
Over pressure
Control

29
 Open Loop Feed Circuit
Holdback System & Graph
Resultant
Pull down Hold back
PSI Force force
0 0 -9484
100 1659 -7825
200 3318 -6165
300 4977 -4506
400 6637 -2847
500 8296 -1188
600 9955 471
700 11614 2130
800 13273 3790
900 14932 5449
1000 16592 7108
1100 18251 8767
1200 19910 10426

Net force on power head

10000
9000
8000
7000
6000
5000
4000

Force on head #
3000
2000
1000
0 40' Tower
-1000
-2000
-3000
-4000
-5000
-6000
-7000
-8000
-9000
-10000
0 200 400 600 800 1000 1200
Pull Down PSI Indicated

30
 Open Loop Feed Circuit
Holdback System & Graph

Pull down
Resultant
Hold back Net force on power head
PSI Force force
0 0 -9484
100 1659 -7825
200 3318 -6165 10000
300
400
4977
6637
-4506
-2847
9000
500 8296 -1188 8000
600 9955 471 7000
700
800
11614
13273
2130
3790
6000
900 14932 5449 5000
4000
Force on head #

1000 16592 7108

1100 18251 8767
1200 19910 10426
3000
2000
1000
0 40' Tower
-1000
-2000
-3000
-4000
-5000
-6000
-7000
-8000
-9000
-10000
0 200 400 600 800 1000 1200
Pull Down PSI Indicated

31
 Open Loop Feed Circuit
Retract mode

In retract mode flow is directed from the B port of the directional control
valve to the rod end of the cylinder. Pilot pressure is also directed to the
pilot chambers of the Vent Valve and Extend CBV.
Vent valve
Note the REGEN CBV pilot chamber is pressurized to the closed position 5:1

to prevent oil being diverted to the return leg and subsequently loosing
retract pressure.
As there is a increased volume of oil from the piston side of the cylinder Extend CBV
2:1
when it is retracted and the directional control valve can only handle
78 GPM, the vent valve has been designed into the circuit to allow +/-
100 GPM of oil to be diverted to the return manifold via port 407 and the
remainder of the oil will flow through the A port of the directional control
valve and back to tank as previously described.

32
 Cable Tension

When pressure is applied to the feed cylinder piston

side to extend the cylinder flow is directed from port
818 to port 161 of the feed cylinder manifold and
cable tension manifold.
Flow goes through the pressure reducing reliving
valve then to the rod side of the tensioning cylinder.
Back pressure in the return line plus the spring
setting in the reducing relieving valve will produce
pressure to tension the pullback cables.
EG: Back pressure +/- 200 PSI + 100 PSI spring
setting = 300 PSI in cable tensioning cylinder.

33
 Cable Tension
When flow is directed from port 817 to the rod side
of the feed cylinder to retract the rods, pressure is
sensed through line 160 to the reducing relieving
pilot spring chamber blocking any pressure being
generated from the rod side of the tensioning
cylinder.
When the operation is in neutral position, no flow to
either side of the feed cylinder will produce a
minimal load on the sensing line 160 and will reduce
any excess pressure that was generated.

34
 Auxiliary Hydraulic Circuits 10 Spool Valve

Fan Circuit
P3/075 Pump

P3/145 Auxiliary Supply Pump

7 Spool Valve
35
 Auxiliary Hydraulic Circuits.
Flow for the hydraulic auxiliary circuits are provided by a Parker P3 load sensed pressure compensated pump
which also supplies flow to the feed and CS propel circuits.
Flow is directed via ports 107 on the pump distribution manifold to the VPL Apitech Pulsar Load Sense Pre-
Comp Directional Control Valve and then to the various auxiliary functions.
Oil is also directed via port 108 on the pump distribution manifold to the Rexroth directional control valve.
Apitech Directional Control Valve.
Pressure compensation maintains a constant flow regardless of pump pressure, load pressure, or any other
load in the system
No change in speed when running multiple sections
The load pressure can be limited without losing flow to a relief valve.
The load sense signal is passed through a damping orifice to the compensator spool

