PV270-D Series OP M English 9-28-10

ATLAS COPCO
Drilling Solutions
Instruction Manual
MODEL: PV 270 Series
Atlas Copco Drilling Solutions, LLC

2100 North First Street
Garland, Texas, 75040
(972)496-7400
Read the instruction manual before operating this equipment.

This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
TABLE OF CONTENTS
PV-270 Series
TITLE
PAGE
SECTION 1 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How this manual is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Where to find information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Procedure When Receiving the Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Identification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Drill Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Instruction Manual Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Drill Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SECTION 2 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 - SAFETY AND HEALTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety and Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Health Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 - SAFETY PRECAUTIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Drill Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Safety Reminder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Qualify Your Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Equipment Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Hydraulic Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Warning of Special Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Transportation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.3 - SAFETY DECALS & NAMEPLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Safety Decals List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Safety Decals & Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.4 - HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2.5 - SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
toc - i
TABLE OF CONTENTS
PV-270 Series
TITLE
PAGE
SECTION 3 - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drill Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Designated Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Non Designated Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Enviroment Rate Factor Ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Operational Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Standard Equipment and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Leveling Jacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Undercarriage and Propel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Tower, Carousel and Drill Pipe Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Drill Pipe Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Cooling Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Dust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Operators Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Night Lighting Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Standard Tools & Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
SECTION 4 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operators Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
toc - ii
TABLE OF CONTENTS
PV-270 Series
TITLE
PAGE
SECTION 5 - OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

OPERATING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Safe Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
WALK AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Pre-start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Propel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Drill Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Carousel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Drill Rod Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Drilling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Angle Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Stopping, Parking & Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Special Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
toc - iii
TABLE OF CONTENTS
PV-270 Series
TITLE
PAGE
SECTION 6 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Maintenance Safety and Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-2 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Maintenance Schedule Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6-3 REFILL CAPACITIES/LUBRICANTS/FUEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Hazardous Substance Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Lubrication Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
AW32 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Compressor Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Lubricant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Pump Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Final Drive Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Hoist/Winch Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Water Injection Pump Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Extreme Pressure Multipurpose Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Central Lube System Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Multi-Purpose Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Rotary Head Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Engine Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Engine Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-4 MAINTENANCE AS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Service As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Clean the Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
FEED CABLE & WIRE ROPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Grease Drum Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
6-5 MAINTENANCE (8-10 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Overpressure Control System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Receiver Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Rotary Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Gearbox Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
6-6 MAINTENANCE (50 Hours or Weekly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Pump Drive Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Cat Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
6-7 MAINTENANCE (100 - 150 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94

toc - iv
TABLE OF CONTENTS
PV-270 Series
TITLE
PAGE
Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Track Planetary Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
6-8 MAINTENANCE (250 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100

6-9 MAINTENANCE (500 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121

Cat Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125
Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133
Automatic Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134
Cat Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
Compressor Air Hose and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136
Compressor Discharge hose and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136
Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136
6-10 MAINTENANCE (1000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138

Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-139
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-140
Rotary Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-142
Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-145
Water Injection Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-147
6-11 MAINTENANCE (1500-2000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149

Track Planetary Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-150
Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151
Compressor Discharge Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-152
Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-153
6-12 - MAINTENANCE (3000 HOURS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-156

CAT Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-157
6-13 - MAINTENANCE (6000 HOURS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-158

Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-159
Drain Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-160
Flush Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-160
Fill the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-161
6-14 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-163

Standard Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-163
toc - v
TABLE OF CONTENTS
PV-270 Series
TITLE
PAGE
SECTION 7 - TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 SYSTEM & TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Operator Observed Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Mechanical Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Mechanical Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-2 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Electrical System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Engine Shutdown Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Murphy Link Powerview System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Faults and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Electric Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Electrical Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
7-3 TROUBLESHOOTING (OPERATOR OBSERVED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Troubleshooting (Operator Observed Problems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
7-4.1 LOW PRESSURE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Pneumatic System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Compressor Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Regulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Anti-rumble System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
7-4.2 LOW PRESSURE COMPRESSOR WITH EARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71

Electronic Air Regulation System (EARS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
SECTION-2 Flow Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
3.1 Standard Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
3.2 Error Code Meaning and Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
3.3 Blown Fuse Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
3.4 Actuator Diagnostics Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
3.6 Potentiometer Testing using a multi meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
Section 3.7 Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102
4.1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106
7-5.1 HIGH PRESSURE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115

Compressor Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117
Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117
Lubricating System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
Separation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123
Regulation System-High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
Regulation System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139
Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-141
Compressor Related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-144
7-5.2 HIGH PRESSURE COMPRESSOR WITH EARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145

Electronic Air Regulation System (EARS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-146
toc - vi
TABLE OF CONTENTS
PV-270 Series
TITLE
PAGE
1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-154
SECTION-2 Flow Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-155
3.1 Standard Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-167
3.2 Error Code Meaning and Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-167
3.3 Blown Fuse Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-173
3.4 Actuator Diagnostics Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-173
3.6 Potentiometer Testing using a multi-meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-175
Section 3.7 Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-176
4.1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-180
7-6 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-189

Hydraulic System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-189
7-7 HYDRAULIC SYMBOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-190

Fluid Power Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-190
7-8 PROPEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-204

Propel Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-204
7-9 FEED & ROTATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-217

Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-217
7.10 - AUXILIARY FUNCTION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-235

Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-235
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-259
7.11 - ELECTRO HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-264

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-264
General Concepts and Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-265
Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-266
Denison 500 Stroker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-267
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-269
Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-273
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-275
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-276
7.12 - EHC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-278

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-278
7.13 - EHC ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-287

EHC Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-287
7.14 - TROUBLESHOOTING (DUST COLLECTOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-292

Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-292
7.15 - TROUBLESHOOTING (CENTROMATIC LUBE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-296

7.16 - ENGINE HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-301

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-301
Troubleshooting & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-308
Component Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-315
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-329
Operational Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-335
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-336
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-343
7-17 DIXON Boss Clamp Selection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-351

7-18 HNBR Hose/Victaulic Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-368
Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-369
7-19 WATER INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-375

Cat Water Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-375
Bean Water Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-387
7-20 DHD LUBRICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-396

DHD Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-396
toc - vii
TABLE OF CONTENTS
PV-270 Series
TITLE
PAGE
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-396
Lube Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-396
Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-397
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-398
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-398
Pressurized Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-399
DHD Lubricator Diagnostic Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-402
7-21 Feed Cable Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-404

Feed Cable Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-404
SECTION 8 - GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 - Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
SECTION 11 - ENGINE OIL ADDENDUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

ENGINE OIL UPDATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CATERPILLAR ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CUMMINS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
toc - viii
Section 1 - Introduction
DRILLING SOLUTIONS
Rev 002 Last Revision 09/2010
1-1
PV-270 Series Instruction Manual
INTRODUCTION
General Information
This Safety, Operation and Maintenance Manual has been developed to present the safety,
operations and preventive maintenance requirements for safe, effective operation of the Atlas
Copco Drilling Solutions PV-270 Series Blasthole Drills.
The purpose of this manual is to provide the operator and site maintenance personnel with the
knowledge of the fundamental rules and criteria to be followed for on-site use and
maintenance of a PV-270 Series Blasthole Drill Rig.
The operator and site maintenance personnel must read and fully understand this Safety,
Operation and Maintenance Manual before operating or servicing the drill. This manual has
been organized to present the safety precautions, operation requirements and appropriate
information needed to:
1. Safely operate the PV-270 Series Blasthole Drills while achieving optimum
production.
2. Understand the operating principal of each system associated with the PV-270
Series Blasthole Drills.
3. React effectively and safely to emergency and alarm conditions.
4. Perform the necessary pre-operational and post-operational checks on the drill.
Always keep the Instruction Manual on the drill and available to the operator and helper.
1-2
DRILLING SOLUTIONS
How this manual is organized

Although there is a substantial amount of information contained in the manual, it has been
organized so the reader can easily find the specific information needed. The present manual
is accompanied with a carrier instruction manual. You are therefore advised to follow the
operation and maintenance instructions as specified in both the carrier and drill instruction
manuals.
The manual is divided into sections by information based on answers to the following
questions:
1. What are the specific operator responsibilities? (See Section 2)
2. What are the specifications of the drill itself? (See Section 3)
3. What instruments and controls are used by the operator to operate and monitor
the drill? (See Section 4)
4. What are the operating capacities and limitations of the equipment? (See
Section 5)
5. What inspections are the responsibility of the operator, and when must they be
made? (See Section 6)
6. What should the operator do when problems arise. What are the types of
hydraulic, electrical and compressor systems? What is the correct operator
troubleshooting response? (See Section 7)
7. What do the various terms mean that are used in this manual? (See Section 8)
Where to find information

Each manual has a table of contents. If you are uncertain which section contains the
information or where the information is located within a particular section, the first step is to
consult the table of contents.
This instruction manual consists of the eight (8) sections shown below:
Section 1 - Introduction describing the drill
Section 2 - Safety
Section 3 - Technical Specifications
Section 4 - Operating Controls and Instruments
Section 5 - Operating Instructions
Section 6 - Maintenance Instructions
Section 7 - Systems/Troubleshooting
Section 8 - Glossary
DRILLING SOLUTIONS
1-3
If any part of this manual cannot be understood, contact your supervisor or local Drilling
Solutions Distributor. This is an essential condition for working safely with the drill.
The correct drill operation, use and regular maintenance are also essential elements
necessary to provide the highest performance and safety.
Note:
The present manual is accompanied with an engine instruction manual. You are therefore
advised to follow the operation and maintenance instructions as specified in both the engine
and drill instruction manuals.
Throughout the manual, Dangers, Cautions, Warnings, Notices and Notes are used to
provide the reader with special noteworthy information. In this manual, these terms have the
following significance:
DANGER
DANGER is used to indicate the presence of a hazard which will cause

severe personal injury, death or substantial property damage if the
warning is ignored.
WARNING
WARNING is used to indicate the presence of a hazard which can cause

severe personal injury, death or substantial property damage if the
warning is ignored.
CAUTION
CAUTION is used to indicates the presence of a hazard which will or can

cause minor personal injury or property damage if the warning is ignored.
NOTICE
NOTICE is used to notify people of installation, operation or maintenance
information which is important but is not hazard related. The hazard
warnings should never be included under the Notice signal word.
1-4
DRILLING SOLUTIONS
Procedure When Receiving the Drill

Your drill has been tested, accurately checked and prepared for shipment. Every part of the
drill, including the detached parts, has been accurately checked before being shipped from the
factory.
When you receive the drill, and before unpacking the equipment, check if damage has
occurred during transport and if any parts are missing.
Check the equipment by consulting the shipment documents.
If the goods are damaged, or if parts are missing, inform the freight agent as soon as possible.
He will inform you regarding how to proceed in order to make a complaint.
Identification Data
An exact description of the model type and the serial number of your drill will facilitate fast and
efficient response from our parts and service support operations.
Always provide the model of your drill and its serial number when you contact the local Drilling
Solutions service or parts office.
We advise you to enter your drill data on the following lines to maintain drill and engine
information necessary to facilitate fast and efficient response from our parts and service
support operations.:
Model
_________________________________________________________________________
Drill Serial Number
_________________________________________________________________________
Year of Manufacture
_________________________________________________________________________
Engine (Mfg. and Type of Engine)
_________________________________________________________________________
Deck Engine Serial Number
_________________________________________________________________________
DRILLING SOLUTIONS
1-5
Drill Identification
Engine Identification
The engine identification number can be found on the engine identification plate. The engine
data plate, as shown above, provides the model identification and other important data about
the engine. Refer to the engine operators instruction manual for further information on the
identification information. Have the following engine data available when communicating with
an Authorized Repair Location. The data on the data plate is mandatory when sourcing service
parts:
1. Engine Serial Number (ESN)
2. Control Parts List
3. Model
4. Advertised Horsepower and RPM
1-6
DRILLING SOLUTIONS
Instruction Manual Location

The instruction manuals are located within easy reach of the operator. A storage compartment
in the operators console provides space for the drill manuals. Also located in the cab, next to
the operators console, is the Laminated Safety Manual.
General Information
All safety rules in section 2 must be observed.
If further information is required concerning recommended blasthole drilling applications,
contact your local Atlas Copco Drilling Solutions distributor.
Atlas Copco Drilling Solutions reserves the right to make any changes or modifications without
prior notice and without incurring any liability to retrofit machines previously shipped from the
factory.
Drill Description
The PV-270 Blasthole Drill Series is made up of the PV-271 Single-Pass and PV-275 MultiPass. Both drills are available with 75,000 lbs [34,020 kg (333.6kN)] of bit load and are
optimized to drill 270mm (10.63) class blastholes. The nomenclature of the drill series
indicates both machines are optimized for 270 mm (10.63 inch) holes; the 1 designates
single-pass capability while a 5 indicates the multi-pass version, which has five pieces of drill
pipe available in the tower.
The PV-270 Series Blasthole Drills utilize a diesel engine (electric motor optional) to drive the
air compressor and hydraulic system. Operation of the drill is performed using electric over
hydraulic controllers ergonomically located so that the operator faces the drill centralizer while
drilling. The PV-270 Series drills come equipped with an asymmetrical rotary screw air
compressor.
DRILLING SOLUTIONS
1-7
PV-271
The PV-271 is the single-pass version of the PV-270 series. The PV-271 features a 55 foot
(16.8m), single-pass depth capacity with a 2-rod changer for 25 foot (7.6m) rods. The PV-271
is a crawler mounted, hydraulic tophead drive, single pass rotary drill specifically designed for
rotary action drilling of blastholes up to a maximum depth of 105 feet (32 meters) and a
maximum hole diameter of from 7-5/8 inches to 10-5/8 inches (193 mm to 270 mm).
PV-275
The PV-275 is the multi-pass version of the PV-270 series. The PV-275 features a 195 foot
(59.4m), multi-pass depth capacity with a 4-rod carousel for 40 foot (12.19m) rods. The PV275 is a tophead drive, multi-pass, track mounted, hydraulic rotary drill specifically designed
for production blasthole drilling to a maximum depth of 195 ft. (59.4m) with a 40 ft. (12.19m)
drill pipe change for mining applications. Nominal hole size is 7-5/8 in. to 10-5/8 in. (193 mm
to 270 mm) for rotary drilling applications. An angle drill option is available.
Derrick
The derrick is constructed of welded rectangular steel tubing with cross bracing on both sides
and the back. A set of sheaves at the top and bottom of the derrick support the feed cables.
The derrick assembly features the hydraulically driven rotary tophead and the hydraulic drill
feed systems. The feed system consists of the rotary tophead, two hydraulic feed cylinders
and a set of cables connected to the top and bottom of the rotary head assembly.
Drill pipe changing is done by emptying the carousel first, then pulling pipe from the pipe rack.
Pulling pipe out of the hole is done just the opposite, after replacing one piece of pipe in the
carousel to stow the rotary tophead.
To permit optimum performance on a wide range of applications and site requirements, PV270 Series drills are equipped with:
1. Asymmetrical rotary screw air compressors.
2. Dust suppression equipment.
3. Standard 2 drill rod internal carousel (PV-271 Single-Pass).
Standard 4 drill rod internal carousel (PV-275 Multi-Pass).
4. Operational controls in a sound proofed cab.
5. High gradeability.
The power pack, which consists of a diesel engine (electric motor optional) directly coupled to
an asymmetrical air compressor on one end and a hydraulic pump drive on the other, is
mounted on its own sub base. The sub base is then mounted to the drill main frame. This inline drive train configuration maximizes mechanical efficiency. The separate sub base isolates
the components from drilling and propel shock loads and maintains alignment between the
components. The PV-270 Series drills incorporates three (3) leveling jacks to keep the drill
level and stable while drilling. An optional four (4) leveling jack installation is available.
The propulsion system features independent hydrostatic drive and service braking of each
track, allowing steering by differential operation of the tramming control levers.
1-8
DRILLING SOLUTIONS
Engine
The PV-270 drills use a water cooled engine with direct injection and turbo chargers. Electric
starting and belt driven alternator battery charging is standard on all drills. The PV-270 Series
drills are equipped with dual system air filtration. Dry type 3-stage air cleaners, with optional
pre-cleaners, provide clean air to the engine and the compressor. The engine power / rpm is
controlled by the engine speed control (throttle) switch. The engine is shutdown either by the
removable key ON/OFF switch or the emergency stop switch.
Main Frame
The drill main frame consists of a track frame which supports the power pack assembly
(engine, compressor, hydraulic pumps), the cooler package (radiator, compressor oil cooler,
hydraulic oil cooler), drill tower assembly, operators cab assembly and leveling jacks.
Drill Tower
The drill tower assembly features the hydrostatic driven rotary head and the hydraulic drill feed
systems. The drill rod carousel can be controlled from the operators console to provide safe
and easy multi-pass drilling. By using the angle drilling accessories, the hole can be drilled at
5 degree increments from vertical up to 20 degrees from the vertical (PV-271) or up to 30
degrees (PV-275) from the vertical.
Controls
All of the controls are positioned for operator convenience in the operators cab. Full details
are provided in section 4.
Tramming (Propelling)
The propulsion system features independent hydrostatic drive/service braking of each track,
allowing steering by differential operation of the tramming control levers. Each track is
provided with direction (Forward and Reverse) speed control levers which control the
tramming speed. This system also provides service braking by moving the respective levers
towards the STOP position.
Steering
The drill can be steered by adjusting the speed of one track relative to the other.
Braking
Service braking is effected by moving the tramming control lever towards the STOP position.
Because the LH and RH track systems are independently controlled, one track acts as
secondary braking for the other.
DRILLING SOLUTIONS
1-9
Parking brakes are incorporated into each track motor assembly and are fail-safe,
hydraulically released, spring applied. These brakes will therefore be applied in the event of
loss of brake release hydraulic pressure due to:
1. Pressing a RED emergency stop switch.
2. Turning the main key operated ON/OFF switch to OFF position.
3. Hose failure resulting in loss of charge pressure when the main pumps cut off
the flow to the tracks.
Operators Cab and Console

The one-piece FOPS (Falling Object Protective Structure) cab is thermally insulated, heated,
pressurized, and sound rated to 85 dBa. Tinted safety glass and an integrated air system with
directional vents and louvers keep the cab comfortable. An ergonomically designed wraparound console provides direct visibility to the drilling table and surrounding bench. Electric
controllers on the console connect to spool valves, eliminating the need for hydraulic hoses in
the cab and creating a quieter work environment. An optional air conditioner is wall mounted
for ease of maintenance.
The operators FOPS cab is designed for convenience, ease of control, comfort and safety
while providing maximum visibility to the work area. The operators station is sound insulated.
A fully adjustable suspension-mounted seat is standard. All of the controls are positioned for
operator convenience in the operators cab. Full details are provided in section 4.
Gradeability
Superior gradeability is the result of a powerful torque-balanced hydrostatic system with
independent drive to both tracks.
Serviceability
The engine, compressor and hydraulic pumps power pack is accessible from the walk around
decking. All daily checkpoints are positioned to encourage preventive maintenance. All grease
points can be serviced from the two banks of grease nipples from which hoses provide grease
to the respective components.
Your life may be endangered if the following is not complied with. DO NOT add
attachments to the machine that intrude into operators protective area, reduce
visibility, restrict emergency exits or add weight exceeding certification weight. See the
operators manual or contact your dealer for complete inspection requirements and
maintenance instructions.
1-10
DRILLING SOLUTIONS
Identification of Major Components

VIEW OF PV-270 DRILL WITH TOWER REMOVED
DRILLING SOLUTIONS
1-11
VIEW OF PV-275 TOWER WITH 4-ROD CAROUSEL
1-12
DRILLING SOLUTIONS
VIEW OF PV-271 TOWER WITH 2-ROD CAROUSEL
DRILLING SOLUTIONS
1-13
This page intentionally blank
1-14
DRILLING SOLUTIONS
Section 2 - Safety
DRILLING SOLUTIONS
2-1
Section 2 - Safety
2.1 - SAFETY AND HEALTH
General Safety and Health

This manual has been published to alert operators, helpers and mechanics to the possible
physical dangers that are present in all phases of operation and maintenance of this drill.
Anyone working around this drill must read and thoroughly understand the precautions
outlined in this manual before attempting to operate or perform work on the drill. In addition,
SAFETY ALWAYS must always be the primary consideration of all personnel when working
around this drill under normal or unusual conditions.
Since this manual cannot cover every possible situation, all personnel are expected to
exercise good judgement and common sense when operating, servicing or working near this
drill.
If there is any doubt about the safe operating procedures of the drill, STOP! Review the
information supplied with the drill, ask your supervisor or contact your nearest Atlas Copco
Drilling Solutions representative for assistance.
Make sure all new employees read and understand the decals in the laminated Decal Safety
Manual that is mounted on the drill. Never remove the Decal Safety Manual. Replace the
manual if it becomes lost, damaged or illegible.
Safety and Health Statement

Every employer should have a safety and health philosophy based on the following
statements:
1. We are committed to providing a safe and healthy workplace for all our
employees.
2. We believe that injuries and accidents are preventable and that the well being
of all our employees can be protected in the work environment.
3. We believe that safety is number one. Safety will not be sacrificed for
production.
4. We believe that housekeeping is an integral part of our safety program and the
protection of our employees health.
5. We believe that all of our employees are responsible for the safety of their coworkers. Each of us has the duty to listen, watch and act upon hazards that
might injure another.
6. We believe that good safety training is necessary to assist employees in
completing their assigned tasks in a safe manner.
7. We believe that safety is a team effort.
2-2
DRILLING SOLUTIONS
Section 2 - Safety
Safety is an integral part of every individuals job responsibility. Every employee must be
committed to these beliefs and must work in a manner that demonstrates that commitment.
Emergencies
Emergencies are situations where there is personal injury or property damage, or when there
is imminent threat of personal injury or property damage. It is important for everyone to know
how to respond to emergency situations in order to minimize injury and damage. Each
operator must have a plan to be able to contact 911 or some other form of help, such as Fire
or Medical Emergency Services, immediately. These plans must be known to everyone
around the drill in case someone is injured.
Important Safety Instructions

Personal safety is of prime importance at all times when performing any operations or
maintenance on a drill. While we have no direct control over the way the drill is operated or
maintained, we wish to call your attention to those procedures which are potentially
hazardous. Knowing the guidelines shown in section 2.2 will help provide for your safety, for
the safety of those around you and for proper operation and maintenance of the drill.
DRILLING SOLUTIONS
2-3
Section 2 - Safety
2.2 - SAFETY PRECAUTIONS AND GUIDELINES
Overview
Before you operate, maintain, work around or in any other way use this drill: READ and
STUDY this manual. KNOW how to safely use the drill controls and what you must do for safe
maintenance. Failure to follow instructions or heed warnings could result in injury or death.
Ensure that the drill is in good operating condition before operating.
If you have ANY QUESTIONS about the safe use or maintenance of this drill, ask your
supervisor or contact your nearest Atlas Copco Drilling Solutions distributor for assistance.
NEVER GUESS-ALWAYS CHECK!
Safety must always be the most important concern. Do not operate the drill when conditions
are unsafe and consult your supervisor when safety is in doubt.
You must be alert, physically fit and free from the influences of alcohol, drugs or medications
that might affect your thinking ability, judgement, sight, hearing or reactions.
Signals must be given by the operator prior to starting or operating the drill.
Make sure all new employees read and understand the decals in the Decal Safety manual that
is mounted on the drill. Never remove the Decal Safety manual. Replace the Decal Safety
manual if it becomes lost, damaged or illegible.
IMPORTANT SAFETY INSTRUCTIONS
Personal safety is of prime importance at all times when performing any operations or
maintenance on a drill. While we have no direct control over the way the drill is operated or
maintained, we wish to call your attention to those procedures which are potentially
hazardous. Knowing the guidelines covered below will help provide for your safety, for the
safety of those around you, and for proper operation and maintenance of the drill.
2-4
DRILLING SOLUTIONS
Section 2 - Safety
Warnings
Throughout the manual, Notes, Notices, Cautions, Warnings and Danger symbols are used
to designate instructions of particular importance. Look for these symbols which point out
items of extreme importance to you and your co-workers safety. Read and understand
thoroughly. Heed the warning and follow the associated instructions. In this manual, these
terms have the following significance:
NOTE: Note is used for supplementary information not directly effecting
safety or damage to equipment. Note can also refer to special information
on the efficient use of the drill.
NOTICE
NOTICE: Notice is used to notify people of installation, operation or
maintenance information which is important but not hazard-related.
Hazard warnings should never be included under the NOTICE signal
word.
CAUTION
CAUTION: Caution is used to indicate the presence of a hazard which

WILL or CAN cause minor personal injury or property damage if the
warning is ignored.
WARNING
WARNING: Warning is used to indicate the presence of a hazard which

CAN cause severe personal injury, death or extensive property damage if
the warning is ignored.
DANGER
DANGER: Danger is used to indicate the presence of a hazard which WILL

cause SEVERE personal injury, death or substantial property damage if
the warning is ignored.
DRILLING SOLUTIONS
2-5
Section 2 - Safety
Drill Applications
The PV-270 Series drills are built in accordance with state-of-the-art standards and
recognized safety rules. Nevertheless, misuse may constitute a risk to the life and limb of the
user or third parties, and may cause damage to the drill or other material property.
The PV-270 Series drill must be used in accordance with its designated use as described in
the operating manual. The drill must only be operated by safety-conscious persons who are
fully aware of the risks involved in operating the drill. Any functional disorders, especially those
affecting the safety of the drill, must be corrected immediately.
Designated Applications
PV-271 (Single-Pass)
The PV-271 is the single-pass version of the PV-270 series. The PV-271 is designed
exclusively for production blasthole drilling for mining applications by rotary/percussive action
with a single-pass depth capability of 55 feet (16.76m) and a total depth capability of 105 ft.
(32.3m) with a 25 ft. (16.76m) drill pipe change on prepared benches which are flat and firm.
The nominal hole size diameter ranges from 7-5/8 in. (193 mm) to 10-5/8 in. (270 mm) for
rotary bit applications. The hydraulic cylinder driven cable feed system is capable of 75,000
lbs. [34,020kg (333.6kN]) of bit loading. The drill operating weight is between 165,000 lbs.
[74,844kg (744.0kN)] to 175,000 lbs [79,380kg (778.4kN)].
PV-275 (Multi-Pass)
The PV-275 is the multi-pass version of the PV-270 series. The PV-275 multi-pass drill is
designed exclusively for production blasthole drilling for mining applications by rotary/
percussive action, to depths of 195 ft. (59.4m) with a 40 ft. (12.19m) drill pipe change, on
prepared benches which are flat and firm. The nominal hole size diameter ranges from 7-5/8
in. (193 mm) to 10-5/8 in. (270 mm) for rotary bit applications. The hydraulic cylinder driven
cable feed system is capable of 75,000 lbs. [34,020kg (333.6kN]) of bit loading. The drill
operating weight is between 165,000 lbs [74,844kg (744.0kN)] to 175,000 lbs [79,380kg
(778.4kN)].
Non-Designated Applications
The PV-270 series drills are not designed for pioneering or earth moving applications. The PV270 series drills are not designed for use on inclined surfaces or on soft and unstable ground.
Use of the drills for purposes other than that mentioned (such as for towing other vehicles or
equipment) is considered contrary to its designated use. The manufacturer and/or supplier
cannot be held liable for any damage resulting from such use. The risk of such misuse lies
entirely with the user.
2-6
DRILLING SOLUTIONS
Section 2 - Safety
Set up the drill on a level surface. If this is not available, the site should be adequately
prepared prior to drill setup.
Operating the drill within the limits of its designated use also involves compliance with the
inspection and maintenance directives contained in the operating manual.
Safety Reminder
physical dangers that are present in all phases of the operation of this drill. Anyone working
around this drill must read and thoroughly understand the precautions outlined in this manual
before attempting to operate or perform work on the drill. In addition, SAFETY ALWAYS
must always be the primary consideration of all personnel when working around this drill under
normal or unusual conditions.
exercise good judgement and common sense when operating, servicing or working near the
drill. If there is any doubt about the safe operating procedure of the drill, STOP! and review the
information supplied with the drill or contact your nearest Atlas Copco Drilling Solutions
representative for assistance.
Qualify Your Personnel

Work on and with the drill must only be performed by qualified personnel. Statutory minimum
age limits must be observed.
Those who operate, maintain and work on Rotary Drill rigs must be competent:
Physically - To react correctly and quickly to avoid accidents.
Mentally - To understand and apply all established rules, regulations and safe practices. To
concentrate on the job to be done.
Emotionally - To withstand stress and prevent mistakes.
Those who operate, maintain and work on Rotary Drill rigs must be experienced:
Trained - In the operation and maintenance of the PV-270 Series drills.
1. They should have read and understood the Manufacturers Instruction Manuals
and know the ratings and capabilities of the drill they are using.
2. They must understand hand signals.
3. They must understand the meaning of various symbols on instruments,
controls and specific parts of the drill.
DRILLING SOLUTIONS
2-7
Section 2 - Safety
Licensed - If required by law.

1. The individual responsibilities of the personnel responsible for operation, setup,
maintenance and repair of the drill should be stated clearly.
2. Define the drill operators responsibility with regard to observing site traffic
regulations.
3. The operator should have the authority to refuse instructions by third parties
that are contrary to safety.
4. Do not allow persons being trained or instructed in the operation or
maintenance of the drill to work without permanent supervision by an
experienced person.
5. Work on the electrical system and equipment of the drill must be done only by
a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician and must be in accordance with electrical
engineering rules and regulations.
6. Work on the mainframe and drill tower, brake, air and hydraulic systems must
be performed by skilled personnel with special knowledge and training for such
work.
General Guidelines
1. STOW instruction manuals in the manual compartment provided in the
operators cab. Manuals must always be available at the site where the drill is
used. The operators instruction manual shall be within easy reach of the
operators station.
2. OBSERVE and INSTRUCT the user in all other generally applicable mandatory
and legal regulations relevant to accident prevention and environmental
protection. These compulsory regulations may also deal with the handling of
any hazardous substances, issuing and/or wearing personal protective
equipment, and traffic regulations.
3. SUPPLEMENT operating instructions with detailed working instructions
covering the methodology of the working sequences, all individual job
responsibilities and the overall supervisory responsibility.
4. ALWAYS be sure that persons entrusted with work on the drill have read the
operating instructions and in particular the chapter on safety before beginning
work. Reading the instructions after work has begun is too late. This is
especially important for persons who work only occasionally on the drill, e.g.
during setup or maintenance.
5. MAKE CERTAIN all personnel are working in compliance with the operating
instructions and are alert to risks and safety factors.
2-8
DRILLING SOLUTIONS
Section 2 - Safety
6. ALWAYS tie back or otherwise secure long hair. Wear close-fitting garments
and avoid wearing jewelry such as rings. Injury may result from clothing, hair or
jewelry being caught up in the machinery.
7. USE protective equipment wherever required by the circumstances or by the
law. Always wear approved safety equipment while working around the drill.
This includes an approved hard hat, safety glasses, protective footwear,
gloves, respirator and ear protection.
8. OBSERVE all safety instructions and warnings attached to the drill.
9. BE SURE all safety instructions and warnings attached to the drill are complete
and perfectly legible.
10. STOP the drill immediately in the event of safety relevant malfunctions or
change in drill behavior during operation. REPORT the malfunction to the
proper authority/person.
11. NEVER provide service or maintenance to the drill unless both tracks are on
firm, level ground.
12. DO NOT make any modifications to the drill which might affect safety without
having the manufacturers approval. This applies to the installation and
adjustment of safety devices and valves as well as to welding work on load
bearing elements.
13. ALWAYS ADHERE to the prescribed intervals and/or those specified in the
operating instructions for routine checks and inspections.
14. ENSURE that people, equipment and material not required for the correct
operation of the drill are removed and kept out of the work area. The operator
must never drill while people are around the drill platform. Alert people and
crew to stay clear of the hole while drilling is in process.
15. ALL PERSONNEL who work around the drill must ensure that any unsafe
conditions and practices are corrected or reported to the drill operator and
supervisor.
16. ALL PERSONNEL who are working around the drill, including support and
maintenance people, must obey all warning signs and must ensure their own
safety and the safety of others.
17. WITH careful planning, most accidents can be avoided.
A. Have a clear understanding of the work to be done.
B. Consider potential dangers or hazards.
C. Develop a plan to do the job safely.
D. Explain the plan to all personnel concerned.
DRILLING SOLUTIONS
2-9
Section 2 - Safety
Equipment Safety Rules