Section 1 & 3 Spools, DCS & CS Leveling jacks have flow of 7 GPM for the rod side and 20 GPM for the
piston side of the cylinder.
Section 2 spool, NDE Leveling jacks flow is set to a max of 14 GPM for the rod side and 30 GPM for the
piston side of the cylinder.
The leveling spools have a common limiting pressure relief set for 4000 PSI
Section 4 Spool, Winch flow is set for 10 GPM and a common limiting relief set for 2500 PSI
Section 5 Spool, Tower raise cylinders flow set for 13 GPM for the rod side and 20 GPM for the piston side of
the cylinder. Pressure setting to lower the tower is 3750 PSI and to raise is set at 3250 PSI.
Section 6 Spool, Water injection/dust collector flow is set 16 GPM both directions and pressure set for 3500
PSI
Section 7 Spool, Rod changer flow is set at 15 GPM and pressure set at 3000 PSI.

36
 P3/145 Pump Controls
Load Sense Control
Load sense control will adjust output flow to maintain a constant pressure drop across an orifice.
The load sense comp will increase or decrease the output flow to maintain a constant delta across the load
orifice.
This means that regardless of load conditions the flow will remain constant for a given orifice opening
Pressure Compensator
The pressure compensator control will limit pump outlet pressure to a predetermined level and adjust
pump outlet flow to the level needed to maintain the set pressure.

 - p adjusting
screw

Max. pressure adjusting

screw

37
 Apitech Auxiliary Hydraulic Circuit

38
 Auxiliary Hydraulic Circuits
VPL Apitech Valve

Pulsar Cyl. Relief

Solenoid Anti-Cav. Check

C1
Pressure Manual
Limiter Override

Flow
Limiters

Individual C2
Optional Compensator Pressure
L.S. Port Limiter

39
 Auxiliary Hydraulic Circuits
VPL Apitech Valve

C2 Port Flow Adjustment

C1 Port Flow Adjustment

C2 Pressure Limiter

C1 Pressure Limiter

40
 Pulsar Pilot Technology

Electric control of the Apitech

directional control valve is
achieved with the PULSAR
electrohydraulic pilot valve. This
pressure control uses digital
electronics to provide a
pressure control which is linear
and repeatable. Being a truly
digital devise means that the
valve is either open or closed.
This results in a devise in which
the current draw is controllable
in the simpler electronic circuits.
( Less than 500 mA).
These electronics use PWM Reduce Pilot Supply Coil
(Pulse Width Modulation) to
vary the modulation ratio, on
time verses of time to provide a
smooth valve operation PULSAR

Drain
Orifices
The Pilot Supply Orifices
Chamber

41
 10 Spool Tower Manifold
.

Flow from pump distribution manifold port 108 enters the manifold through a pressure limiting valve. When flow
is dead headed flow is shut off by the pilot causing the pump to de-stroke .
Each of the valves have specified flow rates regulated by the different orifice sizes as indicated next to each
orifice.
The load sense line is connected to each of the valve ports and is directed to 202 on the control manifold.
Section 1 Breakout wrench. Section 6. Spare.
Section 2. Rod support. Counter balance valve set Section 7. Dust door. Held open by counter balance
at 3000 PSI. valve on the “A” leg
Section 3 & 4. Tower pinning. “A” port relief valves Section 8. Angle dust hood. Held open by counter
set at 1800 PSI. and 4.5:1 ratio counter balance balance valve on the “A” leg
valves located in the cylinders and are set to relieve Section 9. Slide wrench. Held in position by pilot to
at 3000 PSI open check valves.
Section 5. Breakout wrench swing. Held in position Section 10. Carousel index. Proportional valve with
by pilot to open check valves. counter balance valves to block return flow
42
 Breakout Wrench Sequencing.

The breakout wrench sequence is as follows:-

 Breakout arm pin is latched.
 Breakout clamp grips the drill rod.
 Under table housing the slide fork rotates clockwise.
 These steps are repeated until the rod joint is broken.

Function in stand bye mode.

Flow is directed through the pilot operated 3 way 2 position
N/O valve, through port D to the rod side of the breakout
cylinders to keep them disengaged when not in use as A B

illustrated in the schematic on the right.

P T

All return oil flows through ports A, B & C respectively to the C D

return manifold.

A1 B1

43
 Breakout Wrench Sequencing.
Step 1. Pinning.
Indicated by RED arrows.
Flow is directed through the directional control valve,
through port “A” to piston side of the breakout pinning
cylinder.
SV3
Step 2. Clamping.
SV2
Indicated by BLACK arrows.
When 1500 pilot pressure is sensed at SV2 it opens the
sequence valve allowing flow to the breakout clamp cylinder.
Step 3. Rotate Undertable Breakout.
Indicated by BLUE arrows. A B

When 3000 PSI pilot pressure is sensed at SV1 it directs flow through P T

C D
C port to the piston sides of the under table breakout cylinders. This
Allows the table to rotate in a clock wise direction SV1
A1 B1
Pilot pressure opens 3 way 2 position valve
and the B port pilot operated check valve
allowing return oil to be directed to the return
manifold.

44
 Reversing the Breakout Wrench Sequencing.

As mentioned in slide 41, the steps need to be repeated until the

tool joint is lose and therefore sequence needs to be reversed after
each cycle has completed.
Reversing the sequence is as follows. SV3
Flow is directed through the 3 way 2 position pilot actuated valve,
through port D to the under table-cylinders rod side to retract. SV2

The directional control valve solenoid shifts the spool to allow flow to
be directed from ports P to B, through port B1, because pilot
pressure at sequence valve SV3 opens it directs flow to the rod side
of the breakout clamp cylinder. Flow is also directed to the rod side of
the pinning cylinder. A B

Return flow shown by the green arrows returns via ports A1, through P T

C D
ports A to T.
Under-table breakout cylinder return flow enters Port C over the SV1 SV1
sequence by-pass check valve then out through directional control A1 B1

valve ports A to T and back to the return manifold.

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 Hydraulic clutch application

The compressor is driven through a optional engine mounted

hydraulic power take off that contains an integral clutch for
engagement, and a brake to keep the output shaft stopped when
the clutch is not engaged.
The clutch is controlled by hydraulics through the electronic
control module.
Both the clutch and the brake are operated by main pressure oil
provided by a 14 GPM gear pump mounted on the back of the
P3 pump.
The bearings, clutches and gears are lubricated and cooled by
low pressure oil.
3 900 RPM
Acknowledged
On/Off is activated to switch air on, it send the command to the
MC2 controller which commands the engine to 900 RPM. 1 2 900 RPM
8 1800 RPM
When the MC2 sees that the engine is at 900 RPM it sends a
command to the clutch module to engage the clutch. Feedback 4 7 J1939 CAN BUS
from the clutch module to the MC2 will now command the engine 6 Acknowledged
to ramp up to 1800 RPM. 5 Engage clutch
24VDC
If engine speed drops below 900 RPM the clutch will begin to
uncouple.

46
 Twin Fan Circuit.
Flow from the pressure compensated load sense
pump enters the fan manifold at port 110 and is distributed
to both fan motors via the respective N/O flow control
valves to the motor A ports and back to the return A
Manifold via port 423.
A
To regulate the flow, the FCRV1 & 2 is a “Falling
Characteristic Valve” which controls the pilot pressure to
the flow control valves. ACCV 1 ACCV 2
Basically it is a normally closed valve and opens when
current is applied to the solenoid, the more current the FCRV 1
FCRV 2
more the valve opens. (This is a safety feature if the wires
should break or become loose the valves will default to
the closed position and will pilot the flow control valve to
maintain max flow to the motors)
When pressure at FCRV1 or 2 is reduced via electrical FLOW CONTROL VALVE

current, the flow control valve will reduce its respective

flow rate to match the pressure FCRV 1 OR 2 is commanding. . LS

The pilot pressure controlling the flow control valve is also

directed to control the “LOAD SENSE” line to the pump.
The ACCV1 & 2 are ANTI CAVITION valves (coast down
valves) when flow is stopped to the motor the inertia of the
blades continues to rotate and will suck oil from the low side
back into the A port of the motor.

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 Hydraulic tank and manifolds.

Tank is pressurized to 8 PSI

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