Before starting or working around the drill, read and understand the safety manual, decal
safety manual and labels located on the drill. Follow all directions on the labels. Do not remove
or deface the labels. Replace them if they become damaged or lost.
Do not operate or work on this drill unless the instructions in this training manual and the signs
on the equipment are understood. Failure to follow instructions or heed warnings could result
in injury or death. Ensure that the drill is in correct condition before operating.
Safety must always be the most important concern. Do not operate the drill when conditions
are unsafe and consult your supervisor when safety is in doubt. You must be alert, physically
fit, and free from the influences of alcohol, drugs, or medications that might affect your thinking
ability, judgement, sight, hearing, or reactions.
1. Anyone working around this drill must wear an approved hard hat, safety
glasses, safety shoes and ear protection. Do not wear loose clothing that can
get caught in moving parts. Wear gloves when handling heavy parts and tools
or any objects that are sharp or pointed. A respirator may be required in dusty
conditions.
2. Keep work areas clean and free from grease, oil and other items or tools that
could cause a slip or fall.
3. Keep all warning and information labels clean and readable. Replace labels if
they become damaged, torn, painted over or removed.
4. Keep all controls and gauges in good working order. If they are broken or
damaged, replace them before operating the drill.
5. Make a complete walk-around inspection of the drill before starting drill. During
operation, make periodic checks to be sure the drill is operating properly.
6. Watch for leaking or broken hydraulic hoses or air hoses. Replace them before
they cause damage or a fire.
7. Do NOT operate the drill with excessively worn or broken parts.
8. Tighten or replace any loose or broken fittings, bolts or other connections
before operating drill.
9. Check the batteries and connections before starting the drill. Tighten the
terminal clamps. Be sure all batteries have caps. Loose wires can cause fires
and shocks. Spilled fluid can cause burns. Make sure all batteries are charged
properly and are filled with the correct fluids.
10. Use extreme caution when handling, cleaning, wiring or recharging the
batteries. They can explode and spray acid. Keep battery covers in place all the
time.
11. Keep the operators cab clean. Mud, cans, bottles, tools and other debris can
jam controls and cause falls.
2-10
DRILLING SOLUTIONS
Section 2 - Safety
12. Make sure all controls are in neutral before starting the drill.
13. Make sure all guards are in place on the drill. Replace the guards if they have
been removed for maintenance. DO NOT operate the drill if guards are not in
place.
14. Know where your helper or other personnel are at all times. DO NOT move the
drill if they are not in sight.
15. Signals must be given by the operator prior to starting or operating the drill.
16. Before moving drill, make sure there is nothing in the way of travel. Make sure
all the drill pipe is out of the ground and secured before moving.
17. Locate drill on level ground, if possible. Install cribbing (blocking) under each
jack to insure a stable lifting platform in case ground is broken or soft.
18. Before raising the tower, make sure it is clear of any tools or objects that could
fall. Check to see that all hydraulic and air hoses do not become snagged
during raising. Watch all hoist cables and keep them clear or unspooled
properly while raising the tower. Make sure any helpers or visitors are away
from drill while raising or lowering the tower.
19. When working on any air compressor hose or the receiver tank, relieve all
pressure in the system before removing any cap, plug or hose connection.
20. Never move the drill with the tower partially raised, unless it is an angle drill with
the proper locking pins in place.
21. Never move the drill with tower locking pins removed or unpinned. The tower is
not designed to be held up by the tower raising cylinders alone.
22. Keep the work area clear of cuttings, tools and other objects.
23. Make sure all new employees read and understand the decals shown in the
Safety Manual, mounted in the operators cab. Never remove the Safety
Manual. Replace the manual if it becomes lost or illegible.
24. All personnel setting up drills or handling maintenance or repairs must know
and practice proper procedures, including lockout and tag out practices.
25. All personnel must watch for hazards during operations and alert the operator
of potentially dangerous situations, such as the presence of other personnel,
other equipment, unstable ground or overhanging obstacles.
26. To avoid accidents, factors such as the following must be considered.
a. Are there structures, power lines or other equipment which must be moved
or avoided during operation of the drill?
b. Is the surface firm enough to support the drill and auxiliary equipment?
c. What steps must be taken in order to keep all unnecessary people and
equipment at a safe distance from the drilling area?
DRILLING SOLUTIONS
2-11
Section 2 - Safety
27. Determine the load-bearing capacity of the ground or other surface on which
the drill will be operating. Be sure drill is adequately supported. Avoid soft or
unstable ground and areas with high water tables.
28. Prior to servicing or repairing the drill, follow lockout and tag out procedures.
Injury or death can occur if the drill is started before servicing is finished. Never
start drill or operate the equipment if lockouts or tag outs are on the controls.
Look inside and outside, underneath and all around the drill to be sure
everyone is clear.
29. Keep the drill clean and as dry as possible. Slippery surfaces can cause slips
and falls.
30. Wire rope running over drums and through sheaves creates pinch points. Do
not use hands or bars to guide wire rope onto drums; instead, use rope guides.
Keep clothing and all parts of the body away from running rope and from the
machinery that moves the rope.
Contacting power lines with any part of the drill will cause death! Keep at
least 10 feet (3m) away from power lines. If there appears any danger of
wind or other obstruction closing the distance, do not drill in that area.
31. During the drilling operation, keep all people away from the drilling platform,
tower and drill string. Moving components and rotating drill string can entangle
clothing and may pinch, crush or strangle personnel.
32. Exceeding the slope or grade limitations of the drill and its configuration can
cause the drill to tip over. Prior to moving the drill into position, always
determine the safe operating grade of the drill with the tower up and down. Do
not move the drill with the tower up unless the ground is firm and level and no
obstructions will cause the drill to tip.
33. Personnel can be pinched, entangled or crushed by moving machinery while
the drill is in operation. Crew members must never place any part of their
bodies or clothing on or near any rotating machinery, gears, pinions, ropes,
cables, chains or wrenches.
34. The drilling process can produce flying debris and dust which can cause
serious respiratory difficulties for personnel working in or visiting the drilling
site. Always use water or foam to keep dust under control and keep the dust
curtains in place to prevent flying debris.
35. Always wear hard hats, safety glasses, ear protection, and steel-toed shoes
while working around the drill. Wear gloves when handling sharp objects or hot
items.
36. Wear respirators if there is any danger of blowing dust or cuttings.
2-12
DRILLING SOLUTIONS
Section 2 - Safety
Pre-Start Inspection
1. INSPECT the drill daily. Ensure that the routine maintenance and lubrication
are being dutifully performed. Have any malfunctioning, broken or missing
parts repaired or replaced before use.
2. VERIFY that all instruction and safety labels are in place and readable. These
are as important as any other equipment on the drill.
3. NEVER fill the fuel tank with the engine running, while near an open flame, or
while smoking. ALWAYS wipe up any spilled fuel.
4. CHECK for WARNING or lockout tags placed on the drill. DO NOT operate the
drill until all of the repairs have been made and all the WARNING or lockout
tags have been removed by authorized personnel.
5. CLEAN any and all foreign material from the operators platform to reduce the
danger of a slipping or falling.
6. KNOW the location of the Emergency Shut Down Control if the drill is so
equipped.
7. ALWAYS know the capabilities and limitations of the drill: speed, gradeability,
steering and braking.
8. BE AWARE of the dimensions of the drills height, width and weight when
moving the drill.
9. CHECK for any conditions that could be dangerous: such as unstable ground
condition or an overhanging rock face.
Operation Safety
Safety Instructions Governing Operation
1. OBSERVE the location of fire extinguishers, if so equipped, and ensure that
they are fully charged and inspected regularly.
2. AVOID any operational mode that might sacrifice safety.
3. TAKE all necessary precautions to ensure that the drill is used only when in a
safe and reliable condition.
4. OPERATE the drill only if all protective and safety oriented devices, such as
removable safety devices, emergency shut off equipment, sound proofing
elements and exhausts are in place and fully functional.
DRILLING SOLUTIONS
2-13
Section 2 - Safety
5. START the drill from the operators cab seat only. If the drill is equipped with an
optional remote tramming control console, use the remote control unit from a
safe location when tramming over unstable ground conditions, loading the drill
on ramps for trailer transport or when there is a risk of a roll over condition.
6. WATCH all of the indicators during startup and shutdown procedures in
accordance with the operating instructions.
7. MAKE SURE no one is at danger or risk before starting up or setting the drill in
motion.
8. PERSONNEL can be pinched, entangled or crushed by moving machinery.
While the drill is in operation, crew members must never place any part of their
bodies or clothing on or near any rotating machinery, gears, pinions, ropes,
cables, chains or wrenches.
9. CHECK that the propel, steering, signaling and lighting systems are fully
functional before starting work or traveling with the drill.
10. CHECK that the accessories have been safely stowed away and that all
levelling jacks are retracted fully before moving the drill.
11. ALWAYS SWITCH ON the lighting system in conditions of poor visibility and
after dark.
12. MAKE SURE there is sufficient overhead clearance when crossing
underpasses, bridges and tunnels, or when operating under overhead lines.
13. ALWAYS KEEP at a safe distance from the edges of quarry face, pits and
slopes.
14. AVOID any operation that might be a risk to drill stability.
15. ALWAYS SECURE drill against any inadvertent movement and unauthorized
use before leaving the operators cab.
Setup and Start

1. ALWAYS USE handrails and steps to get on and off the drill. ALWAYS
MAINTAIN a three point contact when climbing onto or off the drill. Watch for
slippery surfaces when mounting.
2. READ and FOLLOW ALL instruction decals.
3. Before starting the drill or propelling the drill, check inside, outside and
underneath drill for people or obstructions.
4. Check for Warning or Lockout tags on the controls. If there is a tag attached to
the key start switch, do not start the engine until the warning tag has been
removed by the person who installed it or by authorized personnel only.
2-14
DRILLING SOLUTIONS
Section 2 - Safety
5. BEFORE starting the engine, ENSURE the propel/drill mode selector is in the
Drill position and all tramming and drilling control levers are in the STOP or
neutral position.
6. BEFORE starting the engine, ENSURE that the track brakes are applied
(propel controllers are in STOP position).
7. Check all controls to be sure they are in neutral before starting the engine.
8. ALWAYS sound the horn before starting the drill to alert everyone in the area
(if the drill is so equipped).
9. START the engine from the operators position only.
10. ALWAYS USE EXTREME CAUTION if you have to jump-start the engine.
11. Check all gauges and controls for correct operation. Stop the drill immediately
and replace any that are defective.
12. Check all safety devices. Report any defects immediately.
13. Make sure you are on solid, level ground before raising tower. Use cribbing
and/or blocking if you are not sure.
14. When raising the tower, make certain there are no electrical power lines or
obstruction within the operating area of the drill.
15. Listen for unusual noises.
16. Engage hydraulic controls slowly in cold weather to avoid shock loading.
Electrical Power Line Safety
DANGER
Do not raise the derrick or operate this drill in the vicinity of electrical
power lines. Operating too close or contacting a power line with any part
of the drill can result in electrocution.
Contacting power lines with any part of the drill will cause death! Keep at
least 10 feet (3 meters) away from power lines. If there appears any
danger of wind or other obstruction closing the distance, do not drill in
that area.
1. Place the drill as far as possible from electrical power lines and never work
inside the minimum specified distance set by local, state or federal regulations.
2. Treat all electrical lines as live power lines.
DRILLING SOLUTIONS
2-15
Section 2 - Safety
3. Clear the area. Slowly raise and lower the derrick. If the distance to the line has
been misjudged, your reaction time might be too slow.
4. A signal person must be used to guide the drill in the vicinity of power lines. The
signal person and drill operator must be in direct visual contact at all times.
Operating Safely
1. ALWAYS make sure that no person or obstruction is in your line of travel before
you start tramming the drill.
2. NEVER CLIMB on or off the drill while it is in motion. If the drill is equipped with
an optional remote tramming control console, always use the remote control
unit from a safe location when tramming over unstable ground conditions,
loading the drill on ramps trailer transport or when there is a risk of a roll over
condition.
3. USE EXTREME CAUTION and be very observant when operating in close
quarters or congested areas.
4. NEVER carry passengers.
5. KNOW the area in which you are working. Familiarize yourself with any and all
work site obstructions and any other potential hazards in the area.
6. KNOW and USE the hand signals required for particular jobs and know who
has the responsibility for signaling.
7. DO NOT work in the vicinity of overhanging banks or on grades that could
cause the drill to slide or roll over.
8. AVOID side hill travel. ALWAYS operate up and down slopes. ALWAYS keep
the propel control lever in low speed close to STOP position when ascending
or descending hills.
9. NEVER allow bystanders, other than authorized persons, to stand within the
drill rig danger (working) area when the engine is running.
10. ALWAYS LOOK in all directions BEFORE changing your direction of travel and
sound the horn prior to moving.
11. DO NOT attempt to control drill rig travel speed with the throttle control. When
operating the drill rig, maintain the engine speed at full operating rpm.
12. DO NOT run engine in a closed building for an extended length of time.
EXHAUST FUMES CAN KILL.
2-16
DRILLING SOLUTIONS
Section 2 - Safety
Drilling Safety
All Atlas Copco Drilling Solutions drills are equipped with an overpressure control system
which will vent feed pressure if the drill end leveling jacks are not supporting the weight of the
drill. To ensure someone has not disabled the system, each operator must perform the
overpressure control system operational check procedure daily as described in sections 6.5
of this manual.
1. Use the proper tools for the job. Do not attempt to lift DHDs, subs, stabilizers
or bits without the proper lifting devices.
2. Do not attempt any repairs to the drill while it is running. Stop the drill to make
repairs.
3. Do not allow anyone to climb the tower. If repairs must be made, lower the
tower or use a manlift to reach the repair area.
4. Do not use the hoist cable as a manlift.
5. Do not ride the rotary head for any reason. It is not meant to be an elevator.
6. Do not operate the drill except from the operators console. Trying to operate
from any other position is a safety hazard and can cause serious injury.
7. If the drill is equipped with an optional remote tramming control console, always
use the remote control unit from a safe location when tramming over unstable
ground conditions, loading the drill on ramps for trailer transport or when there
is a risk of a roll over condition.
8. Do not hoist or brake too sharply. This can cause premature failure of
equipment and can be dangerous.
9. Dont retract the hoist so far that it slams into the crown block. Continuous pull
on the wire rope can break it and drop the load.
10. Know the limitations of your drill and dont exceed the design limits.
11. Use the proper technique in loading and unloading drill pipe. If a lifting bail is
used, make sure it can be detached by a helper while standing on the ground.
Use a pipe handling tool if the carousel needs to be filled. Make sure the safety
clip is in place.
Propel (Tram) Safety

1. Make sure all drill pipe is out of the hole before moving the drill.
2. Do not get on or off the drill when it is moving.
3. Lower the derrick if moving a long distance.
4. Secure all drill pipe and tools before moving the drill.
DRILLING SOLUTIONS
2-17
Section 2 - Safety
5. Know the drills height, width, weight and length before moving the drill.
6. Use the main pumps to control speed and direction. If a problem with tramming
arises and the pumps dont respond to controls, shift Drill/Propel Valve back to
DRILL. This will set the parking brakes and stop the drill.
7. Use caution when loading a drill onto a trailer. Make sure the ramp will hold the
weight of the drill.
8. If tramming with the tower raised, make sure all locking pins are in place and
the ground is level and solid.
9. Be careful cornering to allow for tower overhang.
10. Know where your helpers are at all times. Do not move the drill if they are not
in view.
11. Know and use proper signals when moving the drill.
Stopping and Shutdown Safety

1. Move drill away from high wall or face before shutting the drill down for the day.
2. Dont park drill under an overhang or where a bank can cave in.
3. ALWAYS park the drill rig on solid, level ground. If this is not possible, always
park the drill at a right angle to the slope and chock the tracks.
4. If drill is left over a hole, lower jacks so tracks touch the ground.
5. Be sure to relieve all air pressure in the systems before leaving the drill.
6. Place all controls in neutral or park position before leaving the drill.
7. ALWAYS move the tram/drill mode selector to DRILL and make sure the
tramming and drill controllers are all in the STOP positions.
8. AVOID leaving the controls with the engine running. NEVER leave the
operators cab while the engine is running.
9. Move the Engine Throttle (speed selector) to LOW idle (1200 rpm) position for
about five (5) minutes to allow the engine to cool down before turning the key
switch to OFF.
10. Lock the ignition and remove the keys before leaving the operators cab. Lock
all of the lockable compartments.
11. USE proper flags, barriers and warning devices, especially when parking in
areas of heavy traffic.
2-18
DRILLING SOLUTIONS
Section 2 - Safety
Maintenance Safety
In any work concerning the operation, conversion or adjustment of the drill and its safety
oriented devices or any work related to maintenance, inspection and repair, always observe
the startup and shutdown procedures set out in the operating instructions and the information
on maintenance work.
All personnel involved in setting up drills or handling maintenance and repairs must know and
practice proper procedures, including lockout and tagout practices.
1. Ensure that the maintenance area is adequately secured.
2. When the drill is completely shut down for maintenance and repair work, it must
be secured against inadvertent starting by:
a. Locking the principal control elements and removing the ignition key.
b. Attaching a warning sign to the main starter key switch.
3. Carry out maintenance and repair work only if the drill is positioned on stable
and level ground and has been secured against inadvertent movement.
4. USE CARE when attaching and securing lifting tackle to individual parts and to
other large assemblies being moved for replacement purposes to avoid the risk
of accidents. ALWAYS USE lifting gear that is in perfect condition and with
adequate lifting capacity. NEVER work or stand under suspended loads.
5. ALWAYS USE the correct tools and workshop equipment when performing
maintenance to the drill.
6. ALWAYS USE specially designed or otherwise safety oriented ladders and
working platforms when doing overhead assembly work. Never use drill parts
as a climbing aid and never climb the tower.
7. KEEP all handles, steps, handrails, platforms, landings and ladders free from
mud, dirt, snow and ice.
8. CLEAN the drill, especially connections and threaded unions, of any traces of
oil, fuel or preservatives before carrying out maintenance or repair. NEVER use
aggressive detergents. Use lint free cleaning rags.
9. Before cleaning the drill with water, steam jet (high pressure cleaning) or
detergents, COVER or TAPE up all openings which, for safety and functional
reasons, must be protected against water, steam or detergent penetration.
Special care must be taken with electric motors and switch gear cabinets.
10. ENSURE during cleaning of the drill that temperature sensors do not come into
contact with hot cleaning agents.
11. REMOVE all covers and tapes applied for that purpose after cleaning the drill.
DRILLING SOLUTIONS
2-19
Section 2 - Safety
12. After cleaning the drill, EXAMINE all fuel, lubricant and hydraulic fluid lines for
leaks, loose connections, chafe marks and damage. REPAIR or REPLACE
defective parts immediately.
13. Always TIGHTEN any and all screwed connections that have been loosened
during maintenance and repair.
14. Any safety devices that were removed for setup, maintenance or repair
purposes must be refitted and checked immediately upon completion of the
maintenance and repair work.
15. ENSURE that all the consumable and replaced parts are disposed of safely in
accordance with local regulations and with minimum environmental impact.
16. AVOID, whenever possible, the servicing, cleaning or examining the drill with
the engine running.
17. AVOID whenever possible; servicing or providing maintenance to the drill
unless the tracks are adequately chocked and the parking brake is applied.
18. DO NOT alter the engine governor settings from those indicated in the engine
manual and the engine option plate.
19. ALWAYS replace damaged or lost decals. Refer to the parts manual for proper
location and part number for all decals.
20. Use only original circuit breakers with the specified current rating. Shut down
the drill immediately if trouble occurs in the electrical system.
21. Work on the electrical system or on electrical equipment may only be carried
out by a skilled electrician or by specially instructed personnel under the direct
supervision and control of an electrician and in accordance with the applicable
electrical engineering.
22. If provided for in the regulations, power supply to parts of the drill on which
inspection, maintenance and repair work is to be carried out, must be cut off.
23. Before starting any work, check the de-energized parts for the presence of
power and ground or short circuit them in addition to insulating adjacent live
parts and elements.
24. The electrical equipment of the drill is to be inspected and checked at regular
intervals. Defects such as loose connections or scorched cables must be
rectified immediately.
25. Welding, flame cutting and grinding work on the drill should only be done if
expressly authorized, as there may be a risk of explosion and fire.
26. Before beginning any welding, flame cutting and grinding operations, clean the
drill and surrounding area from dust and other flammable substances. Make
sure that the premises are adequately ventilated (risk of explosion). Place fire
blankets on and around equipment where welding, flame cutting or grinding to
protect equipment from damage when welding, flame cutting or grinding. Have
a fully charged and inspected fire extinguisher immediately available.
2-20
DRILLING SOLUTIONS
Section 2 - Safety
27. Winches and ropes must be inspected frequently for unforeseen wear patterns
and discarded according to certain criteria (refer to ISO 4305).
28. Check all lines, hoses and screwed connections regularly for any leaks and for
obvious damage. Repair damage immediately. Splashed oil may cause injury
and fire.
29. Depressurize all system sections and pressure pipes (hydraulic, compressed
air) that are to be removed in accordance with the specific instructions before
carrying out any repair work.
30. Hydraulic lines must be laid and fitted properly and correctly. Ensure that there
are no connections that are interchanged. The fittings, lengths and quality of
the hoses must comply with the technical requirements.
31. Observe all of the product related safety regulations when handling oil, grease
and other chemical substances.
32. Be careful when handling hot consumables (risk of burning or scalding).
Fueling
1. NEVER fill the fuel tank with the engine running, while near an open flame or
while smoking. ALWAYS wipe up any spilled fuel.
2. Do not spill fuel on hot surfaces.
3. Refuel in a well ventilated area.
4. Keep open lights, lighted smoking materials, flames or spark producing devices
at a safe distance when refueling.
5. Keep fuel nozzle in contact with tank being filled, or provide a ground to prevent
static sparks from igniting fuel.
6. Turn off cab and fuel heaters.
7. Never mix any other fuel with diesel oil. An explosion can occur.
Batteries
1. DISCONNECT battery cables when working on the electrical system or when
welding on the drill. Remove ground cable first.
2. BE SURE the battery area is well ventilated (clear of fumes) should it be
necessary to connect a jump battery or battery charger. Fumes from the battery
can ignite by a spark and explode.
3. BE SURE battery charger is OFF when making the connections if battery
charging is required.
4. Always wear safety glasses and protective gear when servicing batteries.
DRILLING SOLUTIONS
2-21
Section 2 - Safety
5. Connect the ground cable last when installing a battery.

6. Battery acid will burn skin, eat holes in clothing and cause blindness if splashed
into the eyes.
7. Batteries generate a highly explosive mixture. A spark could ignite these gases.
8. Do not short across batteries. The spark could ignite the gases.
9. Keep battery covers in place at all times. Be sure there is no connection
between the battery terminals and the cover.
Wire Rope & Cable

Winches and ropes must be inspected frequently for unforeseen wear patterns, and discarded
according to certain criteria (refer ISO 4305).
1. Wire rope running over drums and through sheaves creates pinch points. Do
not use hands or bars to guide wire rope onto drums; instead, use rope guides.
Keep clothing and all parts of the body away from running rope and from
machinery that moves the rope.
2. Replace wire rope when it is worn to the following:
a. Six (6) randomly distributed broken wires are found in one lay.
b. Wear of one-third (1/3) of the original diameter of the outside wires.
c. Evidence of any heat damage from any cause.
d. Any kinking or cracking occurs.
3. Make sure all hooks are connected properly.
a. Saddle and nuts must be around lifting side of the cable.
b. Always use a thimble when installing a hook.
c. Always use the correct number of clamps for cable size.
d. All hooks must have lock type dogs to prevent cable from jumping out of the
hook throat.
4. Do not allow cable to backlash on hoist or drum.
a. Make sure the cable spools properly on hoist or drum.
b. Do not overload the hoist or wire rope.
Hydraulic Maintenance Safety

The normal operating temperature of hydraulic oil is hot enough to cause serious burns. Use
precautions when working on any hot fluid lines or changing filters.
2-22
DRILLING SOLUTIONS
Section 2 - Safety
WARNING
Hot oil or components can burn. Avoid contact with hot oil or
components.
Do not allow used oil to drain into the ground. Dispose of used oil
properly and in accordance with local guidelines.
Cylinder Repairs or Replacement

1. When repairing cylinders, be sure to block them up to prevent dropping or
rolling off the drill.
2. After repairing or replacing cylinders, especially the feed or derrick raising
cylinders, purge all air out of each end of the cylinder before connecting it to the
drill. Air in one end can cause the derrick or rotary head to fall and cause an
accident.
3. Loosen feed cables or chains before trying to remove feed cylinders.
4. Plug all hoses as soon as they are removed from the cylinders to prevent oil
spills and slippery conditions.
5. Use a hoist to lift the larger cylinders.
Pumps and Motors

1. Make sure hoses are plugged when replacing pumps and motors.
2. Always replace pumps and motors with the same size and type.
3. Use the correct adapters when installing pumps or motors.
Valves
1. When working on valves, keep area clean to prevent contamination from
getting inside the valves.
2. Be sure the valve being installed is the same type as the one removed. Motor
and cylinder spools are not interchangeable and may cause an accident or a
failure of a component if used incorrectly.
DRILLING SOLUTIONS
2-23
Section 2 - Safety
Hoses
1. Do not replace a hose with one of lesser strength or capacity. Breakage or
leakage could result.
2. Do not use a will-fit hose as it may fail and cause an accident before it can be
replaced by the correct type.
Coolers and Fans

1. Never remove the fan guard unless the drill is shut down and locked out.
2. When testing fan speed, do so with the guard in place.
3. Do not try to remove debris from inside the fan guard. Stop the drill and lockout
the key switch before removing.
4. Be careful while washing out coolers with pressure washers. Spray can injure
eyes and damage equipment.
5. Coolers are heavy. Obtain a suitable hoist capable of lifting and moving coolers
and/or radiators before replacing.
Guards
1. If any guards must be removed from the drill to perform service, always replace
them before the drill is started.
2. If a guard becomes damaged or lost, repair or replace it before starting drill.
3. Do not cut out or modify a guard. It was designed to protect people from getting
injured.
Tracks
1. Use the correct procedure for adjusting the track tension.
2. Never release all the pressure from the track tensioning spring. It can cause an
accident.
3. Always raise the drill on the jacks before replacing idlers or track pads.
Lubrication
1. Never attempt to lubricate the drill while it is running, unless the drill is fitted with
an automatic lube injection system. Stop the drill for all maintenance.
2-24
DRILLING SOLUTIONS
Section 2 - Safety
2. To lubricate fittings on the tower, lay the tower down and use a manlift to
access hard to reach and inaccessible places. DO NOT climb the tower for
ANY reason.
3. To lubricate drive lines, reach through the guards. Do not remove them.
NOTE: If a lube point will not take grease, report it immediately. A bearing
can get hot and cause a fire if not lubricated properly.
Compressor
WARNING
The normal operating temperature of compressor oil is hot enough to

cause serious burns. Use precautions when working on any hot fluid
lines or changing filters.
Do not attempt to remove any plugs or open the drain valve before
making sure all air pressure has been relieved from the system.
1. Relieve all pressure in the receiver tank and lines before working on the
compressor system.
2. Do not allow tools or air powered equipment to be connected to the drill hoses.
They must be attached to the service regulator and the pressure adjusted to
the working capacity of the tool being used.
3. Do not remove any regulation or control hoses while the drill is running or when
pressure is still in the system. High pressure air can cause serious injuries.
4. Be careful when using service air to clean off the working area. High pressure
air can be dangerous.
5. Turn off drill air and exhaust the drill string before unscrewing drill pipe at the
table.
6. Do not turn on high pressure air too quickly when the air hoses are in the vicinity
of people. Hoses can jump and injure people, especially if there is water or oil
inside the hose.
DRILLING SOLUTIONS
2-25
Section 2 - Safety
Warning of Special Dangers

Overhead Electric Wires
When working with the drill, maintain a safe distance from overhead electric lines. If work is to
be carried out close to overhead electric lines, the working equipment must be kept well away
from them. CAUTION! DANGER! Check out the prescribed safety distances.
DANGER
If your Drill comes into contact with a live wire:
Do not leave the drill.
Warn others against approaching and touching the drill.
Have the live wire de-energized.
Tram the drill out of the hazard zone.
Do not leave the drill until the damaged line has been safely de-energized.
Ventilation
Operate internal combustion engines and fuel operated heating systems only in adequately
ventilated premises. Before starting the drill in enclosed premises, make sure that there is
sufficient ventilation.
Grade Limitations
Exceeding the slope or grade limitations of the drill and its configuration can cause the drill to
tip over. Prior to moving the drill into position, always determine the safe operating grade of
the drill with the tower up and down. Do not move the drill with the tower up.
Transportation Safety
Safety Precautions
The drill must be towed, loaded and transported only in accordance with the operating
instructions.
1. When towing the drill, observe the prescribed transport position, admissible
speed and the itinerary.
2-26
DRILLING SOLUTIONS
Section 2 - Safety
2. DO NOT attempt to load the drill on the transport vehicle without knowledge
and experience with the operation of the drill rig.
3. Keep the trailer deck clean of clay, oil, mud, ice, frost and other material that
can become slippery.
4. Use only appropriate means of transport and lifting gear of adequate capacity.
5. The fastening of loads and the instructions to the crane operators should be
entrusted to experienced persons only. The person giving the instructions must
be within sight or sound of the operator.
6. Always use a ramp when loading the drill rig on a transport vehicle. Be sure
ramps are of adequate strength, low angle, and proper height.
7. Use proper chock blocks in the front and rear of the wheels of the transport
vehicle when loading the drill rig.
8. Be sure the trailer is on level ground. Approach transport vehicle loading ramps
squarely to make sure the drill rig does not drop off the side of the ramp.
9. Position the drill on the transport vehicle, centered from side to side, and use
proper chock blocks in the front and rear of the tracks.
10. Move the tram/drill mode selector to DRILL. Make sure the tramming and drill
controllers are all in the STOP positions.
11. Position the engine speed control to LOW IDLE and turn key switch to OFF.
12. Secure the drill to the deck of the transport vehicle with adequate chains or
cables and blocks to meet local regulations.
13. Lock all lockable compartments.
14. Always know the overall height, weight, width and length of the drill and hauling
vehicle. MAKE SURE that there is sufficient clearance when crossing
underpasses, bridges and tunnels or when passing under overhead lines.
15. When moving the drill rig on public access roads, obey all traffic regulations and
be sure that proper clearance flags, lights and warning signs, including the
Slow Moving Vehicle emblem, are properly displayed. Know your
approximate stopping distance at any given speed. Never turn corners at
excessive speeds. Look in all directions before reversing your direction of
travel.
Towing Safety
The towing procedure is for moving a disabled drill a short distance, only a few meters (feet)
at a low speed not faster than 2 km/h (1.2 mph), to a convenient repair location. This procedure
is for emergencies only. Always haul the drill on a transporter if long distance moving is
required.
DRILLING SOLUTIONS
2-27
Section 2 - Safety
Shielding must be provided on the towing machine to protect the operator if the tow line or bar
should break.
WARNING
Personal injury or death could result when towing a disabled drill

incorrectly. Follow the recommendations below to properly perform the
towing procedure.
1. Block the tracks to prevent any movement of the tracks before releasing the
track brakes or before disconnecting the final gear train. The drill can roll free if
it is not blocked.
2. Relieve the hydraulic tank and hydraulic line pressure before any disassembly.
Operate the track propel controllers in both directions, with the engine stopped,
to relieve pressure.
3. Even after the drill has been turned off, the hydraulic oil can still be hot enough
to burn. Allow the hydraulic oil to cool before draining.
NOTICE
To tow the drill, both final drives must be disengaged. Do not operate the
travel motors with the final drives disengaged. Damage could result.
Clean the final drive covers and the nearby areas before disengaging the
drives. Dirt can contaminate and damage the propel motors, reduce
propel performance and cause drill malfunctions.
CAUTION
Use only draw bars for the towing requirement. Maximum towing speed =
2.0 km/h (1.2 mph). Maximum towing distance = 300 meters (984 feet).
2-28
DRILLING SOLUTIONS
Section 2 - Safety
2.3 - SAFETY DECALS & NAMEPLATES
Safety Decals List

Before you operate, maintain, work around or in any other way use this drill, read and
understand the safety decals and safety labels located on the drill. Follow all directions on the
labels. Do not remove or deface the labels. Replace them if they become damaged or lost.
Table 1: Safety Decals List

Ref.
Decal
Qty.
Location
Warning: Falling Derrick
4 ea.
Bottom of each Derrick Raising

Cylinders and Bottom of Derrick Front
Chord on each side.
Caution: Excessive Oil
1 ea.
On Side of Hydraulic Reservoir.
Warning: Rotating Parts
4 ea.
One on Alternator Guard; One on A/C

Guard; One on Water Injection Pump
Guard; One on Power Pack Base by
Pump Mounting Bracket.
Warning: Rotating Shaft
4 ea.
One on each Side of Guard, One

each side of Power Pack Base
Warning: Rotating Fan Blade
3 ea.
One on Dust Collector Fan Guard;

Two on Cooler Package Housing.
Warning: Hot Pressurized Fluid
1 ea.
One on Cooler Package Housing.
Warning: High Pressure
2 ea.
One Next To Filler Plug; One on

Receiver Tank Cover.
Warning: High Pressure Air
1 ea.
One on Receiver Tank Cover.
Warning: Combustible Gas
2 ea.
Two Per Battery Box Assembly
10
Warning: Riding Rotary Head
2 ea.
One on Rotary Head; One on Tower

Front Chord.
11
Warning: Falling Rotary Head
4 ea.
On Bottom of each Feed Cylinder;

One on each Front Derrick Chord.
12
Warning: Falling Pipe Carousel
2 ea.
One each Carousel Swing Cylinder.
13
Warning: Rotating Gears
2 ea.
Two on Lower End of Carousel.
14
Danger: Hazardous Voltage
1 ea.
One on Operators Console.
15
Warning: Do Not Modify Or Alter
1 ea.
One on Operators Console.
DRILLING SOLUTIONS
2-29
Ref.
2-30
Decal
Section 2 - Safety
Qty.
Location
16
Warning: Climbing Derrick
4 ea.
Two on each Front Derrick Chord.
17
Warning: Falling Objects
2 ea.
One on each Front Derrick Chord.
18
Warning: Liquid Explosion
13
ea.
One at each Heater Location.
19
Warning: High Pressure
4 ea.
Two Per Track: One Next to Access

Plate and One Next to Nitrogen
Accumulator.
20
Warning: Hazardous Voltage
10
ea.
One at each Heater.
21
Notice: Engine Failure
1 ea.
One at Top of Radiator next to Sight

Glass.
22
Notice: Hydraulic Oil Failure
1 ea.
One on Hydraulic Tank next to Sight

Glass.
23
Notice: Avoid Damage to

Electrical Components
3 ea.
One on Console in Cab; One on Top

of each Battery Box Cover.
24
Notice: Alternator Housing
2 ea.
One on Drive Line Cover; One on the

Alternator Housing.
25
Notice: Hydraulic Failure
1 ea.
Side of Hydraulic Tank next to Sight

Glass.
26
Notice: Fluid Spill
1 ea.
One on Right outside Bottom corner

of Hydraulic Tank
27
Safety Manual
1 ea.
One inside Operators Cab.
DRILLING SOLUTIONS
Section 2 - Safety
Safety Decals & Nameplates
Safety Decals
DRILLING SOLUTIONS
2-31
2-32
Section 2 - Safety
DRILLING SOLUTIONS
Section 2 - Safety
DRILLING SOLUTIONS
2-33
2-34
Section 2 - Safety
DRILLING SOLUTIONS
Section 2 - Safety
DRILLING SOLUTIONS
2-35
2-36
Section 2 - Safety
DRILLING SOLUTIONS
Section 2 - Safety
DRILLING SOLUTIONS
2-37
2-38
Section 2 - Safety
DRILLING SOLUTIONS
Section 2 - Safety
DRILLING SOLUTIONS
2-39
2-40
Section 2 - Safety
DRILLING SOLUTIONS
Section 2 - Safety
2.4 - HAZARDOUS SUBSTANCE PRECAUTION
General Information
The following information is provided to assist the owners and operators of Atlas Copco Drilling
Solutions Equipment. Further information may be obtained by contacting your Atlas Copco
Drilling Solutions Equipment Distributor.
The following substances are used in the manufacturing of this machine and may be
hazardous to health if used incorrectly.
Table 2: Hazardous Substance Precaution

Substance
Precaution
Anti-Freeze
Avoid ingestion, skin contact and breathing fumes
Hydraulic Oil
Engine Lubricating Oil
Compressor Oil
Preservative Grease
Rust Preventative
Engine Fuel
Battery
SAE Gear Oil
The following substances may be produced during the operation of this machine and may be
hazardous to health.
Table 3: Hazardous Substance Precaution

Substance
Precaution
Engine Exhaust Fumes
Avoid breathing fumes
Avoid buildup of fumes in confined spaces
Electric Motor Dust

(Brushes/Insulation)
Avoid breathing in dust during maintenance
Brake Lining Dust
Avoid breathing in dust during maintenance
DRILLING SOLUTIONS
2-41
Section 2 - Safety
2.5 - SYMBOL IDENTIFICATION
The following drill symbol information is provided to assist the owners and operators of Atlas
Copco Drilling Solutions Equipment. Further information may be obtained by contacting your
Atlas Copco Drilling Solutions Equipment Distributor.
2-42
DRILLING SOLUTIONS
Section 2 - Safety
DRILLING SOLUTIONS
2-43
2-44
Section 2 - Safety
DRILLING SOLUTIONS
Section 2 - Safety
DRILLING SOLUTIONS
2-45
2-46
Section 2 - Safety
DRILLING SOLUTIONS
Section 2 - Safety
DRILLING SOLUTIONS
2-47
Section 2 - Safety
This page intentionally blank
2-48
DRILLING SOLUTIONS
Section 3 - Specifications
DRILLING SOLUTIONS
3-1
SECTION 3 - SPECIFICATIONS
SPECIFICATIONS
General Description
The PV-271 and PV-275 series drills belong to the Atlas Copco Drilling Solutions Pit Viper PV270 Series product line.
The PV-271 drill is a crawler mounted, hydraulic tophead drive, single-pass rotary drill
specifically designed for rotary/percussive action drilling of blastholes with a single-pass depth
capability of 55 ft. (16.8m) and a total depth capability of 105 ft. (32.3 meters) and a maximum
hole diameter of from 7-5/8 in. to 10-5/8 in. (193 mm to 270 mm) on prepared benches which
are flat and firm. The PV-271 utilizes a diesel engine to drive the air compressor and hydraulic
system. Operation of the drill is performed using electric over hydraulic controllers
ergonomically located so that the operator faces the drill centralizer while drilling. The PV-271
comes equipped with an asymmetrical rotary screw air compressor.
The PV-275 drill is a crawler mounted, hydraulic tophead drive, multi-pass rotary drilling rig
specifically designed for rotary/percussive action drilling of blastholes up to a maximum depth
of 195 ft. (59.4m) and a maximum hole diameter of from 7-5/8 in. to 10-5/8 in. (193 mm to 270
mm). The PV-275 utilizes a diesel engine to drive the air compressor and hydraulic system.
Operation of the drill is performed using electric over hydraulic controllers ergonomically
located so that the operator faces the drill centralizer while drilling. The PV-275 comes
equipped with an asymmetrical rotary screw air compressor.
Drilling functions on the PV-270 Series drills are hydraulically powered. Compressed air is
used to clean the hole. The hydraulic pumps and the compressor are driven by a diesel
engine. The systems that support the drilling and propelling functions of the drill are controlled
by pneumatic, hydraulic and electrical components.
Table 1: General Specification

General Specifications
Description:
Hole Diameter (Rotary)

Bit Load:
Maximum Depth:
3-2
PV-271 (Single Pass)
PV-275 (Multi-Pass)
Tophead drive, singlepass, track mounted

blasthole drill for mining
applications
Tophead drive, multi-pass,

track mounted blasthole
drill for mining applications
7-5/8 to 10-5/8 (193 mm to 270 mm)

75,000 lb. (333.6kN)
55 ft. (16.8m) single-pass
depth with tracks ground
and ability to pull bit 6 in.
(152.4mm) off level above
bit basket for changes. 105
ft. (32m) maximum depth.
195 ft. (59.4m)
DRILLING SOLUTIONS
General Specifications
Drill Rod Diameters:
6-1/4, 7, 7-5/8,8, 8-5/8 (159mm, 178mm, 194mm,

203mm, 219mm)
Drill Rod Wall Thickness:
1 inch (25.4mm)
Drill Rod Length:
25 ft.(7.6m)
40 ft. (12.2m)
Operating Weight:
165,000 to 175,000 lb. [74,844kg (734.0kN) to 79,380kg

(778.4kN)]
Drill Applications
The PV-270 Series drills are built in accordance with state of the art standards and recognized
safety rules. Nevertheless, misuse may constitute a risk to the life and limb of the user or third
parties, and may cause damage to the drill or other material property.
The PV-270 Series drill must be used in accordance with its designated use as described in
the operating manual. The drill must only be operated by safety conscious persons who are
fully aware of the risks involved in operating the drill. Any functional disorders, especially those
affecting the safety of the drill, must be corrected immediately.
Designated Applications
The PV-271 is the single-pass version of the PV-270 series. The PV-271 is designed
exclusively for production blasthole drilling for mining applications by rotary/percussive action
with a single-pass depth capability of 55 feet (16.8m) and a total depth capability of 105 ft.
(32.3m) with a 25 ft. (16.76m) drill pipe change on prepared benches which are flat and firm.
The nominal hole size diameter ranges from 7-5/8 in. (194mm) to 10-5/8 in. (270mm) for rotary
bit applications. The hydraulic cylinder driven cable feed system is capable of 75,000 lbs.
[34,020kg (333.6kN)] of bit loading. The drill operating weight is between 165,000 lbs.
[74,843kg (734.0kN) to 175,000 lbs [79,379kg (778.4kN)].
PV-275 (Multi-Pass)
The PV-275 is the multi-pass version of the PV-270 series. The PV-275 multi-pass drill is
designed exclusively for production blasthole drilling for mining applications by rotary/
percussive action, to depths of 195 ft. (59.4m) with a 40 ft. (12.19m) drill pipe change, on
prepared benches which are flat and firm. The nominal hole size diameter ranges from 7-5/8
in. (194mm) to 10-5/8 in. (270mm) for rotary bit applications. The hydraulic cylinder driven
cable feed system is capable of 75,000 lbs. [34,020kg (333.6kN)] of bit loading. The drill
operating weight is between 165,000 lbs [74,843kg (734.0kN) to 175,000 lbs [79,379kg
(778.4kN)].
DRILLING SOLUTIONS
3-3
WARNING
Set up the drill on a level surface. If this is not available, the site should
be adequately prepared prior to drill setup.
Operating the drill within the limits of its designated use also involves
compliance with the inspection and maintenance directives contained in
the operating manual.
Non Designated Applications

The PV-270 series drills are not designed for pioneering or earth moving applications. The PV270 series drills are not designed for use on inclined surfaces or on soft and unstable ground.
Use of the drills for purposes other than that mentioned (such as for towing other vehicles or
equipment) is considered contrary to its designated use. The manufacturer and/or supplier
cannot be held liable for any damage resulting from such use. The risk of such misuse lies
entirely with the user.
Design Features
1. The PV-271 blasthole drill is a crawler mounted, hydraulic tophead drive,
single-pass drill rig designed specifically for production blasthole drilling in
mining applications by rotary / percussive action on prepared benches which
are flat and firm.
2. The PV-270 Series utilize an excavator-type undercarriage driven directly by a
planetary gear system and two hydraulic motors. A walking beam oscillation
yoke allows the rig to propel over uneven ground with reduced torsional
stresses on the main frame.
3. The PV-270 Series drills are powered by a large diesel engine and includes a
large cab with ample head room. The hole range is 7-5/8 in. to 10-5/8 in. (194
mm to 270 mm) diameter.
4. The PV-270 Series drills utilize a diesel engine connected directly to a threehole hydraulic pump drive gearbox on one end and the air compressor directly
connected to the other end. The pump drive gearbox, diesel engine and air
compressor are mounted on a floating power pack. This independent frame
strengthens the main frame and floats to maintain proper power train
alignment.
5. The PV-270 Series drills are equipped with an oil flooded asymmetrical rotary
screw design compressor for high performance rotary drilling. Tapered roller
bearings are used on the air end to handle thrust and radial loads.
6. Drilling functions are hydraulically powered. Compressed air is used to clean
the hole. The hydraulic pumps and the air compressor are driven by a diesel
3-4
DRILLING SOLUTIONS
engine. The systems that support the drilling functions are controlled by
hydraulic and electrical components.
7. The PV-270 Series drills incorporate three (3) leveling jacks, as a standard
feature, to keep the drill level and stable while drilling. A four jack option is also
available.
8. The tower is constructed of welded rectangular steel tubing. The PV-271
features a 55 foot (16.76m) single-pass depth with a 2-rod internal carousel rod
changer for 25 foot (7.6m) rods; and the PV-275 features a 195 foot (59.4m)
multi-pass depth capacity with a four rod carousel for 40 foot (12.19m) rods.
The tower is raised and lowered by two hydraulic cylinders.
9. Drill rod changing is done by moving drill rod in and out of the carousel and
rotary head. The rotary head is used to move all drill rod in and out of the hole.
All the drilling functions are controlled from the operators console adjacent to
the drill table. The operating controls and gauges are positioned within easy
reach of the operator.
10. Built to last, the structural components and integrity of the PV-270 Series drill
separate this drilling rig from all of its competitors. The crawler mounted, deck
powered, blasthole drill is designed for heavy duty drilling, providing a pullback
force of up to 35,000 lb. [15,876 kg (155.7kN)].
11. The PV-270 Series drills have a 188 hp spur gear rotary head which provides
9,000 ft/lb. (12,202.4Nm) of torque.
Enviroment Rate Factor Ranges

Duty:
1. Heavy - Hard Rock
2. Normal - Soft Rock
3. Light - Sand and Gravel
Ambient Temperature:
1. Hot- Above 125F (52C)
2. Nominal- Between limits of 125F (52C) Maximum and 15F (-9C) Minimum.
3. Cold- Between limits of 15F (-9C) and -30F (-35C)
4. Extreme Cold- Below -30F (-35C)
Service:
1. Excellent- Well Prepared Benches, Scheduled Maintenance Program,
Advanced Training of Operators and Mechanics.
DRILLING SOLUTIONS
3-5
2. Nominal- Good Operating Conditions, Normal Maintenance, Basic Training for

Operators and Mechanics.
3. Poor- Bad Operating Conditions, Limited Maintenance, Limited Training for
Operators and Mechanics.
Application Type:
1. Construction - Nominal Application
2. Aggregates - Light Application
3. Gold - Heavy Application
4. Copper - Heavy Application
5. Coal - Nominal Application
6. Iron - Heavy Application
7. Waterwell - Light Application
8. Oil & Gas - Nominal Application
Operational Limitations
Ambient Temperature Range:
The standard drill comes equipped for a nominal ambient temperature working range between
limits of 125F (52C) Maximum and 15F (-9C) Minimum.
Ground Pressure:
The PV-270 Series drill utilizes an excavator type undercarriage with design ground pressure
limit of 13 psi (89.64 kPa).
Maximum Allowable Slope Angle:
The drills come equipped for operation on slopes not exceeding 5 degrees inclination.
WARNING
Do not move or transport the PV-270 Series Blasthole drill with the tower
in the raised (up) position.
3-6
DRILLING SOLUTIONS
Operating Conditions For Stability:

Stability is affected by the tower position and orientation of the drill on the slope, surface
stability (bearing strength), and wind conditions. Refer to the PV-270 Series Stability/
Gradeability chart for further guidance. Note: Drilling Solutions does not authorize use on
slopes exceeding 5.
WARNING
Set up the PV-270 Series Blasthole drill on a level surface. If this is not
available, prepare the site and the way to the site before set up and
drilling with the PV-270 Series drill.
Contact your local Atlas Copco Drilling Solutions distributor, dealer or
service office for further information.
Sound Pressure Limitations (EEC Requirement):
Operator Exposure to Noise Emission In accordance with the requirements of clauses 1.75f
of Annex I of the Machinery Directive 89/392/EEC and Directive 91/368/EEC, EN791 Annex
A Cl. 4.1, the drill has been tested at normal engine operating speed at the following maximum
values: At Operators Station (in closed cab, seated/standing positions = less than 85 dBA.
Tests were conducted with machine running at operating engine speed. Machine was in an
open field with no structural objects reflecting sound.
Vibration Exposure Limitations (EEC Requirement):
Operator Exposure to Vibration In accordance with the requirements of clauses 22.2 of Annex
I of the Machinery Directive 89/392/EEC and Directive 91/368/EEC, EN791Annex ACl. 4.1,
the drill has been tested and the weighted root mean square acceleration value to which arms
are subjected does not exceed 2.5 m/s. Weighted root mean square acceleration to which
body (feet and posterior) is subjected does not exceed 0.5 m/s. Tests were conducted with
machine running at operating engine speed . Machine was on a concrete surface.
DRILLING SOLUTIONS
3-7
3-8
DRILLING SOLUTIONS
DRILLING SOLUTIONS
3-9
Standard Equipment and Specifications
DANGER
Your life may be endangered if the following is not complied with. DO

NOT add attachments to the machine that intrude into operators
protective area, reduce visibility, restrict emergency exits or add weight
exceeding certification weight. See the operators manual or contact your
dealer for complete inspection requirements and maintenance
instructions.
Standard Features
1. Insulated, pressurized, air conditioned cab with tinted glass and suspension
operator seat.
2. 1900CFM @ 110 psig air compressor (54.0 cubic m/min. @7.6 bar)
3. Cummins QSK19 diesel engine - 755 HP (563kW) @ 1800 RPM
4. Caterpillar C27 diesel engine - 800 HP (597kW) @ 1800 RPM
5. Caterpillar C32 diesel engine - 950 HP (708kW) @ 1800 RPM
6. Hydraulic cylinders driven cable feed system
7. Hydraulic motor driven rotary head; maximum 8,700 ft-lbs (11,800 Nm) torque;
speed range 0 - 150 rpm
8. Rotary head tachometer on operators console
9. Remote hydraulic tower pinning
10. No-bump rod changer
11. Hydraulically powered breakout wrench (fork chuck)
12. Hands Free auxiliary hydraulic chain wrench
13. 8000 lb. (3628.7 kg) capacity auxiliary hoist.
14. Separate air intake filters for engine and air compressor.
15. Cooling package (hydraulic/compressor oil cooler, engine radiator and engine
charge air cooler) rated to 125F (52C) ambient at standard air conditions.
16. PV-271 Single Pass:
a. Two rod carousel, hydraulic cylinder indexing, for 6-1/4 to 7-5/8 diameter
x 25 drill pipe (159mm to 193mm x 7.62m). This is 55 ft. (16.76m) singlepass depth, 105 ft. (32m) maximum depth.
b. Caterpillar 345XL undercarriage with hydraulic track tensioners
3-10
DRILLING SOLUTIONS
17. PV-275 Multi-Pass:

a. Four rod carousel, gear indexing, for 6-1/4 to 7-5/8 diameter x 40 drill pipe
(158.75mm to 200mm x 12.19m). 195 foot (59.4m) maximum depth.
b. Caterpillar 345SL undercarriage with hydraulic track tensioners
18. 350 U.S.gallon (1,325 liters) fuel capacity.
19. Hydraulically retractable dust curtains
20. Jack Up Indicator Lights.
21. Two 48 inch stroke drilling end and One 60 inch stroke non-drilling end (option
two non-drilling end) leveling jacks
22. Wide flange structural steel beam frame with oscillation yoke mounting
23. Full deck service catwalks and railings.
24. Backup Alarm
25. 12-light night lighting package 70 watt halogen
Note: Specifications represented are calculated values at 100% efficiency.
Main Frame
The PV-270 Series drill main frame, designed and weld fabricated by Atlas Copco Drilling
Solutions, makes the drill exceptionally stable. The 24 in. (610 mm) by 162 lbs/ft (241 kg/m)
wide flange structural steel beam for both rails and crossbeams.
Table 2: Mainframe Specification:

Mainframe Specification:
Design:
Weld fabrication by Atlas Copco Drilling Solutions
Construction:
24 x 162 lb/ft. (610 mm x 241 kg/m) Wide Flange

structural steel I-Beam
Leveling Jacks:
Non Drilling End (Standard):
(1) 7 bore x 60 stroke (177.8mm x 1,524mm)
Non Drilling End (Option):
Drilling End :
Access:
DRILLING SOLUTIONS
Two access ladders with flexible lower steps
3-11
Leveling Jacks
The standard PV-270 Series drills utilize a three point hydraulic leveling jack system to keep
the drill level and stable while drilling. An optional four (4) leveling jacks system is available.
Table 3: Leveling Jack Specifications:

Leveling Jack Specifications:
Type:
Hydraulic cylinder with double holding valves
Number:
Three (standard with drill Number: )

Four (available as an option)
Bore x Stroke/Rod Diameter:

(Two) Drilling End:
7 in. bore dia. x 48 in. stroke/ 5.25 in. rod diameter

(177.8 mm x 1,219 mm / 133 mm)
(One) Non-Drilling End (Standard):

(177.8 mm x 1,524 mm / 133 mm)
(Two) Non-Drilling End (Option):

(152 mm x 1,524 mm / 114 mm)
Lifting Capacity, each:
77,000 lbs. each (34,927 kg)
Double Holding Valves:
Set 4500 PSI (310.3 bar))
Jack Pad Diameter:

(Two) Drilling End:
(One) Non-Drilling End: (Optional
Two Non-Drilling End)
Pad Bearing Pressure (Maximum):
Triangle shape 760 square in. each (4903 square

cm) or Round shape 34 in.dia. (863.6 mm)
Front: 58 psi (400 kPa)

Rear: 77 psi (531 kPa)
Jack Indicator Lights:
Lights on the cab console illuminate when the jacks

are fully retracted.
Undercarriage and Propel System

The PV-270 Series drill utilizes an excavator type undercarriage, built to Atlas Copco Drilling
Solutions specifications. A walking beam oscillation yoke allows the drill to propel over
uneven ground without imposing excessive torsional stress on the main frame.
The undercarriage is driven directly by a planetary gear system and two hydraulic motors. Both
tracks are individually controlled with each track acting as an independent unit for steering
purposes. The tracks are hydraulically adjustable with a spring recoil system and are equipped
with replaceable triple bar grouser pads.
3-12
DRILLING SOLUTIONS
Table 4: Undercarriage and Propel Specifications

PV-271 Specifications
Model:
Caterpillar 345XL
Atlas Copco ACGT3400EXT.
Construction:
Excavator-style lower with 345-class rollers, sprockets, and

tracks
Length:
21-5 (6.53 m)
Mounting:
Oscillating walking beam (5 each side; 10 total)
Side Frame:
Custom Weld Fabrication
Rated GVW:
175,000 lbs (79,379 kg) G.V.W.
Take Up
Adjustment:
Grease slack adjustment, spring recoil
Rollers:
Top Rollers:
3 per side, 345 class with sealed for life bearings
Bottom Rollers:
Location:
Equally Spaced between idler and sprocket
Towing Release:
Track drive manually releases

for emergency towing
Track Final Drive:
GFT110 planetary reduction
Final Drive Ratio:
99:1
Propel Motors:
(Two) Hydraulic, axial piston - 9.76 cubic in./rev. (160 cubic cm/
rev.)
Motor Ground
Clearance:
19.4 in. (49.3 cm)
Drive:
Hydrostatic, closed loop motor drive, through speed reducer to

drive sprocket
Propel Speed:
0-1.1 mph (0-1.77 km/hr.)
Track Pads:Width:
35.4 in. (899 mm)
Track Pad Type:
Triple Bar Grouser
Brake:
Plate type, spring applied, hydraulically released
Turnability Ratio:
0.4
Ground Pressure:
13 psi (89.6 kPa)
DRILLING SOLUTIONS
Standard disengagement for

towing
3-13
Table 5: Undercarriage and Propel Specifications

PV-275 Specifications
Model:
Caterpillar 345SL
Atlas Copco ACGT3400
Construction:
Excavator-style lower with 345-class rollers, sprockets, and

tracks
Length:
19-5 (5.92m)
Mounting:
Oscillating walking beam 5 each; total 10
Side Frame:
Custom Weld Fabrication
Rated GVW:
175,000 lbs (79,379 kg) G.V.W.
Take Up
Adjustment:
Grease slack adjustment, spring recoil
Rollers:
3-14
Top Rollers:
Bottom Rollers:
Location:
Equally Spaced between idler and sprocket
Towing Release:
Track drive manually releases

for emergency towing
Track Final Drive:
GFT110 planetary reduction
Final Drive Ratio:
99:1
Propel Motors:
(Two) Hydraulic, axial piston - 9.76 cubic in./rev. (160 cubic cm/
rev.)
Motor Ground
Clearance:
19.4 in. (49.3 cm)
Drive:
Hydrostatic, closed loop motor drive, through speed reducer to

drive sprocket
Propel Speed:
0-1.1 mph (0-1.77 km/hr.)
Track Pads:Width:
35.4 in. (899 mm)
Track Pad Type:
Triple Bar Grouser
Brake:
Plate type, spring applied, hydraulically released
Turnability Ratio:
0.41
Ground Pressure:
13 psi (89.6 kPa)
Standard disengagement for

towing
DRILLING SOLUTIONS
Tower, Carousel and Drill Pipe Handling

The tower is constructed of welded rectangular steel tubing with cross bracing on both sides
and the back. The fabrication is constructed by Atlas Copco Drilling Solutions in a special rollover fixture that helps provide optimum welds. A set of sheaves at the top and bottom of the
tower support the feed cables.
The tower assembly features the hydrostatic driven rotary head and the hydraulic drill feed
system. The feed system consists of the rotary head, two hydraulic feed cylinders and feed
cable connected to the top and bottom of the rotary head.
An internal carousel type drill rod changer is mounted in the tower. The tower is raised and
lowered by two hydraulic cylinders. Tower pinning is performed from within the operators cab.
An angle drilling option is also available.
Table 6: Tower Specifications

Tower Specifications
PV-271 Single-Pass
PV-275 Multi-Pass
Tower Design:
Weld fabrication by Atlas Copco Drilling Solutions
Construction:
Four (4) main member, open front, rectangular steel

tubing.
Tower Raising:
Rotation:
Rod Changing:
Drill Pipe Length:

Carousel Swing:
Carousel Index:
Two hydraulic cylinders; live tower (raise and lower with

full carousel and rotary head at top of tower.
Tophead drive
Two (2) rod internal
carousel with key-lock
retention
Four (4) rod internal

carousel with key-lock
retention
25 feet (7.6 mm)
40 feet (12.2 mm)
Two (2) hydraulic cylinders

Hydraulic Cylinder
Hydraulic motor driven

bullgear
Carousel Protection:
No-bump feed force limit system when carousel is out

of stowed position
Rod Support:
Hydraulic cylinder clamping and actuation to center drill

rod.
Primary Breakout:
Hydraulically actuated sliding fork, reverse rotation,

actuated from operators console
Auxiliary Breakout:
Hydraulically actuated tong wrench with adjustable jaw

for wear compensation (patented design)
Auxiliary Hoist:
Hydraulic motor driven hoist; 8000 lb. (3628.73kg) bare

drum capacity; 4000 lb. (1814.4kg) actual rating
DRILLING SOLUTIONS
3-15
Tower Specifications
Hose Management:
Traveling hose carrier with hose tray guide
Drill Pipe Change

Drill pipe changing is accomplished from the operators console. A hydraulic positioned sliding
fork wrench is used to break the joint with limited impact that minimizes shock loads on the
tower, carousel, rotary head and feed components.
The carousel holds two 25 ft. (7.6m) drill rods. Two hydraulic cylinders swing the rod changer
into and out from the loading position under the rotary head. A single hydraulic cylinder rotates
the carousel to index the drill pipe under the rotary head for changing. An exclusive keylock
carousel design securely locks the drill pipe at both the bottom and the top of the carousel to
insure maximum safety for drill rod storage and changing.
PV-275 (Multi-Pass)
The carousel holds four 40 ft. (12.19m) drill rods. Two hydraulic cylinders swing the carousel
into and out from the loading position under the rotary head. A hydraulic motor driven bullgear
rotates the carousel to index the drill pipe under the rotary head for changing. An exclusive
keylock carousel design securely locks the drill pipe at both the bottom and the top of the
carousel to insure maximum safety for drill pipe storage and changing.
An auxiliary hoist is provided as standard for drill pipe and accessory handling. A No-Bump
drill pipe changer, which limits the feed force of the rotary head until the carousel is moved into
the complete out position and prohibits movement of the carousel if the head is not at the top
of the tower, is provided as a standard.
Table 7: PV-271 Standard Drill Pipe
3-16
Pipe
Diameter
(inches)
Pipe
Diameter
(Millimeters)
Maximum
Number
Hole Depth
(Feet)
Hole Depth
(Meters)
6-1/4
159mm
105 ft.
32 m
178mm
105 ft.
32 m
7-5/8
194mm
105 ft.
32 m
203mm
80 ft.
24 m
8-5/8
219mm
80 ft.
24 m
DRILLING SOLUTIONS
Table 8: PV-275 Standard Drill Pipe

Pipe
Diameter
(inches)
Pipe
Diameter
(Millimeters)
Maximum
Number
Hole Depth
(Feet)
Hole Depth
(Meters)
6-1/4
159mm
195 ft.
59.4 m
178mm
195 ft
59.4 m
7-5/8
194mm
195 ft
59.4 m
203mm
115 ft.
35 m
8-5/8
219mm
115 ft.
35 m
Table 9: Drill Pipe Specifications

Diameter
Rig Type
6-1/4
(159mm)
PV-271
7 (178mm)
PV-271
PV-275
PV-271
8 (203mm)
PV-271
Thread
25ft. (7.62m)
1 in. (25.4mm)
4 Beco
1 in. (25.4mm)
4-1/2 Beco
1 in. (25.4mm)
5-1/4 Beco
1 in. (25.4mm)
5-1/4 Beco
1 in. (25.4mm)
6 Beco
40ft. (12.2m)
40ft. (12.2m)
25ft. (7.62m)
PV-275
40ft. (12.2m)
25ft. (7.62m)
PV-275
8-5/8
(219mm)
Wall
25ft. (7.62m)
PV-275
7-5/8
(194mm)
Length
PV-271
40ft. (12.2m)
25ft. (7.62m)
PV-275
40ft. (12.2m)
Rotary Head
The rotary head (also called power head or tophead) is used to rotate the drill bit and to add
and remove drill rod from the drill string. The drill string is directly connected to the rotary head
and all rotation and feed pressure is exerted through the rotary head.
Two hydraulic motors power the rotation of the rotary head. The rotation pressure gauge
(Section 4 Operating Controls and Instruments), located on the control console, will show the
amount of hydraulic pressure being applied to the rotary head motors in the form of rotation
speed. Speeds varying from 0-150 rpm can be obtained using this rotary head. Refer to
SECTION 4.1 for further information about the operators controls.
A replaceable spindle adapter between the rotary head spindle and the drill pipe is furnished
as standard equipment, along with replaceable head guides. Pulldown (feed) and pullback (retract) cables are attached to mounting plates which are attached to the rotary head housing.
DRILLING SOLUTIONS
3-17
Table 10: Rotary Head Specifications

Rotary Head Specifications
Design:
Two stage, spur gear reduction in cast housing
Rotation Motors:
Two (2) variable displacement, axial piston hydraulic motors

(6 cu. in/rev.)
Rotation Power:
181 HP (136kW) (100% efficiency)
Rotation Torque:
8,700 ft/lb. (1203 kg/m gross at maximum displacement)

(0-105 RPM)
Rotation Speed:
150 RPM at minimum displacement (6500 ft/lb. torque)
Speed Control:
Infinitely adjustable throughout range; maximum speed set by

manual adjustment of motor displacement
Head Guides:
Replaceable, Nylatron
Function:
Rotate the drill bit
Feed System
The closed-loop hydrostatic feed system is powered through two dual rod, dual piston
hydraulic feed cylinders that raise and lower the rotary head smoothly and positively by way
of high strength steel cables for pulldown (feed) and pullback (retract). This system operates
more efficiently than other designs due to lower flows and the resulting reduced pressure drop.
This enables the hydraulic pumps to operate in the more efficient portion of their performance
curves. When the carriage structure moves up and down the tower, the rotary head moves in
the same direction but at twice the speed of the carriage. The use of Feed Cable System has
an advantage over Mechanical Feed, such as overall weight reduction in the tower and feed
system. Also easier to detect wear in the cable system.
The automatic cable tensioning on the PV-270 Series ensures accurate head alignment,
improves cable life and eliminates drill downtime for cable tensioning. The PV-271 and PV275 use a cable feed system which is lighter and less expensive than traditional chain feed
systems. The cable also leads to smoother drilling, which helps increase the life of the bit and
feed system.
The pulldown pressure gauge (section 4 Operating Controls), located on the control console,
shows the amount of hydraulic down pressure being exerted on the bit by the feed (cylinders)
system. A single drill feed controller for the operation of direction and rate of drill feed allows
the operator greater ease of operation while providing faster down feed and retract speeds
(see section 4 Operating Controls).
3-18
DRILLING SOLUTIONS
Table 11: Feed System Specifications

Feed System Specifications
Design:
Hydraulic cylinder driven cable feed
Maximum Hole Depth:
The PV-271 (single-pass) drill is designed to drill to

depths of 55 ft. (16.76 m) in a single pass. A standard
carousel, which holds two additional 25 ft. (7.6 m) rods,
increases on-board depth capacity to 105 ft. (32m).
The PV-275 (multi-pass) drill is designed to drill to a
maximum depth of 195 ft. (59.4 m). A standard carousel
holds four 40 ft. (12.19 m) rods.
Drill String:
The drill string consists of the rotary head spindle, shock

sub/crossover sub or spindle sub, drill rod, bit sub or
stabilizer and the drill bit.
Feed Cylinders:
Two (2) dual rod, dual piston hydraulic cylinders

(patented design)
Bit Load:
0 to 75,000 lbs. (0 to 34,019 kg)
Cylinder Bore:
5.0 in. (127 mm)
Rod Diameter:
3.75 in. (95.25 mm)
Stroke:
PV-275
23 ft.-3 in. (7.1 m)
PV-271 (55 ft. SP)
32 ft.-3 in. (9.8 m)
PV-271 (65 ft. SP)
33 ft.-3 in. (10.1 m)
Sheave Outside Diameter:
23.5 in. (597 mm)
Hydraulic Pulldown Force:
0 to 70,000 lbs. (0 to 31,752 kg)
Hydraulic Pullback Force:
0 to 35,000 lbs. (0 to 15,876 kg)
No. of Pulldown Sheaves:
Four (4)
Pulldown (Feed) Cables:
Two (2)-1 in. (25.4 mm) diameter
No of Pullback Sheaves:
Four (4)
Pullback (Retract) Cables:
Two (2)-in. (25.4 mm) diameter
Feed Speed:
126.7 ft./min. (38.6 m/min.) feed
Retract Speed:
158.1 ft./min. (48.2 m/min.) retract
Automatic Tensioning:
Automatic tensioning - hydraulic motor driven jackscrews

for pulldown cables; hydraulic cylinders for pullback
cables (patented design)
DRILLING SOLUTIONS
3-19
Power Pack
The power pack (or power train) consists of a diesel engine (optionally an electric motor)
directly coupled to an air compressor on one end and a hydraulic pump drive on the other end.
This complete power pack assembly is mounted on its own sub base, which in turn is mounted
to the rig frame. The in-line drive train configuration maximizes mechanical efficiency. The
separate floating sub base isolates the components from drilling and propel shock loads and
helps to maintain alignment between them.
A heavy duty engine silencer/muffler is provided to reduce engine noise emission. Separate
engine and air compressor air cleaners have quick release dust drop covers, as standard, for
easy maintenance.
Table 12: Powerpack Specifications

Powerpack Specifications
Diesel Engine Options:
Cummins QSK19C/755HP (555 kW) @ 1800 RPM

Caterpillar C27 /800 HP (596 kW) @ 1800 RPM
Caterpillar C32 /950 HP (708 kW) @ 1800 RPM
Electric Motor (Option)
WEG 6808 - 6000 VAC @ 50 HZ - 700 HP (521 kw) @

50 HZ
WEG 6811 - 4160 VAC @ 60 HZ - 900 HP (671 kw) @ 60
HZ
Engine Speed:
1800 RPM / 2100 RPM for 1450 CFM
Emissions Rating:
EPA Certified for 750+ hp TIER 2
Air Compressor:
XL1900 CFM @ 110 PSI

XL2600 CFM @ 110 PSI
1450 CFM @ 350 PSI
3-20
Cooling System:
Side by side radiator, hydraulic oil / compressor oil

cooler, engine radiator and engine charge air cooler.
Cooling Capability:
125F (52C)
Fuel Capacity:
350 gallon (1324.89 liter) capacity is standard. Optional

625 gallons (2365.88 liters) capacity in two tanks is
available.
Powerpack Mounting:
Isolation mounted subframe
Air Cleaners:
Separate three-stage air cleaners for engine and air

compressor (2 air cleaners required for Caterpillar
engine).
DRILLING SOLUTIONS
Cooling Package
The single side by side coolers package is designed to cool the hydraulic oil, engine oil,
compressor oil and diesel engine coolant. The coolers are mounted side by side in one
package and each section can be individually removed for easy maintenance. This package
provides 125F (52C) ambient cooling with a single motor assembly and a large fan rotating
at relatively low speeds. This design is more efficient and produces less noise than dual cooler
arrangements. Low oil pressure, low coolant level, high water temperature or high compressor
temperature will shut down the engine.
Table 13: Cooling System

Cooling System Specifications
Type:
Side by side radiator, hydraulic oil / compressor oil cooler,

engine radiator and engine charge air cooler
Fans:
Hydraulically driven, 54 (1371.6mm) diameter, 8-blade
Fan drive:
Fixed displacement, axial piston motor 8 cu. in/rev (131 cc/rev)
Rating:
125F (52C) ambient at sea level
Function:
Cools the engine water, hydraulic and compressor oil
Air Compressor
The standard air compressor used on the 270 series drill are manufactured by Ingersoll-Rand
and are of the oil flooded asymmetrical rotary screw design. Tapered Roller bearings are used
to handle thrust and radial loads. The receiver capacity is 38 gallon (144 liter). The compressor
is directly driven by the diesel engine (Optional Electric Motor).
Regulation of the low pressure or high pressure compressor is controlled by an ON-OFF type
system. When the drilling operation does not demand air, the air compressor load can be
removed, thereby conserving engine horsepower, extending compressor life and providing
ease of starting, particularly under cold weather conditions. A standard oil pump is available
to maintain continuous oil flow when the compressor inlet is closed.
Standard equipment for the air compressor includes a separate three-stage dry type air
cleaner and full instrumentation and controls. The lubrication system includes an oil cooler,
bypass valve, oil filter, oil pump, and combination air receiver and oil separator tank. A safety
shut down system is provided for high discharge air temperature.
The oil pump allows the operator to close the intake valve when no air is required. This greatly
reduces the engine load which saves fuel and facilitates cold weather starting.
DRILLING SOLUTIONS
3-21
Low Pressure Air Compressor Specifications

Low pressure compressors are the single stage asymmetrical rotary screw type with tapered
roller bearings and lubricated by a positive gear oil pump. For low pressure compressors with
EARS see section 7-4.2 for information.
Table 14: Low Pressure Air Compressor

Type:
Low pressure, single stage, oil flooded asymmetrical

rotary screw
Volume:
1900, 2600 CFM @ 110 psi, (53.81 cu. m/min. @ 758

kPa),
Bearing Type:
Tapered Roller Bearing
Air End Lubrication:
Positive, Gear Oil Pump
Receiver Capacity:
38 gallon (143 liters)
Air Cleaners:
Three 3-stage with 1 primary and 1 safety element
Dirt Alarm Indicator:
Restriction indicators indicate when filters require

service.
Oil Type:
PROTEC (low pressure only)
Operational RPM:
1800 RPM
Power Source:
Directly driven by diesel engine (Optional Electric Motor)
High Pressure Air Compressor Specifications

High pressure compressors are the HR2.5 two-stage, over/under, oil flooded asymmetrical
rotary screw type with tapered roller bearings and lubricated by a positive gear oil pump. For
high pressure compressors with EARS see section 7-5.2 for information.
Table 15: High Pressure Air Compressor
3-22
Type:
High pressure HR2.5 two-stage, over/under, oil flooded

asymmetrical rotary screw
Volume:
1450 CFM @ 350 psi, (41.06 cu. m/min. @ 2,413 kPa),
Bearing Type:
Tapered Roller Bearing
Air End Lubrication:
Positive, Gear Oil Pump
Receiver Capacity:
Air Cleaners:
Three 3-stage with 1 primary and 1 safety element
Dirt Alarm Indicator:
Restriction indicators indicate when filters require

service.
Oil Type:
XHP605 (high pressure only)
DRILLING SOLUTIONS
Operational RPM:
2100 RPM (All other high pressure compressors 1800

RPM)
Power Source:
Directly driven by diesel engine (Optional Electric Motor)
Engine
The PV-270 Series drills use a water cooled engine with direct injection and turbo chargers.
Electric starting and belt driven alternator battery charging is standard.
Table 16: Engine Specifications

Engine Specifications
Diesel Engine Options:
Cummins QSK19C/755HP @ 1800 RPM (XL1900)

Cummins QSK19C/755HP @ 2100 RPM (HP 1450)
Caterpillar C27/830HP @ 1800 RPM (XL1900)
Caterpillar C27/830HP @ 2100 RPM (HP 1450)
Caterpillar C32/1050HP @ 1800 RPM (XL2600)
Optional Electric Motor
Weg 6808-6000VAC/700HP (521kw) @ 50HZ

Weg 6811-4160VAC/900HP (671kw) @ 60HZ
Engine Cooling Package:
Rated at 125F (52C) ambient at sea level.
Air Cleaners:
2-stage, dry type
Exhaust System:
Silenced for reduced noise levels
Fuel Capacity:
350 gallon (1324.89 liter) capacity is standard. Optional

625 gallons (2365.88 liters) capacity in two tanks is
available.
Auto Shutdown:
Low oil pressure, low coolant level, high water

temperature, high compressor temperature.
The PV-270 Series drill is equipped with dual system air filtration. Dry type 3-stage air
cleaners, with optional precleaners, provide clean air to the engine and the compressor. The
engine power / rpm is controlled by the engine speed (throttle) control. The engine is shutdown
either by the removable key ON/OFF switch or the emergency stop switch.
Hydraulic System
All drilling and propel functions are hydraulically powered. The hydraulic system consists of a
150 gallon (567.8 liter) hydraulic reservoir, hydraulic pumps mounted on a pump drive
gearbox, hydraulic motors and various valves, cylinders, pipes, hoses, filters and gauges. A
hydraulic oil cooler assures cool oil temperatures to maximize system efficiency and
component life.
DRILLING SOLUTIONS
3-23
The three hydraulic pumps are mounted for convenient service access on a single three hole
pump drive gear box driven off the diesel engine (optional electric motor) through a drive shaft.
The two main pumps supply hydraulic power to either drilling functions (drill feed and rotation)
or tram (propel) functions. The auxiliary circuits double pump supplies oil for all other functions
through the 7-spool and 10-spool valves (or 11-spool valves).
Table 17: Hydraulic System Pressures

Hydraulic System Pressures
Rotation System:
4,500 psi (31,026 kPa)
Propel System:
4,500 psi (31,026 kPa)
Feed System:
3400 psi (23,442 kPa) MAX. pulldown and pullback
Auxiliary Circuits:
3000 psi (20,684 kPa)
Table 18: Hydraulic System Specifications:

Hydraulic System Specifications:
Pump Drive:
Three-hole gearbox driven from driveshaft coupled to

engine (electric motor optional)
Main Pumps:
Two (2) variable displacement, axial piston, bi-directional

pumps for feed, rotation and propel
Auxiliary Pump:
One (1) double section vane pump for all auxiliary

hydraulic functions
Hydraulic Tank Capacity:
150 gallon (567.8 liters)
Hose Management:
Stauff type clamps for hoses; hard piping where possible
Hydraulic Fittings:
SAE O-ring face seal
Filtration:
2 filters in drain line upstream from tank; 2 filters in return

line upstream from supercharge manifold
Filtration Rating:
3 micron
Table 19: Hydraulic Reservoir

Hydraulic Reservoir Specifications:
3-24
Capacity:
150 gallons (567.8 L)
Location:
Next to the cooler package on the dust collector side of

the drill
Standard Equipment:
Oil level indicator and oil temperature gauge
DRILLING SOLUTIONS
Pumps
Table 20: Main Pumps
Main Pump Specifications:
Number:
Two (2)
Location:
Mounted on the main hydraulic drive gearbox
Type:
Variable displacement, axial piston, bi-directional pumps for

feed, rotation and propel
Displacement:
7.25 cu. in/rev (118.8cc), 1800 x 1.27 = 2286 RPM, 71.7 GPM
7.25 cu. in/rev (118.8cc), 2100 x 1.10 = 2310 RPM, 72.5 GPM
Function
Supplies oil to rotary head motors, feed cylinders and propel

motors (one pump per track)
Table 21: Double Pump (Auxiliary Pump)

Double Pump Specifications:
Number:
One (1)
Location:
Mounted on the main hydraulic drive gearbox
Type:
Two (2) section, vane, fixed displacement pump for all auxiliary
hydraulic functions
Capacity:
P1 Section: 28 GPM at 1200 RPM, 5.42 cu. in./rev. (88.82cc)

P2 Section: 17 GPM at 1200 RPM, 3.56 cu. in./rev. (58.34cc)
Function:
P1 Section: Cooler package fan motor, cable tension cylinders.
Function:
P2 Section: Supplies oil to the 7-spool valve (hoist motor, tower

raising cylinders, dust curtain cylinders, cabside leveling jack
cylinder, rear leveling jack cylinder, dust collector side leveling
jack cylinder, water injection motor and the 10 or 11-spool valve
(rod changer cylinders, breakout wrench swing cylinder,
breakout wrench rotate & clamp cylinders, breakout sliding fork
cylinders, rod support cylinders, tower pinning cylinders, angle
drill pinning cylinders, rod indexing cylinder, lower cable
tensioner motors and the high pressure air control option)
DRILLING SOLUTIONS
3-25
Motors
Table 22: Propel Motor
Propel Motor Specifications:
Number:
Two (2)
Type:
Hydraulic, fixed displacement, axial piston, 9.79 cu. in./rev.

(160cc) displacement
Propel Speed:
0 to 1.1 mph (0-1.77 km/hr.)
Function:
Enables left hand track drive and right hand track drive to
function
Table 23: Rotation Motors

Rotation Motors Specifications:
Number:
Two (2)
Type:
Variable displacement, axial piston hydraulic motor, 6 cu. in./rev.

(98cc) displacement
Speed Range:
Variable, 0-150 rpm at minimum displacement (6500 ft./lb

torque)
Rotation Torque:
9,000 ft/lb (1224.7 kg/m) gross at @ max. displacement (110

rpm)
Rotation Power:
188 HP gross (135 kW)
Speed Control:
Infinitely adjustable throughout range, maximum speed set by

manual adjustment of motor displacement
Function:
Drill string rotation (rotate the drill bit)
Table 24: Fan

Fan Motor:
3-26
Number:
One (1)
Type:
Variable displacement, 8.0 cu. in/rev (131.1cc)

1000 RPM for XL1900 and HP1250
1175 RPM for HP1450
Function:
Rotates 8-blade fan (54 in.dia.) in cooler package
DRILLING SOLUTIONS

Table 25: Hoist
Hoist Motor:
Number:
One (1)
Type:
Fixed displacement, 1.96 cu. in/rev (32.12cc)
Function:
Facilitates drill pipe handling
Table 26: Rod Indexing

Rod Indexing Motor (PV-275):
Number:
One (1)
Type:
Function:
(PV-275) Rotates carousel to index drill rod under rotary head
Table 27: Cable Tension

Cable Tension Motor:
Number:
Two (2)
Type:
Function:
Maintains tension on feed cables
Table 28: Water Injection Pump

Water Injection Pump Motor (Option):
Number:
One (1)
Type:
8 GPM; Fixed Displacement, 6.2 cu. in/rev (101.60cc)

8 GPM; Fixed Displacement, 9.9 cu. in./rev (162.23cc) OPTION
Function:
Drives Water Injection Pump
Table 29: Dust Collector Fan

Dust Collector Fan Motor:
Number:
One (1)
Type:
Fixed displacement, hydraulic spring vane motor, 1.49 cu.in/rev

(24.42cc)
DRILLING SOLUTIONS
3-27
Dust Collector Fan Motor:

Theoretical Torque:
24 in/lb/100 psi (2.71 Nm/6.9 bars)
Maximum
Pressure:
2500 psi (172.4 bars) at 2500 rpm
Function:
Drives dust collector fan
Cylinders
Table 30: Leveling Jack
Leveling Jack Cylinder Specifications:
Type:
Hydraulic cylinder with double holding valves Set @ 4500 psi

(310.3 bar)
Quantity:
Three (3) standard. Four (4) available as an option.
(Two) Drilling End:
7 in. bore dia. x 48 in. stroke/ 5.25 in. rod diameter (177.8 mm x
1,219 mm / 133 mm)
(One) Non-Drilling
End: Standard
7 in. bore dia. x 60 in. stroke/ 5.25 in. rod diameter (177.8 mm x
1,219 mm / 133 mm)
(Two) Non-Drilling
End: Option
6 in. bore dia. x 60 in. stroke/ 4.5 in. rod diameter (152 mm x
1,524 mm / 114 mm)
Function:
Raise, level and lower the drill
Table 31: Tower Raising

Tower Raising Cylinder Specifications:
Type:
Hydraulic cylinder with double holding valves Set @ 3500 psi

(241.3 bar)
Quantity:
Two (2)
Description:
7.5 in. bore diameter x 77.75 in. stroke/ 4.5 in. rod diameter
(19.05 cm x 197.49 cm / 11.43 cm)
Function:
Raise and lower the tower
Table 32: Tower Pinning

Tower Pinning Cylinder Specifications:
Type:
3-28
Hydraulic cylinder
DRILLING SOLUTIONS
Tower Pinning Cylinder Specifications:

Quantity:
Two (2)
Description:
3 in. bore diameter x 6 in. stroke/ 1.5 in. rod diameter (7.62 cm x
15.24 cm / 3.81 cm)
Function:
Automatic vertical tower pinning
Table 33: Angle Drill Pinning

Angle Drill Pinning Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
Two (2)
Description:
3 in. bore diameter x 10 in. stroke/ 1.25 in. rod diameter (7.62 cm
x 25.4 cm / 3.175 cm)
Function:
Automatic tower pinning for Angle Drill Package Only
Table 34: Feed

Feed Cylinder Specifications:
Type:
Dual rod, dual piston hydraulic cylinder
Quantity:
Two (2)
PV-271 (55ft)
5 in. bore diameter x 387 in. stroke/ 3.75 in. rod diameter (12.7
cm x 983 cm / 9.53 cm)
PV-271 (65ft)
cm x 1,013.46 cm / 9.53 cm
PV-275
cm x 708.66 cm / 9.53 cm)
Function:
Raise and lower the rotary head
Table 35: Cable Tension

Cable Tension Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
Two (2)
4 in. bore diameter x 15.5 in. stroke/ 2 in. rod diameter (10.16 cm
x 39.37 cm / 5.08 cm)
Function:
Keeps tension on the pulldown cables
DRILLING SOLUTIONS
3-29
Table 36: Rod Changer

Rod Changer Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
Two (2)
PV-271
12.7 cm / 3.81 cm)
PV-275
15.24 cm / 3.81 cm)
Function:
Swing carousel into and away from loading position under rotary
head
Table 37: Rod Indexing

Rod Indexing Cylinder Specifications (PV-271 Single-Pass):
Type:
Hydraulic cylinder
Quantity:
One (1)
12.7 cm / 3.81 cm)
Function:
(PV-271 only). Rotates carousel to index drill rod under rotary

head
Table 38: Rod Support

Rod Support Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
One (1) - Swing cylinder

One (1) - Clamp cylinder
15.24 cm / 3.8 cm)
Function:
3-30
Positions the rod support during drill rod change
DRILLING SOLUTIONS
Table 39: Breakout Wrench Swing

Breakout Wrench Swing Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
One (1)
4.5 in. bore diameter x 9 in. stroke/ 2 in. rod diameter (11.43 cm
x 22.86 cm / 5.08 cm)
Function:
Swing breakout wrench into and out of breakout position
Table 40: Breakout Wrench Clamp

Breakout Wrench Clamp Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
One (1)
x 22.86 cm / 5.08 cm)
Function:
Engages and disengages breakout wrench on drill rod
Table 41: Breakout Wrench Rotate

Breakout Wrench Rotate Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
One (1)
x 22.86 cm / 5.08 cm)
Function:
Used for breaking drill rod joints
Table 42: Sliding Breakout Fork

Sliding Breakout Fork Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
One (1)
1.5 in. bore diameter x 8 in. stroke/ 1 in. rod diameter (3.81 cm x
20.32 cm / 2.54 cm)
Function:
DRILLING SOLUTIONS
Holds drill rod at table level for breakout procedure
3-31
Table 43: Dust Curtain

Dust Curtain Cylinder Specifications:
Type:
Hydraulic cylinder
Quantity:
Two (2)
3.5 in. bore diameter x 10 in. stroke/ 1.75 in. rod diameter (8.89
cm x 25.4 cm / 4.45 cm)
Function:
Raise and lower dust curtains
Table 44: Drill Air Control

Drill Air Control Cylinder Specifications (HP Option):
Type:
Hydraulic cylinder
Quantity:
One (1)
2.5 in. bore diameter x 5 in. stroke/ 1.5 in. rod diameter (6.35 cm
x 12.7 cm / 3.81 cm)
Function:
Turns drilling air on/off during drill rod or hammer changes
Dust Control
Water Injection System (option)
The Water Injection System injects a regulated quantity of water into the air flow to the drill
pipe. The water content suppresses the dust created by the drilling operation. The Water
Injection system has a hydraulic motor drive.
Table 45: Water Injection System

Water Injection System Specifications:
3-32
Type:
John Bean
Size:
8 GPM (30.3 L/min.)
Capacity:
0 to 8 GPM (0 to 30.3 L/min.)
Hydraulic Motor Drive:
Fixed displacement, 6.2 cu. in/rev (101.62cc) or 9.9 cu.

in/rev (162.23cc)
Water Tank:
Function:
Dust suppression
DRILLING SOLUTIONS
Dust Collector
A No Visible Emission dry dust collector is standard equipment on the drill. It is a pleated
paper element type fan/filter unit. Interval flushing is controlled by an electronic timer. A
vacuum hose allows the fan/filter unit to draw the dust out of the collection area. The dust is
removed from the air stream as the air flows through the pleated paper filter elements. Heavy
cuttings are contained around the hole.
Table 46: Dust Collector

Dust Collector Specifications:
Type:
No Visible Emission pleated paper element with

pneumatic flushing
Model:
7SB
Capacity:
7,000 CFM (198 cu.m/min.)
Mounting:
Post type mounting on top of dust collector side leveling

jack
Configuration:
Cyclone
Dimensions:
139.1 in. High x 54 in. Diameter (3533.1mm x

1371.6mm)
Filter Elements:
Nine (9)
Inlet Diameter:
12 Inches (305 mm)
Air Compressor Size:
XL1900, XL2600, 1450HP
Dust Hood Connection:
12 in. (305mm) O.D. suction hose
Fan Motor:
Hydraulic vane motor, fixed displacement, 1.49 cu.in/rev

(24.42cc)
Operating Pressure:
3,000 psi (20,684 kPa)
Flow Control Valve:
Yes
Internal Baffle:
Internal baffle between dust collector intake duct and

filters
Dust Hood:
Rectangular with split curtains and hydraulically

retractable front curtain
Dust Curtain Material:
Conveyer belting
DRILLING SOLUTIONS
3-33
Operators Cab
The operators cab is thermally insulated, heated, and ventilated. The cab is equipped with
tinted safety glass windows, kick plates, an operators adjustable swivel seat and two lockable
doors. There is an internal 40-watt light for cab interior illumination. Night Lights are operated
from a 24-volt electrical system. All operational functions can be controlled from the drillers
console within the cab of the drill.
Table 47: Operators Cab

Operators Cab Specifications:
Construction:
One piece, Drilling Solutions design common to Atlas

Copco Drilling Solutions drills.
Falling Object Protection:
FOPS (Falling Object Protective Structure) certified (ISO

3449 Level 2 Test - 500 lb. projectile from 17).
Thermal/Sound Insulation:
Noise abated (Less than 80 dBa) with doors closed and

air conditioner running at full speed.
Dimensions:
64 inch width x 76 inch length x 86 inch height (1.63m x

1.93m x 2.18m)
Doors:
One (1) hinged on drill deck side, lockable

One (1) hinged on outboard side, lockable
Heater/Air Conditioner:
DTAC side mounted unit with adjustable vents

A/C 22,500 BTU/HR;
Heater 40,000 BTU/HR
450 CFM (12.7 m3/min.) fresh air supply, stainless steel
components, copper/brass heat exchanger.(Note:
pressurizer is included in standard package)
Pressurizer:
Integrated with heater/air conditioner
Pressurization:
0.2 in HO minimum with doors closed
Ventilators:
Louver style vents are provided to direct the air flow for
optimal comfort.
Cab Glass:
Tinted Safety Glass
Kick Plates:
Yes
Wipers:
2 wipers with washers standard
Operator Seat:
One suspension swivel type, adjustable, high back with

arm rests.
Options:
Pulldown Sunshades
Fold-up buddy seat
3-34
DRILLING SOLUTIONS
Operators Console
All operational functions can be controlled from the drillers console within the cab of the drill.
See Section 4 Operating Controls & Instruments for further information on the drillers console.
Table 48: Operators Console

Operators Console Specifications:
Control Console
Serviceability:
All controls are electric over hydraulic. The console is hinged

for simplified access to the controllers. A wiring harness
leads from the controllers to the spool valves and main pump
controllers.
Controls:
Electric-over-hydraulic joysticks for hydraulic functions;

switches and push buttons for electric functions; cable
control for low pressure air compressor.
Gauges:
Hydraulic feed pressure, hydraulic rotation pressure, bit air

pressure, rotation speed, engine oil pressure, engine
hourmeter, battery voltmeter.
Indicator Lights:
Tower locking pins engaged, angle locking pins engaged,

jacks retracted, engine diagnostics.
Night Lighting Specifications

A twelve (12) light halogen, 70 watt each, night lighting system is provided as standard for
operator visibility under low light operating conditions for:
1. Drilling End Platform Area Illumination
2. Power Pack Illumination
3. Tower Illumination
4. Tramming Illumination
There is also one internal 40-watt light for cab interior illumination.
Standard Tools & Manuals

1. Hoist Plug for Drill Pipe
2. Spindle Sub
3. Blow Gun with Hose
4. Maintenance and Parts Manuals (3 sets)
5. CD ROM Serial Parts Manual (3)
DRILLING SOLUTIONS
3-35
Dimensions and Weights

The following dimensions and weights are for a PV-270 Series drill. Option packages and addons are not included in these measurements or weights.
Table 49: Weights and Dimensions

Estimated Weights and Dimensions*
Dimensions
Length (tower down):
Length (tower up):
83 ft.-10 in. (25.55 m)
39 ft.-5.25 in. (12.02 m)
PV-275 (Multi-Pass)
63 ft.-10 inches (19.74 m)
41 FT.-6 IN. (12.68 M)
24 ft. (7.32 m)
Width (operating):
22.3 ft. (6.81 m)
Height (tower down):
87 ft. (26.52 m)
Height (tower up):
67 ft. (20.42 m)
Cab Dimensions:
64 inch width x 76 inch length x 86 inch height (1.63m x

1.93m x 2.18m)
Operating Weight:
165,000 lbs to 175,000 lbs. (74,844kg to 79,380kg)
* Excluding Drill Rod and Accessories

Performance specifications are based on maximum computed values and are subject to
revision without notification. Nothing in this manual is intended to extend any warranty or
representation, expressed or implied, regarding the products described herein. Any such
warranties or other terms and conditions shall be in accordance with Atlas Copco Drilling
Solutions standard terms and conditions of sale for such products, which are available upon
request.
Specifications represented herein are calculated values at 100% efficiency. Atlas Copco
Drilling Solutions is constantly striving for product improvements and enhancements.
Accordingly, Atlas Copco Drilling Solutions reserves the right to make such changes in
specifications and design as the company considers in conformity with this policy or are due
to unavailability of materials or assemblies.
3-36
DRILLING SOLUTIONS
DRILLING SOLUTIONS
3-37
3-38
DRILLING SOLUTIONS
DRILLING SOLUTIONS
3-39
Optional Equipment
Air Conditioner Option
The operator can control the blower speed to regulate flow through the air conditioner
evaporator. He also has the capability of directing the air flow with the use of vents and louvers
placed above and below the control panel. A heater / ventilator is standard equipment and is
enclosed in the same package. Air Conditioner Specifications are:
3-40
DRILLING SOLUTIONS
Table 50: Air Conditioner

Air Conditioner Specifications:
Air Conditioner/Heater:
(A/C) 22,500 Btu/hr. (Heater) 40,000 Btu/hr.
Coolant:
R-134A
Miscellaneous Optional Equipment:

Angle Drill Package:
PV-271: Angle Drill Package: 0 to 20 degrees in 5 degree

increments; patented Drilling Solutions design.
PV-275: Angle Drill Package: 0 to 30 degrees in 5 degree
increments; patented Drilling Solutions design.
Diesel Fuel:
Two tank, 625 gallon (2365.88 liter) fuel capacity
Four Leveling Jacks

Installation:
Drill Side: 2) 7 in. bore dia. x 48 in. stroke/ 5.25 in. rod
diameter (177.8 mm x 1,219 mm / 133 mm)
Non-Drill Side: 2) 6 in. bore dia. x 60 in. stroke/ 5.25 in. rod
diameter (152 mm x 1,524 mm / 133 mm)
Miscellaneous Options:
Variable speed fan control

Wiggins central service (fuel, hydraulic oil, coolant,
engine oil)
Fire suppression: Ansul dry chemical system with
manual actuation
Master battery selector switch
Jump start receptacles
Torque limit control
Ground level emergency shutdowns
Warning horns
Central hydraulic test station
Cab window wipers
Cab window washers
Tow hooks (non drill end)
DRILLING SOLUTIONS
3-41
Miscellaneous Optional Equipment:

Miscellaneous Options:
Export lifting hooks

Washdown, Gun
Remote Propel
Battery Equalizer
Mirror assembly
Strobe lights
Rig access light switch
DEI Plus
Table 51: Lubrication Optional Equipment:

Lubrication Optional Equipment:
Lubrication Options:
Automatic lube system (Lincoln Centromatic)

Automatic thread greaser
DHD lubricator, 60 gallon (227.12 liter)
Engine prelube starter
Table 52: Dust Control Options

Dust Control Optional Equipment:
Dust Control Options:
Dust Collector, 7000 CFM

Water Injection; 400 (1514.16L) gal. tank, 0-8 gpm pump
3-42
DRILLING SOLUTIONS
Table 53: Cold Weather Option

Cold Weather Optional Equipment:
Cold Weather Options:
IR G40 diesel generator: 30kw, 240V AC

240V AC heater for engine coolant
240V AC heater for engine oil pan
240V AC heater for hydraulic oil tank
240V AC heaters for water tank
240V AC heater for air receiver tank
240V AC heater for batteries
240V AC Kim Hot - Start recirculation heater for engine
coolant and fuel
Additional cab heater
Insulated battery enclosure
Thermostatically controlled two-speed cooler fan
240V AC fuel heater
Arctic Fox water tank heaters
Diesel fired engine coolant preheater
Arctic Fox engine heaters
DRILLING SOLUTIONS
3-43
This page is intentionally blank
3-44
DRILLING SOLUTIONS
Section 4 - Controls
DRILLING SOLUTIONS
4-1
Operating Controls
General Information
WARNING
Read and understand Section 2 - Safety Precautions and Guidelines

before you operate or perform any maintenance, service or repairs on the
drill.
Safety should be the main concern for anyone working on or around the drill. Do not perform
any function that could put someone in danger.
Always wear correct safety gear while working on or around the drill. This includes Approved
Hard Hat, Safety Glasses, Steel Toe Shoes, Gloves, Respirator and Ear Protection. Do not
wear loose fitting clothing that can become caught in rotating components.
WARNING
If you are not experienced with the drills controls and instruments, read
and understand Section 4 - Operating Controls & Instruments.
Unexpected drill motion or moving parts can cut or crush. Shut down
engine before working on the drill.
The following operational hints should be observed:
1. Do not speed engine when it is cold.
2. Do not lubricate the drill while the engine is running.
3. Always perform safety checks prior to starting and using the drill.
4. Always operate the drill at full engine power when drilling.
5. Never stop the drill on a slope or surface that is liable to collapse.
6. Never stop the drill against a high wall that is liable to collapse or cause a
crushing risk.
7. Before starting the engine, make sure all operator console controls are either
in OFF or NEUTRAL positions and that the parking brake is applied.
8. Always sound the horn before moving the drill in either direction to alert
personnel and to allow sufficient time before putting the drill in motion.
4-2
DRILLING SOLUTIONS
Operators Console
The operating controls section provides basic information about the operating controls,
instruments and indicators, located on the control panel and the drill, that are used when
operating the drill.
All operating functions can be controlled from the drillers console within the cab of the drill.
Operation of the drill is performed using electric over hydraulic controllers ergonomically
located so that the operator faces the drill centralizer while drilling.
The controls on the console are arranged in operating function panels.
DRILLING SOLUTIONS
4-3
Drill/Feed Function Panel
4-4
DRILLING SOLUTIONS
Drill / Feed Function Panel

1. Controller - Hoist
The hoist controller controls the hoists direction and speed when raising or
lowering drill pipe during loading into or unloading from the carousel.
To use the hoist in either raise or lower operations, gradually move the control
in the required direction. To slow and stop the hoist, move the control slowly to
the STOP position and release the handle. A spring applied brake will
automatically apply when the control is released in the STOP position.
2. Controller - Breakout Fork
Place the sliding breakout fork controller in the engaged position and the sliding
breakout wrench will slide forward and engage the flats on the drill rod or DHD.
Moving the controller to the disengaged position will retract the sliding breakout
fork wrench.
3. Controller - Carousel Index
The carousel index controller activates the rod indexing cylinder (PV-271
single-pass) or the hydraulic motor driven bullgear (PV-275 multi-pass) that
rotates the carousel. Placing the controller into forward position will rotate the
carousel clockwise to align the drill rod under the rotary head. When correctly
aligned, the drill rod will have been positioned with its axis aligned to the axis
of the rotary head spindle. The loading or unloading process can then be
completed. Placing the controller into reverse position will rotate the carousel
counterclockwise to the next loading or unloading position.
4. Controller - Carousel Swing
The carousel swing controller activates the carousel swing cylinders which
move the carousel under the rotary head to add and remove drill rod.
5. Controller - Breakout Wrench
The breakout wrench controller activates the breakout wrench swing cylinder,
breakout wrench clamp cylinder and breakout wrench rotate cylinder that are
used when loosening the threaded joints between drill rod and also during bit
replacement. Placing the controller in the extend position will extend the
cylinder. Placing the controller into the retract position will retract the cylinder.
6. Control - Torque Limit (HP Option)
The rotation torque limit control knob and gauge controls the amount of
pressure being applied to the rotary head rotation motors. It can be adjusted to
limit torque on the bit during difficult drilling conditions. This is an option for
high pressure drills only.
DRILLING SOLUTIONS
4-5
7. Controller - Rotation
The drill rotation controller controls the direction and speed of drill rotation. To
rotate the drill in either the clockwise or counterclockwise direction, gradually
move the controller in the required direction and speed of rotation will
progressively increase. To stop rotation, move the controller into the STOP
position where the indent should click into place.
Note: Rotation is only possible when the mode selector valve (#59) is in the drill
mode position.
8. Controller - Drill Feed
The drill feed controller controls the direction and rate of drill feed. To feed the
drill in either the UP or Down direction, gradually move the controller in the
required direction. The feed rate will progressively increase. To stop feed,
move the controller into the OFF position. The indent should click into place.
Note: Rotation is only possible when the mode selector valve (#59 is in the drill
mode position.
9. Controller - Drill Throttle (HP Option)
The drill air throttle controller controls the air flow to the drill string and allows
air flow down the hole to operate the DHD (Down Hole Drill) and clean the hole.
It is used to turn ON/OFF the drilling air during drill rod or hammer changes. It
can be adjusted to a lower setting while collaring the hole. This is an option
for high pressure drills only.
10. Rotary Switch - Drill Feed Force Control
The drill feed pressure control rotary switch controls the down feed pressure to
the feed cylinders while doing actual drilling. Turning the control clockwise will
increase feed pressure. Turning the control counterclockwise will reduce the
feed pressure. Note: When using downhole hammer drilling, use only sufficient
feed pressure to match the rate of penetration.
4-6
DRILLING SOLUTIONS
11. Button Switch - Joint Lubricator

The joint lubricator is used to grease the threads on the drill pipe or DHD or any
other drill string joints when adding or removing drill pipe or accessories from
the drill string. Push down on the button switch to inject lubricant.
12. Rotary Switch - Holdback Force (HP Option)
The Drill Holdback Pressure Control Rotary Switch is provided to avoid
excessive down feed pressure on the drill bit. This is an option for high
pressure drills only.
On deep holes, the weight of the drill string may become excessive and
overload the drilling system. To avoid this problem, drill holdback pressure can
be varied so that the downhole drill bit is not overloaded. Turning the control
clockwise will increase and counterclockwise will reduce the holdback
pressure.
13. Gauge - Bit Air Pressure

The (drilling) bit air pressure gauge monitors the air pressure available for
drilling. The range shown on the face of the gauge is 0-160 psi (0-11 bar) on
Low Pressure rigs. On high pressure drills, the range shown on the face of the
gauge is 0-400 psi (0-27.58 bar), this pressure is adjusted by turning the air
DRILLING SOLUTIONS
4-7
pressure regulator adjustment knob clockwise to increase and turn

counterclockwise to decrease the compressor discharge air pressure.
Note: Ensure that the pressure is adjusted to the type of downhole hammer
being used. Do not operate 250 psi (17.24 bar) hammers on 350 psi (24.13
bar).
14. Gauge - Supercharge Pressure
The supercharge pressure gauge monitors the main pump supercharge
pressure. It shows the operator how much pressure is being delivered to the
main pump inlet. The range shown on the face of the gauge is 0-400 psi / 02758 kPa (27.6 bar).
Note: It is essential that the supercharge pressure gauge reads not less than
125 psi (8.62 bar) during normal operation. Shutdown the machine to avoid
serious damage to the main hydraulic system components. Call for service
assistance to detect cause of the low pressure reading.
15. Gauge - Rotation Pump Pressure
The rotation pressure gauge shows the amount of hydraulic pressure being
applied to the rotary head motor(s). It corresponds to the amount of torque
developed by the rotary head during operation. The range shown on the face
of the gauge is 0-7500 psi (517.11 bar)
The Rotation Torque Limit Control Option can restrict the torque value.
16. Gauge - Pulldown Pressure
The pulldown pressure gauge shows the amount of hydraulic down pressure
being exerted on the bit by the feed (cylinder) system. The range shown on the
face of the gauge is 0-7500 psi (517.11 bar). Pressure can be increased or
decreased by turning the Drill Feed Force Control. MAX is 3400 psi pulldown.
17. Gauge - Holdback Pressure (HP Option)
The feed holdback pressure gauge shows the hydraulic pressure in the feed
cylinder when drill holdback pressure is applied to prevent excessive down
pressure on the drill bit. This is an option for high pressure drills only.
Pressure can be increased or decreased by turning the Feed Holdback
Pressure Rotary Switch Option.
4-8
DRILLING SOLUTIONS
ENGINE FUNCTIONS PANEL
18. Button Switch - Emergency Stop

The RED emergency stop button switch shuts off power to the fuel valve and
stops the engine when it is pushed. A red light inside the button switch is lit if
the button switch is in run position. An optional second emergency stop switch
is mounted on the main frame, located on the cab side non-drilling end of the
drill.
After depressing the switch, it is necessary to reset the switch before the engine
can be restarted. To reset, pull the switch out into its active position.
Note: This switch has the same effect as turning the ON/OFF key switch fully
to the STOP position.
19. Engine Speed Selector
The engine speed control regulates the speed (RPM) of the engine. The engine
has an idle speed of 1200 rpm and a high idle of 1800 rpm. The engine should
always be run at low idle for 5 minutes before shutdown. This allows the
turbocharger to cool down.
Turn the control knob CCW (with Cat engine) to increase the RPM. Turn the
control knob CW (with Cummins engine) to increase the RPM. Turn the
opposite direction too decrease the RPM. The controller is equipped with a
tension nut to maintain the required engine RPM. The tension nut is located just
behind the control knob. By turning the tension nut clockwise, it tightens against
the seal and holds the shaft at the desired setting. To release the setting, simply
turn the tension nut counter-clockwise and the shaft will be free to allow RPM
to be adjusted with the knob. In the event the RPM needs to be returned to low
idle quickly, push the control knob in (towards the tension nut) and the RPM will
return to low idle. The tension nut has to be released to adjust RPM to different
setting. Do not try to turn control knob with tension nut tightened. Can cause
damage to controller.
DRILLING SOLUTIONS
4-9
NOTE: Always ensure that the engine speed is at Operating RPM before
tramming or drilling. Full Power is necessary to obtain the proper component
operation and maximum rpm for greatest efficiency
WARNING
A run away drill can cause injury or death. Do not attempt to control drill
travel speed with the engine speed control. Use the tram control (F-STOPR) to control travel speed. Maintain engine speed at operating RPM for all
drill operations.
20. Gauge - Discharge Temperature
The compressor discharge air temperature gauge shows the temperature of
the oil and air leaving the air end. The range shown on the face of the gauge is
140-300F (60-148C).
Normal operating temperatures are 180-230F (82-110C). This gauge also
contains a switch that will stop the engine if the oil temperature in the
compressor exceeds 248F (120C).
21. Gauge - Fuel Level
The fuel gauge monitors the level of fuel in the fuel tank. The tank should be
refilled when the indicator needle moves to below 1/4 tank.
22. PowerView Diagnostic Display
The PowerView display is a multifunction tool which enables equipment
operators to view many standard engine parameters as well as active and
stored trouble codes. The display can show either a single parameter or a
quadrant display showing four parameters simultaneously. Diagnostic
capabilities include codes with text translation for most common fault
conditions.
23. Toggle Switch - Drill Lights
The drill lights control switch is an ON/OFF switch that controls all the work
lights. Move the switch to the ON position to turn on the lights and illuminate the
working area.
24. Toggle Switch - Tram Lights
The tram (propel) lights control switch is an ON/OFF switch that controls all
the tramming lights. Move the switch to the ON position to turn on the lights and
illuminate the area ahead of the direction of travel.
25. Gauge - Engine Oil Pressure
The engine oil pressure gauge indicates the engine oil pressure. The range
shown on the face of the gauge is 0-75 psi/0-517 kPa (5.18 bar). This gauge
should not read less than 10 psi (.69 bar) on LOW idle nor less than 27 psi (1.86
bar) on HIGH idle.
4-10
DRILLING SOLUTIONS
Note: There is a pressure monitoring system on the engine that will shut down
the engine immediately in the event that the oil pressure drops below 10 psi
(.69 bar) on LOW idle or less that 27 psi (1.86 bar) on HIGH idle; otherwise the
engine could be severely damaged. Check the oil level according to the
instructions provided in Section 6 Maintenance Instructions.
Note: Refer to engine diagnostics section for checking engine problems in
Section 7 Trouble Shooting.
26. Gauge - Engine Coolant Temperature
The engine coolant temperature gauge shows the temperature of the engine
coolant system. The range shown on the face of the gauge is 130F-250F
(54C-121C). Normal operating temperature is from 150F-208F (66C98C). The system will shut down if the temperature exceeds 210F (99C).
27. Gauge - Tachometer
The tachometer gauge shows the RPM of the engine while the engine is
running. The tachometer is calibrated in RPM x 100 with a range of 0 to 25
(2500 RPM).
28. Circuit Breakers
The bank of seven (7) circuit breakers protect the drills electrical circuits. The
circuit breakers are mounted between the current producer, batteries or
alternator and the devices they are protecting. In the event of an overload of a
circuit, press in the tripped circuit breaker.
Note: If there is a re-occurrence, call for service assistance to correct the cause
of the overload in the circuit.
The circuit breaker identification is as follows:
1.) 5 amp Engine Shutdown
2.) 15 amp Windshield Wiper System
3.) 20 amp Power Distribution for OEM Controllers
4.) 20 amp Air Conditioner/Pressurizer System
5.) 15 amp Power Distribution for Engine
6.) 20 amp Drill Working Lights
7.) 20 amp Tram (Propel) Lights
29. Hourmeter
The elapsed time meter records the number of hours and partial hours the
engine has operated. It only works when the key is turned on.
30. Key Switch - Electrical System ON/OFF
The electrical system ON/OFF key switch turns on all electrical power to the
engine and controls stopping and run operations.
DRILLING SOLUTIONS
4-11
The electrical system ON/OFF key switch also activates the ECM (Electronic
Control Module) that controls all aspects of the engine, including most
shutdown devices.
Note: Always stop the engine and remove the key when leaving the drill
unattended and/or performing certain maintenance procedures.
31. Button Switch - Engine Fuel Primer
The engine fuel primer button switch permits the priming of the engine fuel
system after the drill has been standing idle for an extended period of time or
after fuel filter replacement. It is used to pump diesel fuel from the fuel tank to
the engine. It can also be used to fill fuel filters after a filter change.
32. Button Switch - Engine Starter
The engine starter button switch energizes the starter motor and engages the
starter motor solenoid to crank the engine for startup. Press the engine starter
button switch and the engine bypass button switch together to start the engine.
Once the engine starts, release the engine starter button switch immediately.
NOTICE
Do not engage the starter motor solenoid longer than 30 seconds at a
time or it will overheat and burn up the starter motor. If the engine does
not start, WAIT 3 minutes to allow the starter to cool before trying again.
33. Not Used Here
34. Button Switch - Ether (Option)
The engine ether cold start button switch controls the cold starting aid system.
This is an option. To use this option for starting, press and release the ether
injection button while pressing the starter button switch (figure 4.1-5). Ether is
only injected when the starter button is operated.
NOTE: Starting aid may be required when temperature is below 32F (0C)
and will be required when temperature is below 10F (-12C).
WARNING
Starting aids are extremely flammable and can explode. Overloading the
engine air intake system could result in an explosion. Avoid overloading
the engine air intake when starting.
35. Indicator Light - Vertical Tower Unpinned Warning
The vertical tower unpinned warning light illuminates when the locking pins are
not engaged and the drill tower is not locked in the working position. This
4-12
DRILLING SOLUTIONS
warning light is also effective when using the angle drilling option. Note: It is
unsafe to operate the drill with the raised tower in an unlocked position. If the
locking pin will not engage, notify your service supervisor to correct the fault.
36. Indicator Light - Angle Drill Tower Unpinned Warning
The angle drill tower unpinned warning light illuminates when the locking pins
are not engaged and the drill tower is not locked in the working position. Note:
It is unsafe to operate the drill with the raised tower in an unlocked position. If
the locking pin will not engage, notify your supervisor and call Service to correct
the fault.
37. Button Switch - Horn (Option)
Pressing the horn button switch will sound the horn and is used for a number
of warnings. This is an option. The horn button switch activates the horn to
alert anyone near the drill that the engine is about to be started. The horn button
switch activates the horn to alert personnel in the work zone that the drill is
about to be moved.
38. Not Used Here
39. Not Used Here
40. Switch - Front Windshield Wiper Selector (Option)
The front windshield wiper switch activates the front windshield wiper and has
three positions: High Speed, Low Speed and Off. This is an option.
41. Switch - Rear Windshield Wiper Selector (Option)
The rear windshield wiper switch activates the rear windshield wiper and has
three positions: High Speed, Low Speed and Off. This is an option.
42. Switch - Drilling Side Windshield Wiper Selector (Option)
The drilling side windshield wiper switch activates the drilling side windshield
wiper and has three positions: High Speed, Low Speed and Off. This is an
option.
43. Data Link Socket
The data link socket provides for attachment of computerized engine test
equipment when troubleshooting engine problems. Provided for use by engine
service personnel. Diagnostic lights and toggle switches will be explained
further in the electrical section or TROUBLESHOOTING.
DRILLING SOLUTIONS
4-13
44. Regulator - Air Pressure (HP Only)

The Compressor Air Pressure Regulator regulates the pressure to the
compressor receiver/separator tank. This is for high pressure drills only.
Rotate the adjustment knob clockwise to increase the operating air pressure to
the pressure required for the particular model of down hole drill being used.
Refer to the Bit Air Pressure Gauge (see item 13) while adjusting pressure.
4-14
DRILLING SOLUTIONS
45. Regulator - Compressor Volume Control (HP Only)

The Compressor Volume Control is used to change the angle of the butterfly
valve to decrease the volume (cfm) of air being allowed into the air end. It can
be adjusted to match the volume being used by various down hole drills.
Clockwise rotation increases compressor volume. Counterclockwise rotation
decreases compressor volume. It should be screwed in clockwise for normal
drilling. This is for high pressure drills only.
46. Switch - Compressor ON/OFF (HP Only)
The Compressor ON/OFF Switch opens and closes the inlet valve to allow the
compressor to build pressure or shut off. It makes air when it is in the ON
position and closes the air inlet when it is in the OFF position. This is for high
pressure drills only.
47.
47a Control Lever - Low Pressure Compressor Throttle
This is for low pressure drills only. On low pressure drills, the compressor
control lever is used as an air throttle that turns on the compressed air to
power the Downhole Drill (DHD) and cleans the cuttings out of the hole for
both rotary and downhole drilling.
47b Control Lever - High Pressure Compressor Cold Start
This is for high pressure drills only. The compressor cold start control lever
is used to close the air inlet to the compressor when starting a cold engine.
Closing the air intake prevents build up of pressure within the compressor
rotors and thereby reduces startup torque load on the cold engine allowing
the starter motor to spin the engine at a higher rpm.
DRILLING SOLUTIONS
4-15
48. Controller - Rod Support

The rod support controller activates the hydraulic cylinder that swings the rod
support in and out of position and activates the hydraulic clamp cylinder that
holds the drill rod.
49. Controller-Dust Curtains UP/DOWN
The dust curtain controller energizes the hydraulic cylinders that raise and
lower the dust skirt doors to ensure maximum collection of ejected dust. The
arrow indicates direction of movement. Note: Always check that the dust
curtain is clear of the ground when tramming the drill to avoid damage to the
components.
50. Controller - Tower Locking Pin (Vertical)
The tower locking pin controller activates the hydraulic tower pinning cylinders
and controls the locked or unlocked position of the tower locking pins. Note: It
is unsafe to operate the drill with the raised tower in an unlocked position. If the
4-16
DRILLING SOLUTIONS
locking pin will not engage, notify your supervisor and call Service to correct the
fault.
51. Controller - Tower Locking Pin (Angle)
The angle drill tower locking pin controller activates the hydraulic tower pinning
cylinders and controls the locked or unlocked position of the tower locking pins.
Note: It is unsafe to operate the drill with the raised tower in an unlocked
position. If the locking pin will not engage, notify your supervisor and call
Service to correct the fault.
52. Controller - Tower Raise/Lower
The tower raise/lower controller activates the tower raising cylinders which
extend or retract for raising and lowering of the tower during drill setup.
Note: When raising or lowering the tower, always control the movement to
avoid impact as the tower is brought into final vertical or horizontal positions.
53. Rotary Switch - Water Injection Flow Control (Option)
The water injection flow control rotary switch adjusts the flow rate of water into
the air stream to keep down dust and prevent collaring in the hole when the
water injection pump is running. Rotate the switch clockwise to increase or
counterclockwise to decrease the water flow rate. This is an option.
54. Rotary Switch - Water Injection/Dust Collector Selector
The 3-position water injection/dust collector selector switch is used to select
water injection operation, OFF (neither operation) or dust collector operation.
The water injection operation mode activates the hydraulic motor that engages
the water injection pump which injects a regulated quantity of water into the drill
air stream to suppress dust created by the drilling operation. The center
position disengages both systems. The dust collector operation mode activates
the hydraulic motor that engages the dust collector fan, causing a vacuum
around the hole inside the dust curtain. Small cuttings and dust ejected from
the hole are deposited in the hopper or against the filters.
55. Rotary Switch - Propel/Drill Mode Selector
The propel / drill selector switch is a rotary switch used to select either propel
(tram) mode or drill mode operations.
WARNING
LOSS OF MACHINE CONTROL

Moving the tram (propel) controller (F-STOP-R) quickly may cause loss of
drill control, lurching or serious injury. Move the tram (propel) controller
slowly.
DRILLING SOLUTIONS
4-17
Note: The drilling end is considered the front end of the drill and F & R
symbols relate to the respective directions of travel.
56. Controller - Left Track Propel (Tram)
The left track propel controller is used to control the left hand side track
direction and speed of travel. To propel the drill in either forward or reverse
direction, gradually move the controller in the desired direction until the
required propel speed and direction are effected. To slow and stop drill propel,
move controller slowly towards the STOP position. Positioning the controller in
the STOP position will halt drill propel movement.
57. Controller - Right Track Propel (Tram)
The right track propel controller is used to control the right hand side track
direction and speed of travel. To propel the drill in either forward or reverse
direction, gradually move the controller in the desired direction until the
required propel speed and direction are effected. To slow and stop drill propel,
move controller slowly towards the STOP position. Positioning the controller in
the STOP position will halt drill propel movement.
58. Controller - Dust Collector (DC) Side Leveling Jack
The dust collector side jack controller extends and retracts the leveling jack
cylinder on the DC side drilling end of the drill to raise or lower the drill.
59. Controller - Rear Leveling Jack
The rear jack controller extends and retracts the two leveling jack cylinders on
the non-drilling end of the drill to raise or lower the drill.
60. Controller - Cab Side Leveling Jack
The cab side jack controller extends and retracts the leveling jack cylinder on
the cab side drilling end of the drill to raise or lower the drill.
61. Indicator Light - Dust Collector (DC) Side Jack Retracted
The leveling jack up indicator light illuminates when the leveling jack is up
(retracted) and the drill is safe to tram (propel).
NOTICE
When operating the leveling jack controls, observe the bubble level and
Inclinometer (option). Ensure all three levelling jacks are operated and
adjusted to level the drill in both directions and center the bubble in the
level gauge. Do not exceed 20 degrees inclination on either inclinometer
(option).
62. Indicator Light - Rear Leveling Jack Retracted
4-18
DRILLING SOLUTIONS
NOTICE
(option).
63. Indicator Light - Cab Side Leveling Jack Retracted
NOTICE
(option).
64. Bubble Level (Not Shown)
The air bubble level gauge is used when leveling the drill in both directions. The
tower is designed to be vertical when the bubble is centered. The bubble must
be centered before drilling begins.
65. Control - Heat/Air Conditioning

The heat/air control includes the ON/OFF switch, heat regulator control knob
and an air regulator control knob.
66. Inclinometers Option (Not Shown)
The Inclinometers (not shown), one measuring the transverse angle (cross
gradient) and one measuring the longitudinal angle, are provided to guide the
operator when tramming on inclines where excessive gradients may create an
overturning hazard.
The longitudinal angle inclinometer registers the inclination in direction of travel
while the other transverse angle inclinometer measures the inclination at 90
degrees to the direction of travel. Lower the tower when tramming over
DRILLING SOLUTIONS
4-19
unstable surfaces.
Note: Do not exceed the regulation 10 degree inclination reading on either
inclinometer.
Note: If you are equipped with the optional remote tramming control, lower the
tower when tramming over unstable surfaces and use the remote control
console from a safe working area.
67. Compartment - Instruction Manual Storage (Not Shown)
The instruction manual storage compartment provides a secure, dry location
within easy reach of the operator. Safety and operator instruction manuals
must be available to the operator at all times.
68. Seat - Operators
The operators seat shown is equipped with adjustments for seat position and
angle. Seat position rotation permits the operator a view of the control console
and also the drill platform areas.
NON-CAB CONTROLS & INSTRUMENTS
69. Gauge - Hydraulic Oil Level
The hydraulic oil level gauge is located on the face of the hydraulic tank. The
hydraulic oil level should be monitored and the level maintained using
respective symbol marks as reference. Refer to the Maintenance Instructions
for detailed information.
4-20
DRILLING SOLUTIONS
70. Gauge - Hydraulic Oil Temperature

The hydraulic oil temperature gauge is located on the face of the hydraulic tank
and indicates the operating hydraulic oil temperature.
Note: If the indicated temperature exceeds 220F (104C), shut down the
engine and call for service assistance to correct the problem.
71. Timer - Engine Preheater (Option)
The engine preheater timer, located above the gauges panel on the operators
console, controls the preheater system. The 7 day timer can be preset for a
single start time, one day at a time or programmed start times per day
constantly activated for multiple days of the week. The clock can be preset for
12 or 24 hour time display. The heater run time duration can be preset for 1 or
3 hours. The manual button can be used to override the program and run the
heater indefinitely until it is switched off. (Refer to engine preheater manual for
more information.) This is an option.
DRILLING SOLUTIONS
4-21
Automatic Cable Tension Controls

The automatic cable tension controls are located inside the operators console
between the drill feed functions panel and the compressor functions panel.
Toggle Switch - Automatic Cable Tensioner (Cab Side)

The automatic cable tensioner toggle switch activates the hydraulic motor
driven jackscrew to automatically tension the pulldown cable on the cab side of
the drill.
Toggle Switch - Automatic Cable Tensioner (DC Side)
The automatic cable tensioner toggle switch activates the hydraulic motor
driven jackscrew to automatically tension the pulldown cable on the dust
collector side of the drill.
Toggle Switch - Pullback Tension Cylinders
There are two pullback tension cylinders located at the top of the tower to
maintain tension on the pullback cables. The solenoid switch activates a dual
solenoid valve that vents pressure-releasing tension on the pullback tension
cylinders.
4-22
DRILLING SOLUTIONS
Section 5 - OPERATING
DRILLING SOLUTIONS
5-1
OPERATING SAFETY
Safe Operations
Introduction
WARNING

drill.
WARNING
Always wear the correct safety gear while working on or around the drill.
This includes an approved hard hat, safety glasses, steel toe shoes,
gloves, respirator and ear protection. Do not wear loose fitting clothing
that can become caught in rotating components.
WARNING
and understand Section 4 - Operating Controls and instruments before
you operate or perform any maintenance, service or repairs on the drill.
WARNING
Unexpected drill motion or moving parts can cut or crush. Shut down the
5-2
DRILLING SOLUTIONS
General Information
2. Always chock the tracks if there is a possibility of uncontrolled movement.
5. Do not control propel speed using the engine speed control lever.
6. Always operate the drill at full engine power when drilling or tramming the drill.
7. If your drill is equipped with remote control system option, always use it from a
safe location when propelling on unstable surfaces where there may be a risk
of overturning or when loading onto a transporter where there is a risk of
overturning.
8. Never propel or stop the drill on a slope or surface that is liable to collapse.
crushing risk.
10. Before starting engine, always check to see that the drill/propel mode selector
is in the drill position and both propel control levers and drill feed are at stop
position and that the track brakes are applied.
11. If equipped with horn option always sound it before moving drill in either
direction to alert personnel and allow sufficient time before putting the drill in
motion.
WALK AROUND INSPECTION

Before every shift and prior to starting the drill, a walk around inspection of the overall drill
should be performed. This is in addition to the 10 hour daily routine maintenance procedures.
Performance of this inspection can result in longer life and maximum productivity from the drill.
Check for Hydraulic System Oil Leaks
WARNING
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
DRILLING SOLUTIONS
5-3
A careful inspection of all hydraulic components (pumps, motors, valves, hoses, etc.) should
be made to detect possible leaks or any irregularities. This is particularly important when the
drill is new. Drills have been equipped at the factory with a hydraulic oil containing a blue
colored dye which will aid in early detection of leaks.
Check for Compressor System Oil Leaks
WARNING
High Pressure can cause severe injury or death. Completely relieve

pressure before removing filler plug, fittings or receiver cover.
A careful inspection of all compressor components (air end, air end pump, valves, hoses,
fittings and filters) should be made to insure there are no compressor oil leaks or any
irregularities. This is particularly important when the drill is new.
Check for Coolant System Leaks
WARNING
Always shut down the engine and allow it to cool down before removing
the radiator cap. Remove cap slowly to relieve pressure. Avoid contact
with steam or escaping fluid. Injury can occur when removing the radiator
cap. Steam or fluid escaping from the radiator can burn. Inhibitor
contains alkali. Avoid contact with skin and eyes.
Power pack engine radiators should be checked for leaks. Failure to cool the engine properly
can result in engine failure or severely reduce engine life.
Check for Fuel System Leaks
WARNING
Fuel is flammable. May cause serious injury or death. Shut down engine,
extinguish all open flames, and do not smoke while filling tank or draining
fuel filters. Always wipe up any spilled fuel.
Maintain fuel tanks at a high level to minimize water condensation inside the tank. This is best
accomplished by filling fuel tanks at the end of each day. Check fuel tanks and fuel lines for
possible leaks. Because of the potential fire hazard, leaks must be corrected as soon as they
are spotted. Select the proper grade of fuel oil in accordance with the instructions given in the
5-4
DRILLING SOLUTIONS
Fuel Specifications section of Section 6 MAINTENANCE.
General Checks
Other general checks should be made at this time for any wear and tear on the drill. Check for
broken or cracked welds, loose or missing bolts, broken or inoperative gauges, or any other
irregularities which could lead to more costly breakdowns.
Frequently walk around the drill and inspect for leaks, loose or missing parts, damaged
parts or parts out of adjustment. Perform all recommended daily maintenance.
Operators Areas
1. Keep operators area clean. Clean windshields and all lights. Check that all
lights function.
2. Make sure the operators areas, steps and grab rails are clean. Oil, grease,
snow, ice or mud in these areas can cause you to slip and fall. Clean your boots
of excess mud before getting on the drill.
3. Remove all loose personal items or other objects from the cab and the
operators platform area. Secure these items in a tool box, tool cabinet or
remove them from the drill.
Pre-start Inspection
Before starting the drill, a pre-operation inspection of the overall drill is very important. This
inspection should be performed before each shift and at every startup. These checks and
verifications are in addition to the 8-10 hour daily routine maintenance. Performance of this
inspection can result in longer life and maximum productivity from the drill.
The following are checks and verifications of the overall drill that should be performed prior to
starting. Refer to the instructions given in Section 6 Maintenance for the correct maintenance
procedures and oil specifications.
Check Engine Oil Level
WARNING
oil or hot components to contact the skin.
Check the engine oil level by viewing the dipstick. The drill must be level when checking the
oil level to be sure the measurement is correct. Wait at least 5 minutes after shutting off the
engine to check the oil level. This allows time for the oil to drain into the oil pan. If the oil level
is low, add oil through the fill cap to the fill mark on the dipstick. Refer to the instructions given
in Section 6 Maintenance for the correct maintenance procedures and oil specifications.
DRILLING SOLUTIONS
5-5
CAUTION
Never operate the engine with the oil level below the L (low) mark or
above the H (high) mark on the dipstick.
Check Engine Coolant Level
WARNING
Injury can occur when removing the radiator cap. Steam or fluid escaping
from the radiator can burn. Inhibitor contains alkali. Avoid contact with
skin and eyes. Always shut down the engine and allow to cool before
removing the radiator cap. Remove cap slowly to relieve pressure. Avoid
contact with steam or escaping fluid.
Check the engine coolant level on the radiator sight glass. The level should be maintained so
fluid can be seen in the sight glass. If the coolant level is low, add through filler cap.
NOTE: If the coolant level is below the minimum level, the low-level probe will activate the
engine shutdown. In the case of repeated low level shutdowns, call for service to investigate
cause of coolant loss.
If coolant must be added, use a reliable brand of permanent antifreeze in a 50-50 mixture. It
must be used year round in all climates. Refer to the instructions given in the Maintenance
Procedures section of this manual for the correct procedures.
Check Fuel Level
WARNING
extinguish all open flames, and do not smoke while filling tank. Always
wipe up any spilled fuel.
Check fuel level sight gauge. The tank should be refilled when the fuel level moves to below
1/4 tank. Add clean filtered fuel through the lockable filler cap and bring to the full level on the
sight gauge. Select the proper grade of fuel oil in accordance with the instructions given in
Section 6.3 Capacities/Lubricants/Fuel section of this manual.
5-6
DRILLING SOLUTIONS
Drain Fuel Filter / Water Separator
WARNING
extinguish all open flames and do not smoke while draining fuel / water
filters. Always wipe up any spilled fuel.
The fuel filter / water separator should be monitored daily for signs of water and sediment. If
water is present, drain the water and sediment from the filters / separators. Refer to the
instructions given in the 6.5 Maintenance Procedures section for further information.
Check Compressor Oil Level
WARNING

pressure before removing filler plug, fittings or receiver cover. Hot oil or
components can burn. Avoid contact with hot oil or components.
Check the compressor oil level in the receiver separator tank. With the drill in a level position,
the oil level should be in the middle of the sight gauge. If oil is required, follow the instructions
in 6.5 Maintenance Procedures for correct procedures. Refer to section 6.3 Capacities /
Lubricants / Fuel Specifications for oil details.
Drain Receiver Tank Water
WARNING
High Pressure can cause severe injury or death. Do not attempt to remove
any plugs or open the drain valve before making sure all air pressure has
been relieved from the system. Hot oil can burn. Avoid contact with hot
oil or components.
When compressing air, water will condense in the receiver tank and mix with the compressor
oil. If allowed to accumulate, the water will significantly reduce bearing life. Follow the
instructions in 6.5 Maintenance Procedures for the correct procedure to relieve water from the
system.
DRILLING SOLUTIONS
5-7
Check the Batteries
WARNING
Batteries contain an acid and can cause injury. Battery fumes can ignite
and explode. Do not smoke when observing battery fluid level. Skin and
eye contact with battery fluid can cause injury. Avoid skin and eye
contact with battery fluid. If contact occurs, flush area immediately with
water.
Check the battery posts and cables for corrosion. Check and keep the electrolyte levels above
the battery plates or to the bottom of the fill holes. Refer to 6.6 Maintenance Procedures for
the correct procedures.
Pump Drive Gearbox Oil Level
WARNING
Rotating Shaft can cause severe injury or death. Do not operate with
guard removed. Hot oil or components can burn. Avoid contact with hot
oil or components.
Check the oil level in the Pump Drive Gearbox and maintain it to the bottom of the oil level
plug. Refer to 6.6 Maintenance Procedures for the correct procedures.
Check Hydraulic Oil Level
NOTICE
Dirt in the hydraulic system will lead to premature component failure. A
clean, contaminant free system is extremely important to the drills
proper function. Take extra care when working around or on the hydraulic
system to ensure its complete cleanliness.
CAUTION
Excessive hydraulic oil can rupture the sealed hydraulic tank and cause
injury or property damage. Do not fill hydraulic tank with hydraulic
cylinders extended. Retract all cylinders and fill tank to indicated level.
5-8
DRILLING SOLUTIONS
CAUTION
Any drill defects should be reported to the proper personnel. Defects

must be corrected before operating the drill.
CAUTION
When operating, the oil level must be between the maximum and
minimum.
The hydraulic oil level should be checked by the sight gauge on the hydraulic tank. The oil level
in the hydraulic tank depends on the extended or retracted positions of the hydraulic cylinders.
It is important to follow the directions in the Maintenance Procedures section of Section 6
MAINTENANCE when reading the level gauge:
1. The oil level with all hydraulic cylinders retracted, tower down, jacks up and
rotary head at the top of the tower should be between the FULL mark and the
MINIMUM mark on the sight gauge.
2. The top of the oil level MUST be visible when the engine is running AND when
the engine is stopped. There must be oil showing on the gauge at all times.
Note: If no oil is showing on the sight gauge, stop the engine immediately. Call
for service assistance to investigate the cause of oil loss.
3. Add oil to bring oil to the level defined above by following directions in the 6.5
Maintenance Procedures section of this manual. Select the proper grade of oil
in accordance with the information given in the 6.3 Capacities / Lubricants /
Fuel Section.
DRILLING SOLUTIONS
5-9
Keep Operators Areas Clean

Clean windshields, mirrors and all lights. Check that all lights function.
Make sure the operators areas, steps and grab rails are clean. Oil, grease, snow, ice or mud
in these areas can cause you to slip and fall. Clean your boots of excess mud before getting
on the drill.
Remove all personal items or other objects from the floor of the operators area. Secure these
items in a tool box or remove them from the drill.
Pre-operation Controls Inspection

Before starting the drill, a check to verify that the Warning Lights, Backup Alarm, Horn and
Emergency Stop controls are functioning properly is very important. This inspection should be
performed before each shift and at every startup.
Any drill defects should be reported to the proper personnel. Defects must be corrected before
starting and operating the drill.
The following are checks and verifications of the drill controls that should be performed prior
to starting. Refer to Section 4 OPERATING CONTROLS.
5-10
DRILLING SOLUTIONS
Warning Controls Check

1. Turn the drill / propel selector switch to the drill mode position.
2. Be sure both the left track controller and right track controller are in the stop
positions. The controllers are spring centered to the stop position when
released.
Note: If the controllers do not return to the stop position when released, have the
defect rectified immediately. In drill mode, propel controllers are de energized.
3. Put both the drill rotation controller and the drill feed controller in their stop
positions.
4. Set the engine throttle (speed) switch to low idle position (1200 rpm).
5. Turn the on/off key switch to on position. The backup alarm should emit an
intermittent beeping sound when the drill / propel selector switch is in propel
mode. Turn the drill / propel selector switch to drill mode and the backup alarm
should stop.
6. With the on/off key switch in the on position, the following warning lights on
the console should illuminate to verify the following warning lights and audible
alarms are functioning.
a. The red tower pinning indicator light should be on if unpinned.
b. All three (3) of the green leveling jacks retracted indicator lights should be
on when jacks are up.
c. In drill mode only, no backup alarm will sound.
Note: If any lights do not illuminate, notify service personnel to rectify the
defect.
7. Turn the on/off key switch to off position.
8. Press the horn button to confirm that the horn is functioning properly. This is
an option.
9. Put the drill / propel selector switch into propel mode position. Move the right
track controller in either direction away from stop. Turn the on/off key switch to
the on position and press the starter button. The engine should not start.
10. Put the drill / propel selector switch into drill mode position. Move the left track
controller in either direction away from stop. Turn the on/off key switch to the
on position and press the starter button. The engine should not start.
11. With the drill / propel selector switch in drill mode position, move the drill feed
controller in either direction away from stop. Turn the on/off key switch to the
on position and press the starter button. The engine should not start.
12. With the drill / propel selector switch in drill mode position, move the drill
rotation controller in either direction away from stop. Turn the on/off key switch
to the on position and press the starter button. The engine should not start.
DRILLING SOLUTIONS
5-11
13. Pull the emergency stop button switch out. Turn the on/off key switch to the on
position. The red light inside the emergency stop button switch should come on
and stay lit when the switch is pulled out in the run position.
14. Check the emergency stop by starting the engine (See instructions for starting
the engine). Push in the emergency stop switch. The engine must immediately
stop and the parking brake light (option) should illuminate, indicating that the
brakes are applied.
Note: Before the engine can restart after being shut down with the emergency stop
switch, the switch will first need to be reset. Pulling out the red button resets the
switch.
Note: If the engine diagnostic lights come on only momentarily, then there is a fault
code. Check engine manufacturers Operation and Maintenance manual for full
trouble shooting instructions.
Engine Operation
WARNING
Read and understand Section 2 Safety Precautions and Guidelines before

you operate or perform any maintenance, service or repairs on the drill.
WARNING
and understand Section 4 OPERATING CONTROLS before you operate
or perform any maintenance, service or repairs on the drill.
1. Before starting engine or beginning to move drill, check inside, outside and
underneath drill for people or obstructions.
2. Check for warnings or lockout tags on the controls. If there is a tag attached to
the switch, do not start the engine until the warning tag has been removed by
the person who installed it.
3. START the engine from the operators position only.
4. AVOID leaving the controls with the engine running. NEVER leave the
operators cab while the engine is running.
CAUTION
If any controls, instruments or devices do not function correctly, refer to
5-12
DRILLING SOLUTIONS
the TROUBLE SHOOTING section or report any drill defects to the proper
personnel. Defects must be corrected before starting and operating the
drill.
Engine Starting Procedure

Move all levers, switches, etc. on the control console to the off, neutral or minimum flow
position. All gauges should read zero. If equipped with horn option, sound it before starting the
drill to alert everyone in the area.
1. Make sure all controls are in neutral or off positions.
2. Make sure the drill / propel selector switch is in the drill mode position.
3. Make sure the left track controller and the right track controller are in the stop
positions.
4. Make sure the drill rotation controller and drill feed controller are at the stop
positions.
5. Make sure the emergency stop button switch is pulled out (reset).
6. Make sure the engine throttle (speed) switch is set at the low idle position (1200
rpm).
7. MAKE SURE no one is at danger or risk before starting the engine.
DRILLING SOLUTIONS
5-13
Start Engine
1. Turn the ignition key switch to the ON position.
2. If engine has been shutdown over night, depress and hold in the fuel primer
button until primer pump forces fuel into the engine and the pump slows down
(an audible clicking is heard while the pump is pumping), then release the
button.
3. Move the compressor control lever to the closed position and hold the lever
there.
4. When the engine starts, release the starter button.
NOTICE
The starter may overheat if operated longer than 30 seconds. If the engine
fails to start, allow the starter to cool 2 to 3 minutes before trying again.
5. Slowly release the compressor control lever once the engine is running evenly.
WARNING
Do not let the engine run for more than 20 seconds with the compressor
control (HP cold start) lever in the closed position. Damage to the
compressor can result (See Compressor Operation).
Note: Run the engine for a short time to warm up the engine and hydraulic
systems.
6. Once the engine is running with the ON/OFF key switch in the ON position,
the fault indicator warning lights should only light up to indicate a fault. If any
light illuminates and stays lit, contact proper service personnel.
7. Allow engine to warm up at idle speed (1200 rpm). The engine water
temperature should be 175F (80C) and the hydraulic reservoir temperature
gauge should read a minimum of 100F (38C) before increasing engine
speed.
8. The compressor should be run unloaded until compressor oil reaches a
minimum temp. of 150F (66C).
9.
After warm up, increase engine speed to full load speed (1800 rpm) by turning
the engine throttle .
10. On cold weather starts, pull and hold compressor control lever (manual inlet
valve control) until engine maintains 1200 rpm, then slowly release the handle.
Compressor should build pressure to 150-175 psi (10.34-12.07 bar) and then
the inlet valve should close.
5-14
DRILLING SOLUTIONS
NOTICE
Do not operate valve to load compressor at less than full load speed (1800
rpm).
Compressor Cold Start

The compressor, connected to the engine, requires a lot of power to run. On a cold day, the
horsepower required may be greater than the engine can deliver at low rpm. Therefore, it is a
good practice to start the engine with the compressor inlet closed.
1. Move the compressor inlet control (cold start) lever to the closed position.
2. Start the engine and warm all fluids up to operating temperature (Refer to the
Start Engine procedure).
3. When engine has reached low idle speed of 1200 rpm, slowly release the
control and let the compressor build up to the starting pressure 150-175 psi
(10.34-12.07 bar).
Ether Cold Start Option

Starting aids are extremely flammable and can explode. Overloading the engine air intake
system could result in an explosion. Avoid overloading the engine air intake system with
starting aids.
1. The ether cold starting air option is available for starting engines when ambient
temperature is below 50F (10C).
2. To use this option for starting, press and release the ether injection button while
pressing the starter button switch. Ether is only injected when the starter button
is operated.
Verify Gauges & Controls

After starting the engine, a check to verify that the gauges and engine diagnostic lights are
functioning properly is very important. This inspection should be performed before each shift
and at every startup.
DRILLING SOLUTIONS
5-15
1. With engine running, verify that engine diagnostic lights temporarily light up and
then go out.
2. With engine running, the engine tachometer should read 1200 rpm on low idle.
3. With the engine running, the engine oil pressure gauge should not read less
than 10 psi (.69 bar) on low idle nor less than 27 psi (1.86 bar) on high idle.
Note: There is a pressure monitoring system on the engine that will shut down the
engine immediately in the event that the oil pressure drops below 10 psi (.69
bar) on low idle or less than 27 psi (1.86 bar) on high idle; otherwise the engine
could be severely damaged.
4. With the engine running, the supercharge pressure gauge must be above 65
psi (4.48 bar).
5. With the engine running, the water temperature gauge indicator will show a
reading as engine warms up. Normal engine operating temperature is from
150-208F (65-98C). The system will shut down if the water temperature
exceeds 210F (99C).
6. With engine running and the air compressor turned off, the air pressure gauge
should show approximately 150 psi (10.34 bar).
7. Before starting any operation of the drill, allow the hydraulic oil in the hydraulic
tank to warm up until the hydraulic oil temperature gauge, located on the side
of the hydraulic tank, indicates 100F (38C).
5-16
DRILLING SOLUTIONS
Engine Speed Control
WARNING
A runaway drill can cause injury or death. Do not attempt to control drill
travel speed with the engine speed control. Use the tram control (F-STOPR) to control travel speed. Maintain engine speed at operating 1800 RPM
for all drill operations.
The engine speed (throttle) control is used to select engine speed (rpm). The engine should
always be run at low idle for 5 minutes before shutdown to allow the turbo charger to cool
down.
Cat engines turn the control knob CCW to increase the rpm and CW to decrease the rpm. The
controller is equipped with a tension nut to maintain the required engine rpm. The tension nut
is located just behind the control knob. Turn the nut CW to tighten and CCW to loosen nut. The
control knob has a quick return to Low Idle, by pushing in on the control knob (towards the
tension nut) the rpm returns to 1200 rpm. The tension nut must be loose to increase or
decrease the rpm with the control knob. Trying to increase or decrease the rpm with the
tension nut tightened down could damage the engine speed throttle control. Engine speed
range is 1200 RPM to 1800 RPM.
Cummins engines turn the control knob CW to increase the rpm and CCW to decrease the
rpm. The controller is equipped with a tension nut to maintain the required engine rpm. The
tension nut is located just behind the control knob. Turn the nut CW to tighten and CCW to
loosen nut. The control knob has a quick return to Low Idle, by pushing in on the control knob
(towards the tension nut) the rpm returns to 1200 rpm. The tension nut must be loose to
increase or decrease the rpm with the control knob. Trying to increase or decrease the rpm
with the tension nut tightened down could damage the engine speed throttle control. Engine
DRILLING SOLUTIONS
5-17
speed range is 1200 RPM to 1800 RPM.

Note: Always ensure that the engine speed is at Operating 1800 RPM before tramming or
drilling. Full engine power is necessary to obtain the proper component operation and
maximum rpm for greatest efficiency
Water Temperature Gauge

The water temperature gauge shows the temperature of the engine coolant system. Normal
operating temperature is from 150-208F (65-98C). The system will shut down if the
temperature exceeds 210F (99C).
Stopping Engine
The following procedure is to inform the operator or service personnel how to turn off the
engine. The procedure is part of the Normal Drill Shutdown shown in the 5.12 STOPPING,
PARKING & SHUTDOWN section.
High Pressure (with out EARs)
1. Return all controls to their neutral, off or minimum flow position. Close all
service valves.
2. Turn compressor switch to off and allow the receiver to blowdown to minimum
pressure. Pressure in the compressor receiver tank must be below 150 psi
(10.34 bar) before stopping engine.
3. Turn the engine (speed) throttle control to low idle (1200 rpm) position for about
5 minutes to allow the engine to cool down.
4. Turn the key switch to the OFF position. The air receiver pressure will
automatically blow down.
5. After the engine has stopped, make sure the compressor blowdown valve
opens and blows all the air out of the receiver tank. Check air pressure gauge
to insure no pressure remains in the system. If so, it may be necessary to purge
5-18
DRILLING SOLUTIONS
the system by opening the manual blow down valve.

6. Remove the key when you leave the operators cab.
Low Pressure (with out EARs)
1. Return all controls to their neutral, off or minimum flow position. Close all
service valves.
2. On low pressure drills, the compressor is turned on and off with the use a
manual inlet control. This is a lever and cable arrangement. Pull the lever
towards the operator to close the inlet.
3. Turn the engine (speed) throttle control to low idle (1200 rpm) position for about
5 minutes to allow the engine to cool down.
5. After the engine has stopped, make sure the compressor blowdown valve
opens and blows all the air out of the receiver tank. Check air pressure gauge
to insure no pressure remains in the system. If so, it may be necessary to purge
the system by opening the manual blow down valve.
DRILLING SOLUTIONS
5-19
High or Low Pressure with EARs
1. Return all controls to their neutral or minimum flow position. Close all service
valves.
2. Turn compressor on/off switch to off position.
3. Move the engine throttle (speed selector) switch to low idle (1200 rpm) position
for about 5 minutes to allow the engine to cool down.
5. After the engine has stopped, the compressor vent valve opens and blows all
the air out of the receiver tank. Check air pressure gauge to insure no pressure
remains in the system. If so, it may be necessary to purge the system by
opening the manual blow down valve.
Emergency Shutdown
Every attempt should be made by the operator to shut the drill down under normal
conditions to prevent damage to the drill. When a high pressure compressor is shut down
at high pressure, the regulation system causes the air end to become a pressure vessel that
will force compressor oil back up into the intake filters when the inlet butterfly valve opens. The
element will have to be replaced and the tubes cleaned before the drill can be put back into
service.
When a high or low pressure compressor with (EARS) Electronic Air Regulation System has
to emergency vent the following occurs. The controller commands the butterfly valve closed
and opens the vent valve. This allows quick system reaction to over pressure spikes.
5-20
DRILLING SOLUTIONS
The Emergency stopping procedure for the drill may be very abrupt. This abrupt stop may
damage the drill due to potentially high stress loading on its components. There are two types
of emergency shutdowns. One is by the operator pushing the Emergency Stop button and the
other is when one of the shutdown devices on the drill has registered an out of limit condition.
If the operator or other personnel are in immediate danger or if an emergency arises that is
not under the protection of the shutdown devices, such as fire or other outside problem, initiate
an emergency stop with the following procedure: Push in the Emergency Stop Button and
exit the drill.
If the operator or other personnel are not in immediate danger and the preservation of the drill
equipment is the primary concern, proceed as follows:
1. All of the drill shutdown devices have gauges that show the operating
temperature or pressure of the system they monitor. Thus, the operator should
be able to avoid a shutdown condition if he checks the gauges frequently.
When one of the emergency stop or shutdown devises is energized, it immediately shuts off
fuel to the engine. All engines are energize to run, which means there must be power to the
fuel valve to allow fuel to flow. If power is lost, the fuel valve closes and stops the engine.
Starting and Stopping Hints

1. Do not operate the starter motor for more than 30 seconds at one time. If it is
operated for 30 seconds and the engine does not start, stop and allow the
starter motor to cool for two minutes before attempting restart.
2. Immediately after starting engine, watch the engine oil pressure for trouble
signs.
3. If engine is shut down during warm up period, do not restart without following
steps 4 and 5 in STOPPING ENGINE
4. When starting up after an oil change, run the engine briefly. Then shut it down
for ten minutes to allow the oil to drain back into the crankcase. Then check oil
level.
5. Other than start up, idling during warm up and cool down, the engine should
always be run at full speed before performing any set up, tramming or drilling
operations.
DRILLING SOLUTIONS
5-21
Compressor Operation
Low Pressure Operation
The following procedure is to inform the operator or service personnel how to turn on, operate
and turn off the low pressure compressor. On low pressure drills, the compressor is turned on
and off with the use of a manual inlet control. This is a lever and cable arrangement. Refer to
7.4 Low Pressure Compressor section in section 7.
Start Position
When the drill is first started, the control handle in the operators cab is in the OFF position.
The inlet butterfly valve is closed. The only air entering the compressor is through the orifice
in the inlet butterfly valve. Air pressure in the receiver tank is maintained at a minimum until
the inlet butterfly valve is opened.
Run Position
1. The compressor should not be turned on until the engine is running at full
speed (1800 rpm).
2. When the operator wishes to drill, he pushes the control handle to the ON
position which opens the inlet butterfly valve and allows the compressor to
compress air.
To Stop Compressor
1. Pull the lever towards the operator to close the butterfly inlet valve.
2. Move the engine throttle (speed selector) switch to low idle (1200 rpm)
position for about 5 minutes to allow the engine to cool down.
5-22
DRILLING SOLUTIONS
High Pressure Operation

and turn off the high pressure compressor. On high pressure drills, the compressor on/off
switch is used to turn compressor on and off. Refer to 7.5 High Pressure Compressor section
in section 7.
Start Position
When the drill is first started, the compressor ON/OFF switch should be in the OFF position.
The inlet butterfly valve is closed.
Run Position
1. The compressor should not be turned on until the engine is running at full
speed (1800 rpm).
2. Push the control handle to the on position and place the on/off switch to on
position. Turn the air pressure regulation knob CW (in) to increase the
pressure to near the desired amount. Turn the compressor volume control
knob CW (in) slowly to fine tune the pressure to the desired pressure
needed.
To Stop Compressor
1. Move the compressor ON/OFF switch to the OFF position. The OFF
position will close the butterfly inlet valve and stop the compressor from
compressing air.
2. Move the engine throttle (speed selector) switch to low idle (1200 rpm)
DRILLING SOLUTIONS
5-23
Ears Compressor Operation

and turn off the EARS compressor. The compressor on/off switch is used to turn compressor
on and off. Refer to EARS Compressor section in section 7.
Start Position
For startup, the controller will command the butterfly valve closed to prevent air entry into the
compressor and command the vent valve (previously called blow down valve) open to vent the
receiver to atmosphere. This allows the engine to start with the least possible load. After the
engine speed reaches the minimum RPM there is a factor set delay to allow the engine to
stabilize after which the controller regulates the compressor.
Run Position
1. The compressor should not be turned on until the engine is running at full speed
(1800 rpm).
2. Turn the compressor on/off switch to on position. To regulate the air flow or the
air pressure is to turn the air flow knob or the maximum pressure knob CW to
the desired air needed. The system automatically maintains the air pressure or
air flow the operator is needing for the job.
To Stop Compressor
1. Turn the compressor on/off switch to the off position. In the off position the Flow
Control is set to minimum flow and the Maximum Pressure is set to minimum
holding tank pressure.
2. Move the engine throttle (speed selector) switch to low idle (1200 rpm) position
for about 5 minutes to allow the engine to cool down.
5-24
DRILLING SOLUTIONS
Propel Operation
RECOMMENDATIONS AND CHECKS
1. Before starting the engine or beginning to move drill, check inside, outside and
underneath the drill for people or obstructions. Check the work area for
obstacles and personnel.
2. Make sure the horn and backup alarm are working properly. Refer to Backup
Alarm Check Procedure shown below.
3. Check all instruments and warning lights. If the instruments and lights indicate
a fault or a problem, contact the appropriate personnel to correct them.
4. Make sure that all drill lights are working and provide a good illumination of the
working area.
5. Always be aware of the risk of overturning when propelling on ramps which are
unstable or have steep slopes. Maintain a safe distance between the edge of
the ramp and the outer edges of the tracks.
personnel in the area. Allow sufficient time before putting the drill into motion.
Backup Alarm Check Procedure

After starting the drill, a check to verify that the backup alarm is functioning properly is very
important. This inspection should be performed before each shift and at every startup.
1. Start the engine (Refer to starting the procedure in shown in Engine Operation).
2. To check that the backup alarm is functioning properly, move the propel/drill
mode selector to propel. An intermittent alarm should sound immediately. If no
alarm sounds, contact the proper service personnel and correct the problem
before operating the drill.
Hydrostatic Brake System Check Procedure

After starting the drill, a check to verify that the hydrostatic brakes are functioning properly is
very important. This inspection should be performed before each shift and at every startup.
DRILLING SOLUTIONS
5-25
NOTICE
Note: This drill rig is equipped with spring applied disc brakes which are
automatically applied in the event of an engine shutdown or hose failure
causing loss of brake release pressure.
Observe the area around the drill for personnel and obstructions. Check for correct operation
of the hydrostatic service brake system by tramming the drill in forward and reverse directions
using the propel controllers to alternately accelerate and brake the drill movement.
Note: Braking should be smooth and capable of bringing the drill to a complete stop when the
propel controllers are placed in the STOP position. If not, contact service personnel
immediately
Propel (Tramming) the Drill

1. Check the travel and work areas for personnel and obstructions.
2. Make sure all the controls are in the neutral, stop or OFF position. The drill/
propel selector should be in the drill mode position.
3. Start the engine (refer to the starting procedure in shown in Engine Operation).
4. When the engine, hydraulic and compressor oils have all reached 100F
(38C), the drill can be operated.
5. Increase the engine speed to full operating speed. This speed affords
maximum torque for tramming up grades and gives a maximum tramming
speed to 1.1 mph (1.77 km/hr).
Note: Never use the engine speed control to control the speed of travel.
6. Move the propel/drill mode selector to propel. The main pump flow is diverted
to the propel controllers. The drill may be moved. The brakes will automatically
release as hydraulic flow to the propel motors increases.
7. The track propel controllers regulate track direction, speed of travel, and the
service braking function. To propel the drill in either forward or reverse
direction, gradually move controllers in the desired direction until the required
propel speed and direction are effected. To slow and stop drill tramming, move
the controllers slowly towards the STOP position. Positioning the controllers in
the STOP position will halt drill propel movement and apply the brakes.
WARNING
LOSS OF MACHINE CONTROL - Moving the propel controllers (F-STOPR) quickly may cause loss of drill control, lurching or serious injury. Move
the tram (propel) controllers slowly.
5-26
DRILLING SOLUTIONS
8. Shift the two controllers, labeled RIGHT TRACK and LEFT TRACK, to
control the speed and direction of each track. If both controllers are pushed
forward evenly, the drill will go straight ahead, towards the non-drilling end.
When the controllers are in neutral, the drill will not move. The drill will move
towards the drilling end when the controllers are pulled toward the operator.
9. Each propel track motor is operated independent from the other. Steer the drill
by moving the propel controllers and control direction of track rotation of the
respective left hand and right hand track. This way, the drill can be counter
rotated when operating in a close area. Controlled radius turning of the drill can
be achieved by holding one controller slightly ahead or behind the other. In
addition, counter rotation and skid steer turns can be accomplished.
WARNING
If the drill is moving and something causes the drill to start to run away,
immediately move the drill/propel selector to DRILL mode. This will shift
the diverter valves to DRILL and stop any more oil from passing through
the propel motors. It will stop the drill.
10. During tramming, monitor the inclinometers to ensure the drill does not exceed
slopes of 10 in either a straight direction of travel or at a 90 angle to the line
of travel.
Stopping Drill Propel

1. For normal braking, move the propel controllers towards the OFF position.
2. To completely stop the drill movement, position the propel controllers in the
OFF position.
3. Unless you are intending to move the drill immediately, move the drill/propel
mode selector switch to DRILL position. This action sets the brakes on the
propel motors and keeps the tracks from moving.
DRILLING SOLUTIONS
5-27
Drill Setup
Prepare Drill and Area
1. Observe the area around the drill for personnel and obstructions.
2. Make sure bits and tools are stowed correctly so people do not fall over them
while doing their jobs.
3. Always sound the horn, located on the operators control panel, before starting
the drill to alert everyone in the area.
4. Monitor all the instruments and warning lights. If any indicate a fault or a
problem, contact the service personnel.
5. Make sure the drilling lights and tram lights are operational before dark.
Leveling The Drill
WARNING
Be sure the ground is level and solid before lowering jacks. Never stop
the drill against a high wall that is liable to collapse or cause a crushing
risk.
1. On arrival at the hole location, position the drill on a level, firm surface.
2. Always check to see that the drill/propel mode selector is in the drill position and
both propel controllers and the drill feed controller are at stop position.
3. Increase engine speed to full speed with the engine throttle selector knob.
4. Evenly extend the leveling jacks. Keep drill level as indicated by the bubble in
the bubble level gauge.
a. First extend the two drilling end leveling jacks on the drilling end and level
the drill side to side by adjusting the drilling end levelling jack controllers.
b. Extend both of the non-drilling end leveling jacks with the non-drilling end
leveling jack controller and level the drill front to back until the level bubble
is centered.
5-28
DRILLING SOLUTIONS
DRILLING SOLUTIONS
5-29
Tower Raising
DANGER
Do not raise the tower or operate this drill in the vicinity of electrical
power lines. Operating too close or contacting a power line with any part
of the drill can result in electrocution. Contacting power lines with any
part of the drill will cause Death! Keep at least 10 feet (3 meters) away
from power lines. If there appears any danger of wind or other obstruction
closing the distance, do not drill in that area.
1. Check all hoses and cables to be sure that they are free and clear. Also, check
for tools and loose objects on tower before proceeding.
2. The engine should be at full speed and the drill must be on the leveling jacks
and be level.
3. Use the tower raise/lower controller to raise the tower. The tower raise/lower
controller is spring loaded to center, so it must be held in position. As the tower
approaches the vertical position, slowly move the controller to its center
position to allow the tower to position without impact. Never slam the tower into
the vertical position. Center the controller when the tower is vertical.
Tower Locking
1. Position the tower locking control into the pinned position and check that the
tower unpinned warning light is not illuminated. When the locking pins are fully
engaged, the light should extinguish.
2. Check the level bubble and adjust leveling jacks as necessary to center the
bubble. The tower is vertical when the bubble is centered.
Angle Locking
1. Position the tower angle locking control into the pinned position and check
that the tower angle unpinned warning light is not illuminated. When the locking
pins are fully engaged, the light should extinguish.
Note: When the drill is being used with the angle drilling option, it is still necessary
to level the drill before raising the tower to the required angle.
Tower Lowering
1. Make sure the drill is level and the rotary head is at the top of the tower so no
components of the drill string protrude from the base of the tower. Also, make
sure there are no tools or other loose objects on the tower or any other place
5-30
DRILLING SOLUTIONS
where they could fall or interfere with the movement of the tower.
2. Move the tower locking control to the unpinned position.
3. Lower the tower using the tower raise/lower controller. As the tower
approaches the tower rest at the rear of the drill, ease up on the controller and
let the tower settle onto the rest. Do not let the tower drop on this rest with
extreme force.
4. Center all controls when the tower is on the support.
Overpressure Control System

Every drill is equipped with an overpressure control system to help prevent tipping of the drill
by over feeding during the drilling process. A pilot valve, mounted under each drilling end jack
cylinder nipple , is closed as long as the jack is extended with the jack pad firmly on the ground.
If the jack pad is raised off the ground, or the ground gives way under the pad, the nipple will
push the pilot valve plunger down and open the two way valve, allowing all pressure to vent
from the A port. This reduces all down pressure from the pump until the jack pad is firmly on
the ground. This action reduces the feed pressure to zero (0) psi and prevents the drill rod from
extending further. Both jack pads must be firmly on the ground so the pilot valve plungers
extend and close. Pressure is then returned to the feed system.
This system does NOT relieve the operator from the responsibility of having control of
the drill at all times. While the OverPressure reduces the chance of a tip over, the
operator must see that he does not overfeed the drill to this extent.
The operator must also take care in locating the leveling jacks on firm ground. Nothing can
prevent the drill from upsetting if the ground or shoring under the leveling jacks gives away.
Note: Liability for tipping a drill over lies solely with the driller.
Over Pressure System Test

Do not test the Overpressure Control System with a drill pipe in the rotary head. 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 (50.8mm) off the ground. The drill
weight must be fully supported by the leveling jacks.
DRILLING SOLUTIONS
5-31
Step Two:
Raise the tower and pin it in the 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, reduce system pressure with the feed controls, level
the drill and contact your supervisor for system repairs immediately.
Step Six:
Repeat steps 4 and 5, this time raising the dust collector side jack slightly. If pressure
vents when the jack pad is lifted slightly off the ground, the system is working.
If it does not vent pulldown pressure, shut down the drill immediately and report any
problems encountered to your supervisor.
5-32
DRILLING SOLUTIONS
Carousel
CAROUSEL PV-275
DRILLING SOLUTIONS
5-33
CAROUSEL PV-271
The carousel (or rod holder) is used to transfer drill rod from the ground or another vehicle to
the rotary head when adding or removing drill rod from the drill string. After the carousel has
been initially loaded with drill rod, it becomes a rod holder and is used to add and remove drill
rod from the drill string.
The carousel is mounted on the rod changer and can be hydraulically positioned under the
rotary head for loading drill rod from the carousel to the rotary head or unloading drill rod from
the rotary head to the carousel.
The drill may be delivered to the work site with or without drill rods loaded into the rod changer
carousel. Before tramming the drill to the work site hole location, it is recommended that the
carousel be loaded with the required amount of drill rods. The PV-271 Single-Pass has a tworod carousel for 25 ft. (7.6m) rods for a 55 ft. (16.7m) single-pass application or 105 ft. (32.3m)
maximum depth. The PV-275 Multi-Pass has a four-rod carousel for 40 ft. (12.19m) for a 195
ft. (59.4m) maximum depth. Refer to section 5.9 Drill Rod Handling for drill rod loading
information.
5-34
DRILLING SOLUTIONS
1. Position the drill on a level, firm surface.

2. Move the propel/drill mode selector to DRILL.
3. Increase engine speed to 1800 rpm.
4. Evenly extend the leveling jacks to maintain the level of the drill as indicated by
the bubble in the level gauge.
a. First adjust the drilling end leveling jacks until the bubble is centered.
b. Adjust the non-drilling end leveling jack until the bubble is centered.
5. Use the tower raise/lower controller to raise the tower. As the tower approaches
a vertical position, slowly move the control to its center position to allow the
tower to position without impact.
6. Position the drill tower locking pin control into the locked position and check that
the drill tower locking pin disengaged warning light is not illuminated. When the
pin is fully engaged the light should extinguish.
Carousel Operating Procedure

The instructions below are for operating the carousel prior to loading.
1. With the tower in vertical position, use the carousel swing controller to swing
the carousel open all the way. The carousel swing controller activates the
carousel swing cylinders which move the carousel under the rotary head.
2. With the carousel index controller, rotate the carousel so an empty drill pipe
holding cup is in line with the rotary head spindle.
PV-271 Single-Pass - The carousel index controller activates the rod indexing
cylinder that rotates the carousel into the forward position (clockwise) to align the
drill rod under the rotary head.
DRILLING SOLUTIONS
5-35
PV-275 Multi-Pass - The carousel index controller activates the rod indexing
motor that rotates the carousel into the forward position (clockwise) to align the
drill rod under the rotary head.
3. When the drill rod is correctly aligned, the drill rod will have been positioned
with its axis aligned to the axis of the rotary head spindle. Continue the loading
or unloading process. Placing the controller into reverse position will rotate the
carousel counterclockwise to the next loading or unloading position.
Drill Rod Handling
WARNING

drill.
Safety should be the main concern for anyone working on or around the
drill. Do not perform any function that could put someone in danger.
Always wear correct safety gear while working on or around the drill. This
includes an Approved Hard Hat, Safety Glasses, Steel Toe Shoes, Gloves,
Respirator and Ear Protection. Do not wear loose fitting clothing that can
become caught in rotating components.
WARNING
drill before performing any maintenance to the drill.
General Operation
1. Do not speed engine when it is cold
2. After starting the engine, wait until the hydraulics and the air end are up to
normal operating temperatures before operating the drill. Do not speed engine
when it is cold.
5-36
DRILLING SOLUTIONS
5. Do not control propel speed using the engine speed control.

6. Always operate the drill at full power when drilling or tramming.
7. If drill is equipped with the remote control system option, always use it from a
safe location when propelling the drill on unstable surfaces where there may be
a risk of overturning or when loading onto a transporter where there is a risk of
overturning.
crushing risk.
is in the drill position and both propel controllers and drill feed controller are at
stop position and that the track brakes are applied.
personnel and allow sufficient time before putting the drill in motion.
Drill Rod Loading

There are two (2) times that drill rod loading is required. The first is at initial start-up and the
second is when the drill rod becomes unusable due to wear or damage and must be replaced.
This section will address both the initial rod loading and the field replacement rod loading
procedures.
Initial Drill Rod Loading (from ground)
WARNING
Drill rods are extremely heavy. All lifting equipment must be adequately
sized for lifting and be in good condition. Extreme care must be exercised
in handling drill rod safely. Death or serious injury can occur if safe work
practices are not followed.
NOTICE
Minimum safe manpower requirements for this task = 3 persons.
Drill rod can be loaded onto the drill from the ground or from a truck. Both methods are
acceptable when safe work practice is followed.
1. Lay out the drill rods in a parallel direction to the undercarriage with the pin end
about three feet (3) or one meter (1m) from the drilling end dust curtain door.
DRILLING SOLUTIONS
5-37
2. Screw the lifting bell on the pin end of the drill rod carefully as far as it will go.
(Note that hand tight is normally satisfactory.)
3. After tightening the lifting bail, inspect it to ensure it is completely screwed on
the pin thread.
4. Remove the plastic thread protector plug installed in the box end of the drill rod.
5. Open the provided access gate in the drill deck guard rail.
6. Lower the dust hood.
7. Ensure the rotary head is parked against the top stops in the tower.
8. Using the hoist winch control, lower the safety hook to the drill rod pin.
9. Release the safety hook and hook it to the lifting bail loop.
10. Using the jack controllers, raise the drilling end jacks until jack pads are just
touching the ground (machine down direction).
11. Lower (extend) non-drilling end jacks to their furthest position (machine up
position).
12. The drill will now be in a position of maximum height on the non-drilling end and
minimum height on the drilling end. This position will also allow the drill rod to
be safely lifted without damaging the drills dust door, deck, kick plate, or items
on the drill table.
13. Open the rod support using the controls in the operator cab.
14. Gently begin picking up the drill rod using the hoist control.
WARNING
Do not stand or work under a suspended load. Failure of lifting equipment

or sudden unforeseen movement can cause death or serious injury.
15. When the drill rod is raised to a level that will allow the box end to clear the drill
deck, lower the non-drilling end of the drill slowly to allow the drill rod to swing
across the deck and rest against the drill table.
16. When the drill rod is resting against the drill table, gently raise the drill rod to a
height that will clear the drill table.
17. Lower the non-drilling end of the drill and level the machine.
18. Using the hoist controller, raise the drill rod so the box end clears the carousel
cup by about two (2) inches (53mm).
19. Carefully open the carousel to the load position.
20. When the carousel is in the correct position, stand beside the drill rod and
maneuver it into the carousel and seat it in the upper lock section of the
carousel.
5-38
DRILLING SOLUTIONS
WARNING
Do not stand directly under the drill rod or put hands and fingers in pinch
points. Serious injury can occur if sudden uncontrolled movement
occurs.
21. When the drill rod is correctly positioned in the top carousel section, the bottom
should be lined up to lower into the carousel cup.
22. Carefully align the wrench flats on the drill rod with the cup flats and lower the
rod into the cup.
23. When the rod is loaded into the carousel, release the tension on the auxiliary
winch line and swing the carousel to the stowed position.
24. Lower the winch line to leave a 1 ft. or (304.8 mm) of slack.
25. Lower the tower to the horizontal position.
26. When the tower is lowered, climb into the tower via a tower access ladder and
tower access platform.
CAUTION
Correct personal fall protection gear must be used in case of a fall or slip
to prevent injury.
27. Using 3-point contact, use the drill tower structure to access the upper end of
the carousel and remove the lifting bail from the drill rod.
28. Leave the lifting bail on the winch hook. Exit the tower access area and return
to the cab area.
29. Raise the tower to the vertical position and repeat the process until the drill rod
is loaded. (First two drill rods for PV-271 single-pass or first four drill rods for
PV-275 multi-pass.
30. This completes the rod loading to meet the initial requirements of the drill.
31. To add the third drill rod to (PV-271) or fifth drill rod (PV-275) requires a slightly
different process.
32. Pick up the drill rod as described above.
NOTICE
Do not attempt to load the drill rod into the carousel.
DRILLING SOLUTIONS
5-39
33. Instead, lower the drill rod into the deck bushing and allow it to remain there.
34. Using the leveling jacks, raise the entire drill to its maximum height.
35. Lower the drill rod into the deck bushing as far as it will go, eventually setting it
on ground.
36. Remove the lifting bail. Use a proper man lift. Do not climb the tower.
37. Lubricate the pin threads with the correct thread lubricant.
38. Lower the rotary head and screw the drill rod onto the rotary head spindle.
Install the bit sub and drill bit.
39. This completes loading drill rod from the ground.
Drill Rod Field Replacement

This process assumes that the replacement drill rod is moved to the drill pad area on a truck
equipped with an on board crane or a crane is available to assist in the removal and reloading
of the drill rod.
1. Level the drill on the jacks.
2. Drill a hole slightly past the first rod joint and flush the cuttings from the hole
with air.
3. Raise the drill string and remove the bit and bit sub.
4. Store the bit assembly in an area that will not interfere with safe movement.
5. Lower the drill string into the hole to the first rod joint.
6. Engage the sliding fork in the drill rod wrench flats.
7. Using the breakout wrench assembly, unscrew the drill rod in the ground from
the drill rod remaining on the drill string.
8. Raise the rotary head and remaining drill rod to the top of the tower.
9. Screw the drill rod lifting bail onto the drill rod held in the sliding fork.
10. Lower the hoist cable and attach the hoist hook to the lifting bail.
11. Use the hoist control and gently lift the drill rod to remove its weight from the
sliding fork.
12. Move the sliding fork to its stowed position.
13. Use the hoist control to raise the drill rod from the ground.
14. Raise the jacks and propel the machine forward a distance that will allow the
drill rod to be laid on the ground. Extend the drill end jacks so they just touch
the ground. Extend the non drill end jacks to tilt the tower so the drill rod will
swing out over the ground.
15. Lower the box section of the drill rod to the ground using the hoist control.
5-40
DRILLING SOLUTIONS
16. While slowly lowering the drill rod to the ground, propel the machine away from
the drill rod and lay the drill rod on the ground.
17. When the drill rod is safely on the ground, unscrew the lifting bail. Leave the
hoist hook on the bail.
18. Raise the hoist hook and the lifting bail to the top of the tower.
19. Propel the drill back over the hole and re-level the drill.
20. Lower the drill rod into the hole and repeat the process with the remaining drill
rod. (Three drill rods will need three trips, four drill rods will need four trips and
five rods will require five trips.)
21. Reloading can begin when all the drill rod have been removed from the drill.
22. Position the drill over the drill hole and level it as previously discussed.
23. Position the drill rod transport truck parallel to the length wise axis of the drill
and place it in front of the drill deck.
24. Use the same procedure of picking up drill rod as described previously.
25. Secure the drill rod using the wrench flats and sliding fork.
26. Remove the lifting bail and stow the hoist line at the top of the tower.
27. Lower the rotary head to the pin section of the held drill rod.
28. Lubricate the threads on the drill rod with an appropriate lubricant.
29. Screw the spindle joint onto the held drill rod.
30. Stow the sliding fork.
31. Raise the drill rod, engage the rod support, and stow the drill rod in the
carousel.
32. Stow the carousel and raise the rotary head to the top of the tower.
33. Using the hoist control and hoist line, repeat the process with the next drill rod.
34. PV-271 single-pass: The last two drill rods to be loaded, assuming a four (4)
rod load, must be screwed onto the rotary head.
PV-275 multi-pass: The last drill rod to be loaded, assuming a five (5) rod load,
must be screwed onto the rotary head.
35. Re-install the bit sub and drill bit. Reverse the procedure previously discussed
for removal of the bit sub and drill bit.
36. When complete, drill is ready to be moved back to the drill pattern to continue
the drilling operation.
Adding Drill Rod Procedures

Drill rod is stored in the carousel rod holder and is indexed (rotated) into position to connect
drill rod to the rotary head. The following procedure applies to all PV-270 Series drills. Follow
the operating instructions previously mentioned.
DRILLING SOLUTIONS
5-41
1. Position the drill on a level, firm surface.

2. Move the propel/drill mode selector to DRILL.
3. Increase engine speed to 1800 rpm.
4. Evenly extend the leveling jacks to maintain the drill level as indicated by the
bubble in the level gauge.
a. First adjust the front jacks until the bubble is centered.
b. Adjust the rear jack until the bubble is centered.
5. Use the tower raise/lower control to raise the tower. As the tower approaches
a vertical position, slowly move the control to its center position to allow the
tower to position without impact.
6. Position the drill tower locking pin switch into the locked position and check that
the drill tower locking pin disengaged warning light is not illuminated. When pin
is fully engaged the light should extinguish.
8. Raise rotary head to top of tower using fast feed.
9. Make sure drill rod is in the correct position on the carousel. Raise rotary head
to top of tower using fast feed
10. Swing the carousel into loading position with drill rod under rotary head.
11. Engage clockwise rotation slowly.
12. Using drill feed, lower rotary head slowly until threads are engaged. Watch the
carousel for an indication of extra loading and listen to the threads making
contact.
13. Continue rotating until drill rod revolves in the bottom cup against stop on
carousel. Stop rotation.
14. If the drill rod rotation is forcing cup against the stop, move drill rod in a counter
clockwise rotation slightly to free the rod.
15. Raise drill rod out of carousel cup and swing the carousel all the way into the
open position.
WARNING
Be sure a good joint has been made by looking up at the connection

between the spindle adapter and the upper pipe joint before moving the
drill rod.
16. Using drill feed, lower the drill rod onto the next joint after lubricating the threads
properly.
5-42
DRILLING SOLUTIONS
17. Engage clockwise rotation slowly.

18. Tighten joint securely. Raise drill string slightly to allow removal of the sliding
fork wrench or J-Wrench if it was used.
Adding Drill Rod to Drill String

Follow the procedure below to add drill rod to the drill string. Follow the operating instructions
previously mentioned.
1. Using proper drilling technique, drill down until the flats on the pin end of the
drill rod pass below the drill table. Reverse feed and bring flats on drill rod
above the table.
2. Stop rotation. Switch off lubricator if it is being used. Turn off water pump if it is
being used. Turn off drill air.
3. Low Pressure Drills - Turn off drill air by moving the Compressor Control
Lever to OFF . The air in the drill string will vent and be relieved from the drill
string.
High Pressure Drills - Use the Drill Air Throttle to turn off the drilling air during
drill rod or hammer changes. The air in the drill string will vent and be relieved
from the drill string.
EARS Drills - Turn the Compressor on/off switch to off position. The air in the
drill string will vent and be relieved from the drill string.
DRILLING SOLUTIONS
5-43
4. Engage the sliding fork (breakout) wrench controller and insert sliding breakout
wrench on to the flats of the drill rod.
5. Use full counter clockwise rotation power to break the joint. As threads
disengage, use drill feed in the UP position to allow threads to separate. When
joints are separated, stop rotation. Stop Feed.
6. Use fast feed to raise rotary head to top of tower.
7. Position drill rod in carousel. Swing carousel in under the rotary head. Using
drill feed, lower the rotary head.
8. Start slow clockwise rotation. Continue to lower the rotary head until the spindle
adapter makes contact with the pin end of the drill rod.
9. Tighten joint threads until the drill rod cup at the bottom of the carousel rotates.
WARNING
Be sure a good joint has been made by looking up at the connection

between the spindle adapter and the upper pipe joint before moving the
drill rod.
10. Stop rotation. Raise drill rod out of the carousel.
11. Swing the carousel out of the way.
12. Lubricate the drill rod threads.
13. Use drill feed to lower the drill rod onto threads of the drill rod in the table.
14. Start slow rotation until joint is tight.
15. Stop feed and rotation.
16. Raise the drill string with drill feed only high enough to relieve pressure on the
sliding fork (breakout) wrench. Disengage the sliding fork wrench from the drill
string. Resume drilling.
17. Refer to Rotary Drilling Procedures or DHD Drilling Procedures for information
on drilling procedures.
Remove Drill Rod from Drill String

1. Raise the rotary head, with drill string, to top of tower until the upper flats on the
bottom drill rod line up with the sliding fork wrench on the drill table.
2. Stop feed and rotation. Engage the sliding fork wrench on the upper flats of
bottom drill rod.
3. Use counter clockwise rotation to break the joint at the table. Watch upper
joint between the drill rod and spindle sub when breaking the joint.
5-44
DRILLING SOLUTIONS
WARNING
If upper joint comes loose instead of lower one, stop rotation

immediately. The drill rod can come loose and fall.
4. If the upper joint breaks loose first, tighten the joint up with clockwise rotation.
5. Use the breakout wrench mounted on side of tower to break the lower joint.
Retract and extend the breakout wrench cylinder back and forth until the joint
breaks.
6. Remove and move the breakout wrench and cylinder out of the way.
7. Use reverse rotation and feed to finish unscrewing the drill rod.
8. Raise the rotary head and drill rod to the top of the tower.
9. Make sure the carousel is indexed properly (Refer to the Carousel Operating
Procedure in CAROUSEL Section). Swing the carousel in line with the drill rod.
10. Feed rotary head down until the hex area on box end of the drill rod is in the
lower carousel cup. The upper pin end of the drill rod must be seated in the
upper carousel holding slot. Refer to Carousel Operating Procedure in
CAROUSEL Section
11. Use full counter clockwise rotation to break the joint between the spindle
adapter and the drill rod. Use drill feed in up position to detach threads.
12. Index the carousel into position to accept the next drill rod and swing the
carousel out of the way into the open position.
13. Fast feed the rotary head to the bottom of tower until the spindle is just above
the threads of the drill rod in the table. Stop the rotary head.
14. Lubricate the threads on the drill rod.
15. Feed down the rotary head until the spindle threads contact the drill rod
threads.
16. Start slow forward rotation until the connection is tight. Stop feed and rotation.
17. Raise drill string slightly to remove pressure on the sliding fork wrench.
18. Disengage the sliding fork wrench.
19. Start forward rotation and drill feed. Raise the rotary head, and one drill rod, to
top of tower until the upper flats on the bottom drill rod line up with the sliding
fork wrench on the drill table.
20. Repeat the process for each drill rod in hole.
DRILLING SOLUTIONS
5-45
Drilling Procedures
Rotary Drilling
Rotary drilling methods use the combination of raw weight and rotation to chip and carve rock
from a hole. The rotary method works fine in soft formations where adequate weight and stress
can be applied to the rock to initiate fracture and chipping.
Rotary drilling is done by rotating a Tricone bit against the rock while using down pressure to
crush the rock. A stabilizer is normally used to keep the hole straight and to prevent the bit
from becoming stuck.
After the drill has been set up for drilling, there are a number of operations which involve
handling heavy drill rods, drill bits and other components used for various drill rod and drill bit
changing procedures.
WARNING
Heavy components must be handled with care using appropriate lifting

aids provided to facilitate heavy component lifting operations.
Rotary Drill String Tools and Accessories

The following are drill string tools and accessories used in rotary drilling for installing or
changing the Tricone drill bit and breaking tight threaded joints between drill rods, rotary head,
spindle or bits.
5-46
DRILLING SOLUTIONS
DRILLING SOLUTIONS
5-47
Starter Rod/Stabilizer Installation Procedure

The procedure below is for installing the starter rod or stabilizer (option) . Before starting, be
sure the rotary head is at the top of the tower and the rod changer/carousel is in the stowed
(in) position.
1. Install the correct lifting bail on the pin end of the starter rod. Use the hoist to
raise the starter rod and line it up over the table.
WARNING
Be sure a good joint has been made by looking at the connection between
the lifting bail and the starter rod pin end threads before moving the
starter rod.
2. Put a block of wood or metal on the ground under the drill table so the starter
rod can rest on the ground while making connections. When using short
stabilizers, secure the upper section in the sliding fork wrench so rotary head
can be threaded to it.
3. Lower starter rod through table and onto the block of wood or plate on ground.
4. Remove lifting bail and move the hoist cable out of the way.
5. Lubricate thread joints properly.
6. Install centralizer bushings around the starter rod.
7. Feed rotary head down to engage threads on pin end of starter rod. Using slow
forward rotation, tighten the stabilizer securely.
8. Raise starter rod above table.
5-48
DRILLING SOLUTIONS
Tricone Bit Installation Procedure

The procedure below is for installing the tricone drill bit on the starter rod or stabilizer (option).
Note that the procedure is the same if you are installing the tricone bit directly onto the drill rod.
1. With the starter rod above the table, remove the centralizer bushings.
2. Install the rotary (tricone) bit basket and the appropriate insert in the drill table.
3. Insert the tricone bit into the insert in the bit basket.
4. Lubricate the threads on tricone bit.
5. Using the rotary head feed controller, lower starter rod (or drill rod) down onto
the threads on the bit and tighten securely by using slow forward rotation.
WARNING
Be sure a good joint has been made by looking at the connection between
the lifting bail and the starter rod pin end threads before moving the
starter rod.
6. Raise rotary head up until the tricone bit clears the bit basket.
7. Remove the bit basket and store it out of the way.
8. Lower the starter rod until the bit is below the table.
9. Install centralizer bushing.
10. Turn compressor on.
11. Open the drill air throttle.
12. Turn on forward rotation and adjust speed.
13. Use drill feed (controller) in the down position to start drilling. Adjust down
pressure with the drill feed pressure control (sometimes called remote relief
valve).
14. Adjust rotation speed as required.
Rotary Drilling Procedure

1. Make sure the starter rod or bit sub, rotary bit and drill rod are installed
correctly.
2. The engine speed should be 1800 RPM (full speed).
DRILLING SOLUTIONS
5-49
3. Turn on the drill air throttle. Refer to instructions shown in the COMPRESSOR
OPERATION section.
4. Push the drill rotation controller to the clockwise (forward) position. With the
controller, adjust to slow rotation speed for starting the hole.
NOTE: Rotation is only possible when the Drill / Propel Mode Selector is
in the DRILL mode position.
5. Turn on the dust collector if necessary. Turn on the water injection pump
(option) if water injection is required at startup.
6. Use drill feed controller in DOWN position until the bit contacts the ground.
7. The first several feet or meters of drilling is called overburden. It usually
consists of soft soil, broken rock, gravel or clay. When drilling through this
mixture, care must be taken to prevent excessive cuttings from being blown out
of the hole and causing a washout.
8. Adjust the rotation and feed speed to fit the type of overburden being drilled.
9. Use the drill feed controller in DOWN position to start drilling. Adjust down
pressure with the drill feed pressure control.
10. Adjust the rotation and feed speed (down pressure) as required by checking
the rotation and pulldown gauges.
11. Watch the cuttings coming from the hole to determine what type formation you
are drilling through.
12. Using proper drilling technique, drill down until the flats on the pin end of the
drill rod pass below the drill table. Reverse feed and bring flats on drill rod
above the table.
13. Stop rotation. Switch off dust collector if it is being used. Turn off water pump
if it is being used. Turn off drill air.
14. Follow the procedures in Adding Drill Rod to Drill String and resume drilling.
15. Follow the procedures in Removing Drill Rod from Drill String.
5-50
DRILLING SOLUTIONS
Rotary Bit Changing Procedure

The procedure below is used when changing or replacing a rotary bit during the rotary drilling
process.
1. Feed the drill rod up until rotary bit is just below the table and raise the
centralizer bushing.
2. Feed the drill rod up until the bit is above the table.
3. Install the bit basket.
4. Lower the bit into the bit basket.
5. Install the breakout wrench onto the breakout wrench hydraulic cylinder.
6. Connect the breakout wrench onto the drill rod.
7. Extend the breakout wrench.
8. Retract the breakout wrench to break the bit loose from the drill rod.
9. When the bit is loose, remove and move the breakout wrench out of the way.
10. Use reverse rotation to unscrew the bit from the drill rod.
11. Use slow feed up to allow the bit threads to unscrew. Raise the drill rod above
the bit.
12. Remove the old bit from the bit basket and replace it with the new bit. Make sure
that the correct size nozzle is installed.
13. Lubricate the threads on the new bit.
14. Lower drill rod onto bit.
15. Use slow forward rotation to tighten bit into drill rod.
16. Tighten securely.
17. Raise drill rod assembly above table.
18. Remove bit basket.
19. Lower drill rod until bit is below table.
20. Install centralizer bushing.
21. Turn on drill air throttle (compressor ON cable control with LP drills only).
22. Engage drill rotation controller in the forward position and adjust rotation speed.
23. Use drill feed in the down position to start drilling. Adjust the down pressure with
the feed pressure control rotary switch.
24. Adjust rotation speed as required.
DRILLING SOLUTIONS
5-51
DHD Drilling
DHDs achieve high productivity in hard rock applications by adding percussion to the drilling
process. In harder rock, the rotary method cannot supply sufficient load on the bit inserts to
crack the rock and produce a chip.
Percussion drills overcome the rotary bit load limitation by producing a very high load during
impact on the hammer. This load is sufficient to drive the cutting inserts into the rock to
produce chips.
DHDs operate by using the position of a piston to direct supply and exhaust air to and from
drive and return volumes. The drive volume drives the piston toward impact and the return
volume returns the piston in preparation for another impact stroke.
Refer to Technical Manual for Quantum Leap Downhole Drills , TM6121 (Part Number
52117397) for detailed information on Model QL Series Downhole Drills.
After the drill has been set up for drilling, there are a number of operations which involve
handling heavy downhole hammers, drill bits and other components used for various drill bit
changing procedures.
WARNING
Heavy components must be handled with care. Use appropriate lifting

aids to facilitate heavy component lifting operations.
Downhole Drill String Tools and Accessories

The following are drill string tools, accessories and items involved with respect to installing and
removing the DHD hammer, bit changing and releasing tight threaded joints.
5-52
DRILLING SOLUTIONS
DHD Processes
Downhole drilling with a DHD consists of several processes. There is an order that should be
followed to maximize performance. To downhole drill, an operator must: Install the DHD on the
lower sub, Install a Button Bit on the DHD, Start the Compressor, Start the hole with the DHD,
Follow DHD Drilling Procedures, Remove the DHD from Drill String, Remove the Bit from DHD
and follow some General Hints.
DRILLING SOLUTIONS
5-53
Install DHD to Lower Sub

Initially, the Downhole Hammer Drill must be connected to the lower sub before the Button Bit
can be installed.
1. Install a piece of wood on top of table bottom.
2. Manually set lower chuck of the DHD on the wooden block.
3. Lubricate backhead threads of DHD with joint grease.

4. Install centralizer bushing over lower sub and hold out of the way until threads
are made up.
5. Feed drill rod down slowly until the backhead threads engage lower sub. Hold
the DHD in vertical position to avoid cross-threading.
6. Slowly engage rotation while feeding drill rod downward until joint is tight and
DHD starts to rotate. Stop drill rod rotation and feed.
NOTE: An alternative method is to set the piece of wood on the ground
under the table opening and manually set the lower chuck of the DHD on
the wooden block. Then follow steps 3 thru 6 above.
DHD Button Bit Installation

The Button Bit must be installed on the Downhole Hammer Drill.
1. Remove the wood and install the Bit Basket and the correct size Bit Detaching
Chuck, for the size bit to be used, into the drilling platform recess.
2. Manually insert the Button Bit into Bit Basket, being careful not to damage
inserts.
NOTE: The Button inserts on a DHD bit are made to take a large force in
one direction only and that is straight up. If a button receives a blow from
any other direction, it may break. Handle bits with care.
5-54
DRILLING SOLUTIONS
3. Manually unscrew the bit chuck and remove bit retaining rings from the DHD.
4. Insert chuck and retainers over bit.
5. Lubricate chuck threads with tool joint lube.
NOTE: Bit Splines should be well lubricated with Rock Drill Oil or thread
grease before the chuck is installed over the splines. Additionally, the
threads on the chuck should be well coated with thread grease before
threading the chuck into the DHD. Remember to install the centralizer
bushing before threading the chuck into the DHD.
NOTE: Follow Actual Manufacturers Lubrication Instructions when
using DHD Hammers. Rock Drill Oil is only used on DHDs.
6. Slowly feed the DHD down over the bit until chuck can be pushed up onto DHD
wear sleeve threads. Stop feed.
7. Hold chuck up into wear sleeve and engage rotation slowly. Chuck should
move upwards as threads are tightened.
8. When rotation stops, increase rotation torque until bit is securely locked in
place.
9. Feed DHD and drill rod up until bit basket can be removed.
10. Feed the DHD and bit down through the main centralizer bushing.
NOTE: An alternative method is to set the Bit Basket and correct size Bit
Detaching Chuck, on the ground under the table opening. Then follow
steps 2 thru 9 above.
DHD Drilling Procedure

When using the DHD for the first time, pour one cup (8 oz./230 ml) of Rock Drill Oil into the
drill backhead to lubricate it before starting the DHD.
DRILLING SOLUTIONS
5-55
NOTE: Follow the Actual Manufacturers Lubrication Instructions when

1. The DHD should be connected to the drill string. Make sure the split DHD
bushings are installed in the main bushing.
2. The engine speed should be at full speed.
3. Turn on the compressor. Adjust the pressure regulator to the desired setting.
Refer to High Pressure Operation instructions in the COMPRESSOR
OPERATION section.
4. Turn on the DHD lubricator switch on the console.
5. The DHD lubricator indicator light will light up to confirm that the lubrication
system is in service.
6. Regulate the flow if necessary. Read the instructions on the side of the
lubricator to regulate for the compressor size of the drill.
5-56
DRILLING SOLUTIONS
7. Start forward (clockwise) rotation using Drill Rotation Controller. Regulate the
speed as needed with the Drill Rotation Controller.
NOTE: Rotation is only possible when the Drill / Propel Mode Selector is
in the DRILL mode.
8. Make sure the dust aprons are in place.
9. Open the Drill Air Throttle slowly and allow air flow to operate the DHD.
10. Move the Drill Feed Controller to the DOWN position and adjust the feed speed
for drilling conditions.
11. The first several feet or meters of drilling is called overburden. It usually
consists of soft soil, broken rock, gravel or clay. When drilling through this
mixture, care must be taken to prevent excessive cuttings from being blown out
of the hole and causing a washout.
12. Turn on the dust collector or water injection, whichever is used for dust control.
13. Start forward rotation and adjust rpm for drilling conditions.
14. Engage down feed and monitor carefully as hole is collared. Do not overfeed.
Removing DHD from Drill String

1. Using drill feed, move the drill string so the backhead on the DHD is slightly
above the table.
2. The centralizer bushing must be held up out of the way so the J-Wrench can
be inserted on the backhead.
3. Install the split bushings around the DHD. Lower the DHD until the flats on the
backhead are just above the table.
4. Use the J-Wrench to secure the backhead on the table. Use drill feed to move
DHD down until J-Wrench rests on table.
5. Slowly reverse rotation until the J-Wrench is almost touching a vertical tower
member.
6. Using full rotation speed with drill rotation controller, reverse rotation and
impact the J-Wrench against the tower member.
DRILLING SOLUTIONS
5-57
7. When the joint is loose, reduce speed on the drill rotation controller and slowly
raise the drill rod until connection is separated.
Bit Removal
Bit removal can be one of the most dangerous and frustrating tasks associated with the drilling
operation. However, with the proper tools and techniques it should require no more than a few
minutes to remove a bit. The following lists pointers which will be beneficial in helping you
remove a bit quickly, safely and with reduced risk to damaging DHD parts and components:
1. Use sharp tong jaws. Worn or rolled over tong jaws increase the jaw pressure
and make the wrench more prone to damaging the hammer case. Many
hammer cases are case hardened which means sharp jaws are needed to grip
through the hardened case.
2. Grip the casing in the proper location. Gripping over threads can make thread
loosening extremely difficult. Example; as the wrench tightens it exerts an
inward force which can pinch the threads if they are under the wrench jaw. This
only increases the torque needed to uncouple the thread. Also, do not grip
casing in an area where the bore is not supported by either the piston or
bearing. Gripping over an unsupported area can distort the bore.
3. Insure the bit fits properly within the bit basket. An improper fit may result in the
bit slipping from the basket.
4. Never weld or hammer on casing to loosen it. All casings except QL200 are
case hardened for extended service life. The hard casing surface can be
cracked by welding or impacting with a sledge hammer.
DANGER
Be sure chain wrenches or tongs are rated for the torque applied. The
flying parts of chain wrenches can cause injury or death when they break.
Removing Bit from DHD

1. Using drill feed, raise DHD up until the bit basket can be installed into table
recess.
2. Insert bit basket and bit detaching chuck into table recess and lower the bit into
basket.
3. Attach tong wrench to lower section of DHD. Do not allow tong wrench to
contact DHD chuck.
4. Use the tong Wrench Controller to extend and retract the tong wrench cylinder.
Loosen the bit chuck from DHD wear sleeve.
5. Remove the tong wrench and feed the drill rod up slowly. Simultaneously
reverse the drill rod rotation and unscrew the bit chuck completely from the
5-58
DRILLING SOLUTIONS
DHD wear sleeve. Stop feed and rotation.

6. Lift the bit chuck and retainers from the drill bit and remove the drill bit from bit
basket.
7. Replace the old bit with new one and manually install bit chuck and retainers
on new bit or manually install bit chuck and retainers back on DHD for storage.
DHD Drilling Procedures

1. Make sure the DHD and button bit are installed correctly.
2. Turn on the drill air throttle controller slowly. Turn on the DHD lubricator. Turn
on the water pump or dust collector if necessary.
3. Push the drill rotation controller to clockwise (forward) position. Adjust the
rotation speed with the controller.
NOTE: Rotation is only possible when the Drill/Propel Mode Selector is
in the DRILL mode.
4. Use drill feed controller in the DOWN position while starting a hole.
5. Regulate the drill feed by using the feed pressure control on the console.
DRILLING SOLUTIONS
5-59
6. Adjust the rotation and feed speed (down pressure) by checking the rotation
and pulldown gauges. The pulldown pressure can be turned to holdback
pressure when there is enough weight on the drill string to pull the drill rod
downward.
7. Watch the cuttings coming from the hole to determine what type formation you
are drilling through.
General Drilling Hints

1. The DHD lubricator must always be used whenever the DHD is being operated.
Use the correct oil for the DHD and the season.
The amount of oil required varies with the size of the air compressor, not the DHD.
Select the compressor size on the three position Lubricator Air Flow Selector
located on the DHD lubricator tank. On 1450 cfm compressors, the setting is
1250 cfm.
NOTE: Follow Actual Manufacturers Lubrication Instructions when

2. Water injection should be used to contain dust. Water injection must be used
whenever water is encountered in the hole to prevent collaring.
3. Do not operate the water pump if no circulation is being observed (i.e., bit is
stuck in the hole). Water will fill up the air supply lines and flow back into the
receiver separator tank of the compressor.
4. Do not open drill air throttle flow control suddenly. It may cause a collapse of
the separator element over a period of time.
5-60
DRILLING SOLUTIONS
Angle Drilling
WARNING

drill.
Always wear correct safety gear while working on or around the drill. This includes an
Approved Hard Hat, Safety Glasses, Steel Toe Shoes, Gloves, Respirator and Ear Protection.
Do not wear loose fitting clothing that can become caught in rotating components.
WARNING
WARNING
drill before performing any maintenance to the drill.
General Information
1. After starting the engine, wait until the hydraulics and the air end are up to
normal operating temperatures before operating the drill.
4. Always operate the drill at full power when drilling or tramming.
5. If drill is equipped with a remote control system option, always use it from a safe
location when propelling on unstable surfaces where there may be a risk of
overturning, or when loading onto a transporter where there is a risk of
overturning.
DRILLING SOLUTIONS
5-61
crushing risk.
The PV-271 single-pass drill has an option available for angle drilling and holes may be drilled
as much as twenty degrees (20), in 5 degree increments, beyond vertical if local conditions
and techniques require. The PV-275 multi-pass drill has an option available for angle drilling
and holes may be drilled as much as thirty degrees (30), in 5 degree increments, beyond
vertical. In the event angle drilling is required, the tower must be lowered to the correct angle
outlined in the following sequence:
1. Physically verify the tower is in the vertical position and the vertical locking pins
are in place and locked.
DANGER
Angle locking pins and vertical locking pins must never be unlocked at
the same time! Serious damage or injury will occur if the tower is moved
in any direction with all pins in the unlock position.
2. Unlock the tower angle locking pins using the angle pinning controllers.
3. Physically verify both the angle locking pins on the tower support are unlocked.
CAUTION
Damage can occur if an attempt is made to move the tower to an angle

drill position with only one (1) angle lock pin unlocked.
4. Using the tower raising/lowering controller, lower tower until the proper angle is
indicated on the angle indicator at the bottom of the tower support.
5-62
DRILLING SOLUTIONS
5. If a pin is stuck between lock or unlock position, use the tower rocking feature.
Move the tower locking angle controller back and forth. If the pin is not freed,
move handle in other direction.
6. After ensuring the correct angle has been reached, lock the angle locking pins
using the tower angle locking pin controller.
7. Due to possibility of slight differences in manufacturing tolerances, wear, or
slight damage, you may find it necessary to gently wiggle the tower-raising
controller to fully lock both of the angle pins.
8. After the angle pin light shows the pins to be locked, ensure that all cab controls
are in the neutral position. Walk out to the tower support area and physically
verify that both of the angle locking pins and both of the vertical locking pins are
in the locked position. Always verify the pins are locked.
Stopping, Parking & Shutdown
Stopping the Drill

1. For normal braking, move the propel controllers towards the OFF position.
2. To completely stop the movement, position the propel controllers in the OFF
position.
3. Unless intending to move the drill immediately, move the propel/drill mode
selector switch to the DRILL position.
Parking the Drill

1. Move drill away from the highwall or face before shutting the drill down for the
day.
2. Dont park the drill under an overhang or where a bank can cave in.
DRILLING SOLUTIONS
5-63
3. ALWAYS park the drill on solid, level ground. If this is not possible, always park
the drill at a right angle to the slope and chock the tracks. Lower the leveling
jacks to the ground.
4. If the drill is left over a hole, lower the jacks so the tracks touch the ground.
5. To park the drill, move it to firm, level ground. Bring the drill to a complete stop
as mentioned above.
6. USE proper flags, barriers and warning devices, especially when parking in
areas of heavy traffic.
Normal Shut Down

Normal shutdown describes how the drill is to be shutdown following a drilling operation or
work shift. See Section 5.4 Emergency Shutdown which is part of the ENGINE OPERATION
section for shutdown emergency conditions.
1. Raise the drill string out of the hole to clear the cuttings. Keep the string rotating
and be sure air is flowing while withdrawing the bit.
2. Stop feed and rotation when the bit enters the table dust seal.
3. Turn off the compressor and allow the receiver to blow down to minimum
pressure. On low pressure drills, the compressor is turned on and off with the
use a manual inlet control. This is a lever and cable arrangement. Pull the lever
towards the operator to close the inlet. On high pressure drills, the compressor
is turned on and off with the use of the compressor ON/OFF switch. Turn the
switch to OFF.
5-64
DRILLING SOLUTIONS
4. If the hole is completed, lower the tower:

a. Move the tower locking control into the UNLOCK position. Be sure the
tower unpinned warning light is illuminated when the pins are fully
disengaged.
b. Use the tower raise/lower controller to lower the tower. As the tower
approaches the horizontal position, slowly move the controller to its center
position to allow the tower to position without impact. Never slam the tower
into the horizontal position.
5. Retract the leveling jacks, starting with the single jack on the non-drilling end.
Raise them all the way up so they do not interfere with the movement of the drill.
6. Disconnect any piping, ropes or cables from the drill and store them properly.
7. Move the engine throttle (speed selector) switch to LOW idle (1200 rpm)
8. Be sure to relieve all pressures in the systems before leaving the drill.
9.
Place all controls in neutral or park position before leaving the drill.
10. ALWAYS move the propel/drill mode selector to the DRILL position and make
sure that the propel and drill controllers are all in the STOP positions before
engine shutdown.
11. AVOID leaving the controls with engine running. NEVER leave the operators
cab while the engine is running.
12. Turn the key switch to the OFF position.
13. After engine has stopped, make sure the compressor blowdown valve opens
and blows all the air out of the receiver tank.
NOTICE
If the blowdown valve opens for a few seconds and then closes, there was
excessive pressure in the tank when the drill was stopped or a
malfunction of a component in the regulation system. It will leak for
several minutes and then the butterfly valve will open and allow air and
oil to flow back up the intake tubes and into the air cleaners. Repair the
problem before using the drill again. This notice does not apply to
compressors with (EARS) Electronic Air Regulation Systems.
14. Lock the ignition and remove the keys before leaving the operators cab.
15. Lock all lockable compartments.
DRILLING SOLUTIONS
5-65
Emergency Shut Down

Every attempt should be made by the operator to shut the drill down under normal
conditions to prevent damage to the drill. When a high pressure compressor is shut down
at high pressure, the regulation system causes the air end to become a pressure vessel that
will force compressor oil back up into the intake filters when the inlet butterfly valve opens. The
element will have to be replaced and the tubes cleaned before the drill can be put back into
service.This does not apply to compressors with (EARS) Electronic Air Regulation
Systems.
The Emergency stopping procedure for the drill may be very abrupt. This abrupt stop may
damage the drill due to potentially high stress loading on its components. There are two types
of emergency shutdowns. One is by the operator pushing the Emergency Stop button and the
other is when one of the shutdown devices on the drill has registered an out of limit condition.
If the operator or other personnel are in immediate danger or if an emergency arises that
is not under the protection of the shutdown devices, such as fire or other outside problem,
initiate an emergency stop with the following procedure: Push in the Emergency Stop
Button and exit the drill.
Using the Emergency Shut down must not become regular practice for shutting down
the engine. If the operator or other personnel are not in immediate danger and the
preservation of the drill equipment is the primary concern, proceed as follows:
1. All of the drill shutdown devices have gauges that show operating temperatures
or pressure of the system they monitor. Thus, the operator should be able to
avoid a shutdown condition by checking the gauges frequently.
When one of the emergency stop or shutdown devises is energized, it immediately shuts off
fuel to the engine. All engines are energize to run, which means there must be power to the
fuel valve to allow fuel to flow. If power is lost, the fuel valve closes and stops the engine.
Daily Precautions After Work

Perform the following precautions each day after work in addition to the daily routine
maintenance on the lubrication chart.
1. Fill the fuel tank to prevent condensation problems.
2. Clean the drill of accumulated material.
3. Lock all lockable devices and compartments on the drill.
Mounting and Dismounting of Equipment and Attachments

NOTE: All optional equipment mounting and dismounting on the drill
must be performed by authorized, trained personnel only.
5-66
DRILLING SOLUTIONS
Towing the Drill

General Towing Information
DO NOT TOW THE PV-270 SERIES DRILL! Always haul the drill on a transporter if moving
is required.
Special Conditions of Use

Cold Weather Conditions
1. Refer to Lubricant, Fuel and Cooling System Specifications in Section 6 Maintenance regarding cold weather lubricants, hydraulic fluids, coolants, etc.
2. Use winter grade diesel fuel for operation at subzero temperatures.
3. Be extremely careful when using cold weather starting aids. Starting aids are
flammable and should only be used if needed.
4. Remove batteries and store in a warm area to about 68F (20C).
Hot Weather Conditions

1. Monitor temperature gauges.
2. Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.
Water and Muddy Conditions

1. Clean the drill of accumulated material and thoroughly grease all lubrication
points. Refer to Lubricant Specifications in Section 6 - MAINTENANCE.
Dusty Conditions
1. Keep air cleaner elements clean and free of accumulation of dirt.
2. Wear protective mask.
High Altitude Conditions

1. Be aware that engine power will be reduced.
2. Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.
Preservation & Storage

Observe the following when storing the drill for short periods of time:
1. Replace and secure all weatherproof covers.
DRILLING SOLUTIONS
5-67
2. Change all lubricants and fluids that may have deteriorated with use. Refer to
Lubricant Specifications in Section 6 - Maintenance.
3. Check that the storage site is not subject to flooding or other natural hazards.
4. Wherever practical, run the engine and operate all the drill functions at regular
intervals.
5-68
DRILLING SOLUTIONS
Section 6 - Maintenance
DRILLING SOLUTIONS
6-1
Section 6- MAINTENANCE
6-1 MAINTENANCE SAFETY

Maintenance Safety and Health
physical dangers that are present in all phases of operation and maintenance of this drill.
WARNING
Improper maintenance can cause severe injury or death. Read and

understand the SAFETY PRECAUTIONS AND GUIDELINES section of this
manual before you operate or perform any maintenance, service or
repairs.
Anyone working around this drill must read and thoroughly understand the precautions
outlined in this manual before attempting to operate or perform work on the drill. In addition,
SAFETY ALWAYS must always be the primary consideration of all personnel when working
around this drill under normal or unusual conditions.
exercise good judgement and common sense when operating, servicing or working near this
drill.
WARNING
and understand the OPERATING CONTROLS & INSTRUMENTS section of
this manual.
6-2
DRILLING SOLUTIONS
Section 6 - MAINTENANCE
If there is any doubt about the safe operating procedure of the drill, Stop! Review the
information supplied with the drill, ask your supervisor or contact your nearest Drilling
Solutions representative for assistance.
Make sure all new employees read and understand the decals in the Decal Safety Manual
mounted on the drill. Never remove the Decal Safety Manual. Replace the manual if it
becomes lost or illegible.
WARNING
SAFETY PRECAUTIONS
Most accidents involving product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially dangerous situations before trouble occurs. Some of the potential problems and
ways to prevent them are shown below.
Fluid Penetration
1. Always use a wooden board or cardboard when checking for leaks.

2. Leaking fluid under pressure can cause serious injury or death.
3. If fluid is injected into the skin, see a physician immediately.
Lines, Tubes and Hoses
1. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can
cause fires.
2. Inspect all lines, tubes and hoses carefully. Do not use your bare hands to
check for leaks.
3. Tighten all connections to the recommended torque.
4. Make sure that all clamps, guards and heat shields are installed correctly to
prevent vibration, rubbing against other parts and excessive heat during
operation.
5. Check for the following:
DRILLING SOLUTIONS
6-3
a. End fittings damaged, leaking or displaced.

b. Outer covering chafed or cut and wire reinforcing exposed.
c. Outer covering ballooning locally.
d. Evidence of kinking or crushing of the flexible part of the hose.
e. Armoring embedded in the outer cover.
Burn Prevention
1. Do not touch any part of an operating engine or its components.

2. Allow the engine to cool before any repair or maintenance is performed.
3. Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings
or related items are disconnected or removed.
Coolant
At engine operating temperature, the engine coolant is hot and under pressure. The radiator
and all lines to heaters or the engine contain hot water. When pressure is relieved rapidly, this
hot water can turn into steam. Always allow the hot cooling system components to cool before
draining. Any contact with hot water or steam can cause severe burns. Check the coolant level
only after the engine has been stopped and the filler cap is cool enough to remove with your
bare hand.
1. Use caution when removing filler cap, grease fittings, pressure taps, breathers
or drain plugs.
2. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids
under pressure.
3. Remove the cooling system filler cap slowly to relieve pressure.
4. Cooling system additive (conditioner) contains alkali. To prevent personal
injury, avoid contact with the skin and eyes and do not drink or ingest coolant
fluids.
Oils
1. Hot oil and components can cause personal injury. Do not allow hot oil or any
components to contact the skin.
6-4
DRILLING SOLUTIONS
2. Keep all exhaust manifold and turbocharger shields in place to protect hot
exhaust from oil spray in case of a line, tube or seal failure.
Batteries
1. Battery electrolyte contains acid and can cause injury. Avoid contact with the
skin and eyes. Wash hands after touching batteries and connectors. Use of
face shield and gloves is recommended. Batteries give off flammable fumes
which can explode. Ensure there is proper ventilation for batteries which are
located in an enclosure.
2. Always thaw a frozen battery before jump starting. Frozen batteries can
explode.
3. Do not smoke when observing the battery electrolyte levels.
4. Always wear protective glasses when working with batteries.
5. Never disconnect any charging unit circuit or battery circuit cable from the
battery when the charging unit is operating. A spark can cause the flammable
vapor mixture of hydrogen and oxygen to explode.
Fire or Explosion Prevention
1. Fire may result from lubricating oil or fuel sprayed on hot surfaces causing
personal injury and property damage. Inspect all lines and tubes for wear or
deterioration. They must be routed, supported or clamped securely. Tighten all
connections to the recommended torque. Leaks can cause fires,
2. Determine whether the engine will be operated in an environment in which
combustible gases could be drawn through the air inlet system. These gases
could cause the engine to overspeed, which in turn could seriously damage the
engine and result in bodily injury or property damage.
3. All fuels, most lubricants and some coolant mixtures are flammable.
4. Diesel fuel is flammable. Gasoline is flammable. The mixtures of diesel and
gasoline fumes are extremely explosive.
5. Do not smoke while refueling or in a refueling area. Do not smoke in areas
where batteries are charged, or where flammable materials are stored.
6. Batteries give off flammable fumes which can explode. Keep all fuels and
lubricants stored in properly marked containers and away from all unauthorized
persons. Store all oily rags or other flammable material in a protective container
in a safe place.
DRILLING SOLUTIONS
6-5
7. Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean
them thoroughly with a nonflammable solvent before welding or flame cutting
on them. Remove all flammable materials such as fuel, oil and other debris
before they accumulate on the engine. Do not expose the engine to flames,
burning brush, etc., if possible.
8. Shields (if equipped), which protect hot exhaust components from oil or fuel
spray in the event of a line, tube or seal failure, must be installed correctly.
9. Provide adequate and proper waste oil disposal. Oil and fuel filters must be
properly installed and housing covers tightened to proper torque when being
changed.
10. Batteries must be kept clean, covers kept on all cells, recommended cables
and connections used and battery box covers kept in place when operating.
11. When starting from an external source, always connect the positive (+) jumper
cable to the POSITIVE (+) terminal of the battery of the engine to be started.
To prevent potential sparks from igniting combustible gases produced by some
batteries, attach the negative (-) boost ground cable last, to the starter
NEGATIVE (-) terminal (if equipped) or to the engine block. See the Operation
section of this manual for specific starting instructions.
12. Clean and tighten all electrical connections. Check regularly for loose or frayed
electrical wires. Refer to maintenance schedules for intervals. Have all loose or
frayed electrical wires tightened, repaired or replaced before operating the
engine.
13. All of the wiring must be kept in good condition, properly routed and firmly
attached. Routinely inspect wiring for wear or deterioration. Loose, unattached,
extra or unnecessary wiring must be eliminated All wires and cables must
conform to the recommended gauge and be fused if necessary. Do not use
smaller gauge wire or bypass fuses. Tight connections, recommended wiring
and cables properly cared for will help prevent arcing or sparking which could
cause a fire.
Fire Extinguisher
1. Have a fire extinguisher available and know how to use it.

2. Inspect the fire extinguisher and have it serviced as recommended on its
instruction plate.
Crushing or Cutting Prevention
1. Support equipment and attachments properly when working beneath them.
6-6
DRILLING SOLUTIONS
2. Never attempt adjustments while the engine is running unless otherwise

specified in this manual.
3. Stay clear of all rotating and moving parts. Guards should be in place whenever
maintenance is not being performed.
4. Keep objects away from moving fan blades. They will throw or cut any object
or tool that falls or is pushed into them.
5. Wear protective glasses when striking objects to avoid injury to your eyes.
6. Chips or other debris can fly off objects when struck. Make sure no one can be
injured by flying debris before striking any object.
Mounting and Dismounting
1. Clean steps, handholds and areas of the drill you will be working on or around.
2. Always use the steps and handholds when mounting and dismounting with a
three point stance.
3. Do not climb on or jump off the drill. Do not stand on components that cannot
support your weight. Use an adequate ladder.
Before Starting the Engine
1. Inspect the drill for potential hazards.

2. Be sure all protective guards and covers are installed if a drill must be started
to make adjustments or checks. To help prevent an accident caused by rotating
parts, work carefully around them.
3. Do not disable or bypass automatic shutoff circuits. They are provided to
prevent personal injury and drill damage.
4. Never start an engine with the governor linkage disconnected.
5. Make provisions for shutting off the air or fuel supply to stop the engine if there
is an overspeed condition on start-up after performing repair or maintenance to
the engine.
Engine Starting
1. DO NOT start the engine or move any of the controls if there is a warning tag
attached to the controls. Check with the person who attached the tag before
DRILLING SOLUTIONS
6-7
starting.
2. Make sure no one is working on, or close to the engine or the engine driven
components before starting the engine. Always inspect the engine before and
after starting.
3. Start the engine only from the operators station. Never short across the starter
terminals or the batteries as this could bypass the engine neutral-start system
as well as damage the electrical system.
4. Always start the engine according to the required Engine Starting Procedure
described in this manual to prevent major engine component damage and
personal injury.
5. Shutdown the engine according to Engine Shutdown Instructions in the
Operation section to avoid overheating and accelerated wear of the engine
components.
6. Only use the Emergency Stop button in an emergency. DO NOT start the
engine until the problem causing the emergency stop has been located and
corrected.
7. On initial startup or overhaul, be prepared to STOP the drill should an
overspeed condition occur. This may be accomplished by cutting the fuel and
air supply to the engine.
8. Check the jacket water and oil temperature gauges frequently during the
operation of jacket water and/or lube oil heaters to ensure proper operation.
9. Diesel engine exhaust contains products of combustion that may be harmful to
your health. Always start and operate the engine in a well ventilated area and,
if in an enclosed area, vent the exhaust to the outside.
Starting Aids
WARNING
Explosion Hazard. Do not use volatile starting aids such as ether,

propane or gasoline in the engine air intake system. Glow plugs and/or
grid heater will ignite vapors, which can cause severe engine damage,
personal injury or death.
1. Ether and other starting aids are poisonous and flammable. Do not smoke while
changing ether cylinders.
2. Use ether only in well ventilated places.
3. Keep ether cylinders out of the reach of unauthorized persons.
4. Do not store replacement ether cylinders in living areas, the storage
compartment or the cab.
6-8
DRILLING SOLUTIONS
5. Do not store ether cylinders in the direct sunlight or at temperatures above

102F (39C). Discard cylinders in a safe place. Do not puncture or burn
cylinders.
Engine Stopping
1. Stop the engine according to the engine stopping instructions in the Operation
Section to avoid overheating and accelerated wear of the engine components.
2. Use the emergency stop button only in an emergency. DO NOT start drill until
the problem is resolved.
3. Be prepared to stop the engine should an overspeed condition occur. This may
be accomplished by cutting the fuel and air supply to the engine.
Maintenance Information
To prevent minor irregularities from developing into serious conditions, several other services
or checks are recommended for the same intervals as the periodic lubrication. The purpose of
these services or checks is to ensure the uninterrupted and safe operation of the drill by
revealing the need for adjustment caused by normal wear.
Prior to conducting any maintenance work, ensure that the following instructions are
observed:
1. The drill should be parked on a firm, level surface.
2. Ensure the engine is shut down and allowed to cool.
3. Disconnect the battery cables and cover exposed terminals before working on
the drills electrical system.
4. Stop the engine and allow the hydraulic oil pressure to fall before working on
the hydraulic hose installations or connections.
5. Stop the engine and allow compressor air pressure to completely relieve from
the receiver tank before working on the compressor, receiver tank and hose
installations or connections.
6. Thoroughly wash all fittings, caps, plugs, etc. with nonflammable, nontoxic
cleaning solution before servicing to prevent dirt from entering while performing
the service.
When there is a need for service personnel to work on the drill in the working area or
danger zone and this involves activation of one or several drill functions, such work
shall only be done under the following conditions:
1. There shall always be two people present: both being fully instructed on the
safety issues. One of them, from the main operators station, shall supervise
the safety of the service man doing the work.
DRILLING SOLUTIONS
6-9
2. The supervisor shall have immediate access to the emergency stop in all
situations.
3. The area where the service work is to be performed shall be properly
illuminated.
4. Communication between the service man and the supervisor at the main
operators station shall be established in a reliable manner.
5. Only when the drill is shut down completely and the means of starting are
isolated is a person allowed to perform repair and maintenance work alone on
the drill.
Handling Fluids, Oil and Fuel Filters

1. When draining fluids, ensure that adequate sealable containers are available
and that every care is taken to prevent spillage.
2. Always ensure waste fluids are disposed of in an environmentally safe manner.
3. Always ensure that used filters are stored in secure containers and disposed of
in an environmentally safe manner.
The maintenance schedule in this section shows those items requiring regular
service and the interval at which they should be performed. A regular service
program should be geared to the items listed under each interval. These intervals
are based on average operating conditions. In the event of extremely severe, dusty
or wet operating conditions, more frequent maintenance than specified may be
necessary.
NOTE:
Refer to the Actual Manufacturers Operation and Maintenance Manual for the
Maintenance Schedules and procedures for the Engine.
NOTE:
Refer to the Actual Manufacturers Service Maintenance Manual for Maintenance
Schedule and procedures for the Engine.
6-10
DRILLING SOLUTIONS
6-2 MAINTENANCE SCHEDULE

Maintenance Schedule Information
Before each consecutive interval is performed, all of the maintenance requirements from the
previous interval must also be performed. Note: If the drill is operating under very severe
conditions (such as very dusty air), the scheduled maintenance intervals should be reduced.
Table 1: Maintenance as Required

Description
Air Cleaner
Action
Check - Visual Restriction
Indicators
Lubrication
See Parts Manual
Check - Connections and

Ducts for leaks
Empty - Dust Cup
Clean - Pre Cleaner Tubes
Check - Rain Guard
Change - Elements only as
required
See Filter Elements and

Kits Chart
Compressor Air Hose and

Clamps
Inspect Hoses, Retighten

Clamp Bolts
See Section 7
Housekeeping
Clean the Drill
Loose Bolted Connections
Check - Tighten to proper

torque
Feed Cable & Wire Rope
Check - Wear and Stretch

conditions
See Torque Specifications
Check - Wire Rope Clamps

Hydraulic Tank Oil Filters
Change - Elements only as

required

Kits Chart
Hydraulic Tank
Pressurized Breather Filter
Change - Breather Filter as

required

Kits Chart
Receiver Separator Tank
Replace Separator
Element

Kits Chart
Grease Drum Option
Change Grease Drum
See Parts Book
DRILLING SOLUTIONS
6-11
Table 2: Maintenance at 8-10 Hours or Daily

Description
Action
Overpressure Control
Check - Overpressure
System
Compressor Air Cleaner
Check - Air Cleaner

Service Indicator
Lubrication
See Parts Manual
Check - Connections and

Ducts for leaks
Empty - Dust Cup
Engine
Check - Crankcase Oil

Level. Add if low.
SAE 15W40 (Refer to

OEM Engine Manual)
Check - Engine Belts &

Tensioner
Engine Fuel Filter
Drain - Water from Fuel/

Water Separators
Cooling System (Radiator,

HOC and COC)
Clean - Cooling Fins
Fuel Tank
Check - Fuel Level
#2 Diesel Fuel
Receiver Separator Tank
Check - Compressor Oil

Level
XHP605 (high pressure)
50/50 - Water & Coolant
Check - Radiator Coolant

Level
Protec (low pressure)
Drain - Water from

Receiver Tank
Hydraulic Reservoir
Check - Oil Level on Tank

Sight Gauge
ISO AW32
Drain - Water from

Hydraulic Reservoir
Hydraulic Oil Filters
Check - Main Return Oil

Filter Restriction Indicator

Kits Chart for replacements
Check - Case Drain Oil

Filter Restriction Indicator
Rotary Head
6-12
Check - Rotary Head Oil

Level
SAE 90W Gear Oil
Grease Upper Bearing
Exxon Mobil Ronex Extra

Heavy Duty Moly 2
DRILLING SOLUTIONS
Description
Action
Lubrication
Gearbox Driveshaft
5 shots of grease into each

fitting
MPG - EP1 Grease
Dust Collector
Check - Dropout and

Suction Hoses, Rod Seal
and Blower Discharge
See Parts Manual
Check - Impulse Air and

Filters
Housekeeping
Clean the Drill
Table 3: Maintenance at 50 Hours

Description
Batteries
Action
Check - Electrolyte Level
Lubrication
Distilled Water (H2O)
Check - Keep Terminals

cleaned and tight
Main Winch/Auxiliary Hoist
Cable and Wire Rope
Periodic Inspection of
cable/rope condition
Cat Water Injection Pump
Change - Initial Crankcase

Oil
Pump Drive Gearbox
Inspect for Oil Leaks.

Clean Breather
Check - Oil Level
Undercarriage
ISO-68 (SAE40 anti rust)
80W90 Gear Oil
Check - Final Drive

Mounting Bolts
Check for Final Drive Oil
Leaks
Check - Final Drive Oil
Level
ISO VG220 (Required

Lubricant)
Check - Track Tension
Refer To Manufactures
Service Manual.
Track Adjustment
DRILLING SOLUTIONS
6-13

Description
Action
Auxiliary Hoist
Change the Initial Oil

Tighten Winch Mounting
Bolts
John Bean Water Injection

Pump
Change the Initial Oil
Lubrication
Texaco Meropa 150 or
Equivalent API GL-2/3
SAE 30 Non-Detergent Oil

Description
Action
Track Planetary Gearbox
Check - Final Drive

Mounting Bolts
Lubrication
ISO VG220 (Required
Lubricant)
Change - Planetary Drive

Initial Oil

Description
Engine
Action
Lubrication
Change - Engine Oil
SAE 15W40 (Refer to

OEM Engine Manual)
Change - Engine Oil Filters

Kits Chart
Replace - Fuel Filter(s)

Replace - Coolant Filter
Check - Engine DCA/SCA
Level
Refer to Engine Manual
Cat Engine Valve Lash

Adjustment
Auxiliary Hoist
6-14
Check - Cable Condition
DRILLING SOLUTIONS

Description
Action
Lubrication
CAT Engine
Change - Primary Fuel/

Water Separators
Batteries
Clean - Batteries, Clamps

and Cables
Fuel Tank
Replace - Fuel Tank

Breather

Kits Chart
Clean - Fuel Primer Pump
See Parts Manual
Change - Hydraulic Tank

Breather

Kits Chart
Hydraulic Oil Analysis
ISO AW32
Compressor
Clean - Compressor Oil

Strainer
See Parts Manual
Pump Drive Gearbox
Change - Initial Oil
80W90 Gear Oil
Water Injection Pump
Change - Crankcase Oil
SAE 30 (anti-rust) Non

Detergent
Auxiliary Hoist
Check - Oil Level

Equivalent 90W GL2/GL3
Hydraulic Reservoir

Kits Chart
Tighten - Winch Mounting

Bolts
Feed Cable & Wire Rope
Clean and Lubricate Cable

and Rope
See Instructions
Pulldown Cable
Jackscrews
Grease Jackscrews
MPG - EP1 Grease
Compressor Air Hose/

Clamps
Inspect Air Hose,

Retighten Clamp Bolts
See Section 7

Description
Receiver Tank
Action
Change Compressor Oil
Lubrication
XHP605 (high Pressure)
Protec (low pressure)
Compressor
Change - Compressor Oil

Filters

Kits Chart
Hydraulics
Change Hydraulic Oil
ISO AW32
DRILLING SOLUTIONS
6-15
Description
Action
Hydraulics
Replace Main Return Oil

Filter
Lubrication
Kits Chart
Replace Case Drain Oil

Filter
Rotary Head
Change - Rotary Head Oil
SAE 90W Gear Oil
Pump Drive Gearbox
Change - Gearbox Oil
80W90 Gear Oil
Auxiliary Hoist
Change -Main Winch Oil

and Auxiliary Winch Oil

Equivalent 90W GL2/GL3
Tighten - Winch Mounting

Bolts
Table 9: Maintenance at 1500 - 2000 Hours

Description
Action
Lubrication
Compressor Air Cleaners
Replace Primary and

Safety Elements

Kits Chart
Compressor
Replace Discharge Hose
See Parts Manual
Receiver Tank
Change Receiver
Separator Elements

Kits Chart
Replace Discharge Hose

and Hose Clamps
See Parts Manual
XHP605 (High Pressure)

Protec (Low Pressure)
Change - Planetary
Gearbox Oil
ISO VG220 (Required

Lubricant)

Description
Engine Maintenance
6-16
Action
Engine Valve Lash
Adjustment
Lubrication
Refer to Manufactures
Service Manual
DRILLING SOLUTIONS

Description
Engine Coolant
DRILLING SOLUTIONS
Action
Drain and Flush Engine
Cooling System. Replenish
Coolant. See
Manufactures Service
Manual
Lubrication
50/50 Water & Coolant
6-17
6-3 REFILL CAPACITIES/LUBRICANTS/FUEL

Hazardous Substance Precaution
The following information is provided to assist the owners and operators of Atlas Copco Drilling
Solutions Equipment. Further information may be obtained by contacting your Atlas Copco
Drilling Solutions Distributor.
The following substances are used in the manufacturing of this drill and may be hazardous to
health if used incorrectly.
Table 12: Oil, Fuel, and Grease

Substance
Precaution
Anti Freeze
Hydraulic Oil
Compressor Oil
Preservative Grease
Rust Preventive
Engine Fuel
Battery
SAE Gear Oil
Rock Drill Oil
The following substances may be produced during the operation of this drill and may be
hazardous to health.
Table 13: Fumes and Dust

Substance
6-18
Precaution
Avoid breathing fumes
Avoid buildup of fumes in confined spaces
DRILLING SOLUTIONS
Substance
Precaution
Electric Motor Dust

(Brushes/Insulation)
Avoid breathing in during maintenance
Brake Lining Dust
Avoid breathing in during maintenance
General Information
Lubrication is an essential part of preventive maintenance, affecting to a great extent the
useful life of the unit. Periodic lubrication of the moving parts reduces to a minimum the
possibility of mechanical failures.
Different lubricants are needed and some components in the unit require more frequent
lubricant than others. Therefore, it is important that the instructions regarding types of
frequency of the application be explicitly followed.
The lubrication chart that follows in this section shows those items requiring regular service
and the interval at which they should be performed. Details concerning fuel, oil and other
lubricants follow the lube chart. A regular service program should be geared to the items listed
under each interval. These intervals are based on average operating conditions. In the event
of extremely severe, dusty or wet operating conditions, more frequent lubrication than
specified may be necessary.
1. Specific recommendations of the brand and grade of lubricants are not made
here due to regional availability, operating conditions and also the continual
development of improved products. Where questions arise, refer to component
manufacturers manual and a reliable supplier.
2. All oil levels are to be checked with the drill parked on a level surface and while
the oil is cold, unless otherwise specified.
3. On plug type check points, the oil levels are to be at the bottom edge of the
check port.
4. All grease fittings are SAE Standard unless otherwise indicated. Grease the
non sealed fittings until grease is seen extruding from the fitting. One ounce (28
grams) of EP-MPG equals one pump on a standard one pound (0.45 kg)
grease gun.
5. Over lubrication on non sealed fittings will not harm the fittings or components,
but under lubrication will definitely lead to a shorter lifetime.
6. Unless otherwise indicated, items not equipped with grease fittings (linkages,
pins, levers, etc.) should be lubricated with oil once a week. Motor oil, applied
sparingly, will provide the necessary lubrication and help prevent the formation
of rust. An anti-seize compound may be used if rust has not formed. Otherwise,
the component must be cleaned first.
7. Grease fittings that are worn and will not hold the grease gun, or those that
have a stuck check ball, must be replaced.
DRILLING SOLUTIONS
6-19
To prevent minor irregularities from developing into serious conditions, several other
services or checks are recommended for the same intervals as the periodic lubrication.
1. Thoroughly wash all fittings, caps, plugs, etc. with a non-flammable, non-toxic
the service.
2. Lubricants must be at operating temperature when draining.
3. During regular lubrication service, visually check the entire unit with regard to
capscrews, nuts and bolts being properly secured.
4. Spot check several capscrews and nuts for proper torque. If any are found
loose, a more thorough investigation must be made.
5. If a defect is detected which requires special maintenance service, stop the drill
operation until the defect has been corrected. If necessary, contact the local
Atlas Copco Drilling Solutions distributor for assistance.
Lubrication Table
Periodic lubrication requirements are listed in the following Lubrication Chart. These
requirements include lubricant checks and greasing designated areas of the drill.
Table 14: Lubrication Chart

SERVICE
INTERVAL
10 HOURS
OR DAILY
50 HOURS
6-20
DESCRIPTION
SERVICE
REMARKS
QUANTITY
ENGINE OIL
ADD
SAE 15W40 (Refer to

OEM Engine Manual)
FILL TO DIPSTICK
FULL
ENGINE COOLANT
ADD
WATER - ANTIFREEZE
AR
FUEL TANK
FILL
# 2 DIESEL FUEL
FILL TO NECK
COMPRESSOR OIL
ADD AS
NEEDED
PROTEC (LP)
FILL TO MIDDLE OF
SIGHT GLASS
XHP-605 (HP)
HYDRAULIC OIL
ADD
ISO AW32
FILL TO FULL MARK
ROTARY HEAD OIL
ADD
SAE 90W GEAR OIL
FILL TO MIDDLE OF
SIGHT GLASS
ROTARY HEAD
GREASE
GREASE
EXXON MOBLE
RONEX EXTRA HD
MOLY 2
ADD UNTIL RELIEF

POPS OUT
GEARBOX DRIVE
SHAFT
GREASE
MPG-EP1 GREASE
5 SHOTS OF MPG-EP1
GREASE
BATTERIES
ADD
DISTILLED WATER
AR
PUMP DRIVE GEARBOX
ADD
80W90 GEAR OIL
FILL TO LEVEL HOLE
TRACK PLANETARY
GEARBOX
CHECK
ISO VG220 (REQIRED

LUBRICANT)
FILL TO LEVEL HOLE
DRILLING SOLUTIONS
SERVICE
INTERVAL
100
HOURS
DESCRIPTION
SERVICE
REMARKS
QUANTITY
AUXILIARY HOIST
CHANGE
TEXACO MEROPA 150

OR EQUIVALENT 90W
GL2/GL3
FILL TO LEVEL HOLE
WATER INJECTION
PUMP
CHANGE
SAE 30 NONDETERGENT
BOTTOM OF PLUG
HOLE (1 QUART or .95
LITERS)
150
HOURS
TRACK PLANETARY
GEARBOX
CHANGE
ISO VG220 (REQIRED

LUBRICANT)
2.7 GAL. (10.5 LITERS)

PER FINAL DRIVE
250
HOURS
ENGINE OIL
CHANGE
SAE 15W40 (Refer to

OEM Engine Manual)
CAT 3412 - 72
QUARTS (68 LITERS)
QSK19C - 72 QUARTS
(68 LITERS)
500
HOURS
1000
HOURS
PUMP DRIVE GEARBOX

(USED IN POSITION 2)
CHANGE
80W90 GEAR OIL
2.75 QUARTS (2.59

LITERS)
AUXILIARY HOIST
CHECK
TEXACO MEROPA 150

OR EQUIVALENT 90W
GL2/GL3
FILL TO LEVEL HOLE
FEED CABLE
JACKSCREWS
GREASE
MPG - EP1 GREASE
FILL UNTIL RELIEF

POPS OUT
JOHN BEAN WATER

INJECTION PUMP OIL
CHANGE
SAE 30 NONDETERGENT
BOTTOM OF PLUG
HOLE (1 QUART or .95
LITERS)
HYDRAULIC OIL
HYD. OIL
ANLYSIS
ISO AW32
150 GALLON (567

LITER)
COMPRESSOR OIL
CHANGE
PROTEC (LP)
FILL TO MIDDLE OF
SIGHT GLASS
XHP-605 (HP)
HYDRAULIC OIL
CHANGE
ISO AW32
FULL MARK ON
HYDRAULIC TANK
(ALL CYLINDERS
RETRACTED)
HYDRAULIC OIL
FILTERS (MAIN & CASE
DRAIN)
CHANGE
ISO AW32
FULL MARK ON
HYDRAULIC TANK
(ALL CYLINDERS
RETRACTED)
ROTARY HEAD OIL
CHANGE
SAE 90W GEAR OIL
7.5 - 8 GALLON (28 30 LITERS)
PUMP DRIVE GEARBOX

(USED IN POSITION 2)
CHANGE
80W90 GEAR OIL
2.75 QUARTS (2.59

LITERS)
AUXILIARY HOIST 8000

LB. HOIST
CHANGE
TEXACO MEROPA 150

OR EQUIVALENT 90W
GL2/GL3
4 PINTS (1.9 LITERS)
DRILLING SOLUTIONS
6-21
SERVICE
INTERVAL
DESCRIPTION
SERVICE
REMARKS
QUANTITY
1500-2000
HOURS
TRACK PLANETARY
GEARBOX
CHANGE
ISO VG220 (REQIRED

LUBRICANT)
345 XL / 345 SL 2.7

GAL. (10.5 LITERS),
ACGT 3400 EXT / 3400
STD 3.7 GAL (14
LITERS) PER FINAL
DRIVE
COMPRESSOR OIL
CHANGE
PROTEC (LP)
FILL TO MIDDLE OF
SIGHT GLASS
XHP-605 (HP)
5000
HOURS
HYDRAULIC OIL
HYD. OIL
ANLYSIS
ISO AW32
150 GALLON (567

LITER)
6000
HOURS
ENGINE COOLANT
CHANGE
WATER - ANTIFREEZE
44 GALLON (166.54
LITER)
Refill Capacities
The following fluid capacities are provided for servicing personnel who must perform drill
maintenance in remote locations where complete shop facilities and resources are not
available. These capacities will give the servicing personnel an approximation of the fluid
capacities of the components to be serviced. Always ensure that the specified method of
checking for accurate fluid levels is used.
Table 15: Capacities

APPROXIMATE CAPACITIES
COMPONENT
APPROXIMATE QUANTITY
SYSTEMS
Hydraulic Tank (ISO AW32):
Receiver Tank Oil:

PROTEC - Low Pressure
XHP605 - High Pressure
Rotary Head Oil (SAE 90W Gear Oil):
7.5 - 8 gallon (28-30 liters)
Pump Drive Gearbox (80W90 Gear Oil):
2.75 quarts (2.59 liters) when used in

position #2
Auxiliary Winch (Texaco Meropa 150):
4 Pints (1.9 liters)
Track Final Drive (ISO VG 220 is Required Lubricant):

345SL Final Drive Gearbox
2.7 gallon (10.5 liters) per drive
345XL Final Drive Gearbox
6-22
DRILLING SOLUTIONS
APPROXIMATE CAPACITIES
ACGT 3400 STD. Final Drive Gearbox
3.7 gallon (14 liters) per drive
ACGT 3400 EXT. Final Drive Gearbox

ENGINES
Engine Coolant (50-50 Water / AntiFreeze
Engine Oil Capacity:

CAT-27 (including filters):
CAT-32 (including filters):
CUMMINS QSK19 (including filters):
Fuel Tank (2# ASTMD-975-60T):
625 gallon (2365.88 liters) (Two Tanks)
AW32 Hydraulic Oil

The quality of the hydraulic oil is important to the satisfactory performance of any hydraulic
system. The oil serves as the power transmission medium, system coolant and lubricant.
Selection of the proper oil is essential to ensure proper system performance and life.
The drill left the factory filled with HUMBLE HYDRAULIC H oil. The following shows the
specifications:
Table 16: Hydraulic Oil Specification

EXXON HUMBLE HYDRAULIC H 32
ISO
Viscosity
Grade
Flash C
(F)
Pour C
(F)
32
206 (403)
-18 (0)
Viscosity
cSt at 40C
cSt -100C
32
5.4
Viscosity
Index
95
Grade AW32 is a general specification. Grade ISOAW32 is a general specification. Hydraulic

oil must conform to Parker Hydraulics Pump Division HF-O Standards (4-11-78) and ISO
Viscosity Grade 32.
Table 17: Approved Oils

The following are approved oils for Parker Hydraulics Pump Division HF-O
Standard.
AMOCO
AMOLITE: HF OIL NO. 21
EXXON
NUTO - H 32
DRILLING SOLUTIONS
6-23
The following are approved oils for Parker Hydraulics Pump Division HF-O
Standard.
GULF
HARMONY AW32
ILLINOIS OIL PRODUCTS
SUPREME R&O ANTIWEAR HYD. OIL
SUN OIL
SUNVIS 816 WR (32)
TEXACO
RANDO OIL NO. 32
PENNZOIL
AWX (WITH EC HI TEC ADD PACKS)
ATLANTIC RICHFIELD CO. (ARCO)
DURO AW-32
Compressor Fluids
Table 18: COMPRESSOR
COMPRESSOR FLUIDS
Design Operating
Pressure
Ambient Temperature
Specification
100 psi to 300 psi
-10F to 125F (-23C to

52C)
Preferred:
PRO-TEC
Alternate:
ISO Viscosity Grade 46
with rust and oxidation
inhibitors, designed for air
compressor service
350 psi
-10F to 125F (-23C to

52C)
Preferred XHP 605

Alternate:
XHP 405
ISO Viscosity Grade 68
Group 3 or Group 5 with
rust inhabiters designed for
air compressor service.
NOTE: Compressor oil carryover (oil consumption) may be greater with the use of alternate
fluids.
6-24
DRILLING SOLUTIONS
Lubricant Oil
Table 19: Rotary Head Oil
ROTARY HEAD OIL
Model
Quantity
Type
PV-271
44 Quarts (11 Gallon)

41.6 Liters
Gear Oil
SAE 90W
PV-275
DRILLING SOLUTIONS
6-25
Lube Viscosity Grade Comparisions

For use as a General Guide Only. Viscosities are based on a 95 VI oil.
6-26
DRILLING SOLUTIONS
Pump Drive Oil

Table 20: PUMP DRIVE OIL
PUMP DRIVE OIL
Model
Quantity
Type
PV-271
6 Quart (1.5 Gallon)

41.6 liters
80W90 Gear Oil
PV-275
This gear lubricant is compounded to achieve high load carrying capacity and meet the
requirements of either API-GL-5 or MIL-L-2105C. Unless otherwise specified, SAE-90
viscosity oil may be used for year round service. Low temperature usage is restricted as
follows:
Table 21: PUMP DRIVE GEAR OIL

PUMP DRIVE EXTREME PRESSURE GEAR OIL
SAE Viscosity Number
Minimum Ambient Temp.F (C)
75W
-40F (-40C)
80W
-15F (-26C)
85W
+10F (-12C)
90W
+20F (-7C)
140W
+40F (+5C)
250W
+50F (+10C)
Final Drive Lubricating Oil

Normal Operating Conditions
The actual manufacturer recommends only using lubricants that fulfill necessary viscosity
requirements for lubricating the final drives.
The viscosity rating on the rating plate on the final drive and the following requirements must
be observed: Use only lubricants with viscosity ratings for ISO VG150 and ISO VG220 for
normal operating conditions from 50F to 86F (+10C to +30C).
DRILLING SOLUTIONS
6-27
Severe Operating Conditions

Under severe operating conditions, e.g. in an ambient temperature range between -22F and
122F (-30C and +50C), the actual manufacturer recommends using transmission oil with
appropriate viscosity or a fully synthetic lubricant.
For lower operating temperatures, use oil with a lower viscosity (SAE 80W-90) and
for higher temperatures, use oil with a higher viscosity (SAE 85-140).
Oil Recommendation
1. For lubrication of planetary gears (transmissions), use only the below listed or
evident related type of oil!
2. The noted class of viscosity on the gearbox label is to be observed, respectively
the following instructions are to be regarded.
3. Usually the noted viscosity of ISO-VG150 and ISO-VG220 is only given for
normal operation temperature 30F to 50F (-1.1C to 30C).
NOTE: Choose by working temperature of 14F to 50F (-10C to +10C) one
viscosity class lower and at a range of 86F to 122F (30C to 50C) one grade
higher as the necessary oil quality.
Table 22: FINAL DRIVE OIL

FINAL DRIVE OIL RECOMMENDATION
6-28
BRAND
NAME / DESIGNATION
ARAL
DEGOL BG 150, BG 220
AVIA
AVILUB RSX 150
BP
ENERGOL GR-XP 150, GR-XP 220
CASTROL
ALPHA SP 150, ALPHA SP 220
CHEVRON
NL GEAR COMPOUND 150 220
DEUTSCHE SHELL
OMALA EP 150, EP220
ESSO
SPARTON EP 150, EP220
FINA
GIRAN 150, GIRAN 220
FUCHS
RENAP COMPOUND 104
GULF
EP LUBRICANT OIL HP 150, HP220
MOBIL
(MOBIL GEAR) GF 629, GF30
TEXACO
MEROPA 150
DRILLING SOLUTIONS
FINAL DRIVE OIL RECOMMENDATION

TOTAL
CARTER EP 150, CARTER EP 220
Hoist/Winch Lubricant
Required lubricant:
Table 23: HOIST/WINCH LUBRICANT

HOIST/WINCH LUBRICANT RECOMMENDATION
Temperature Range
Required Lubricant
-30F to 80F (-34C to 27C)
Mobil SHC629 or Texaco Pinnacle 150
-10F to 80F (-23C to 27C)
Texaco Meropa 150 or equivalent AGMA

#4EP
50F to 130F (10C to 54C)
Texaco Meropa 220 or equivalent AGMA

#5EP
Water Injection Pump Lubricant

Required lubricant:
Table 24: WATER INJECTION PUMP LUBRICANT

WATER INJECTION PUMP LUBRICANT RECOMMENDATION
Component
Quantity
Type

Drive
32 ounce (946 milliliter)
SAE 40W (anti-rust)
Extreme Pressure Multipurpose Grease

Under normal operating conditions, the following consistency grades are recommended:
Table 25: MULTIPURPOSE GREASE

CONSISTANCY GRADES
Grade
Temperature Range
NLGI No.0
Subzero Fahrenheit Temperatures
NLGI No. 1 or No. 2
Ambient Temperatures 0-100F (-18C38C)
DRILLING SOLUTIONS
6-29
CONSISTANCY GRADES
NLGI No. 2 or No. 3
Temperatures over 100F (28C)
Central Lube System Grease

When the Central Lube system is used, the drill leaves the factory with following grease. The
following shows the specifications.
Table 26: CENTRAL LUBE SYSTEM GREASE

AUTOMATIC CENTRAL LUBE SYSTEM GREASE SPECIFICATION
Descriptions
Specifications
Manufacturer:
Texaco, Inc.
Type:
Multi-Purpose Lithium Grease, Multipak

EPO
Quantity:
120 lb. Drum (54.4 kg)
Soap, Lithium:
2.8%
Lead:
0.3%
Penetration, ASTM at 77F (25C)

398
Unworked:
378
Worked:
Dropping Point:
367F (186C)
Oil Viscosity,
SUS at 100F (38C)
960
(207)
(cSt)
81.0
SUS at 210F (99C)
(15.8)
(cSt)
Guide to Maximum Usable Temperature:
Color:
6-30
350F (177C)
Continuous Usable Temperature
250F (121C)
Minimum Usable Temperature
-30F (-34C)
Dark Green
DRILLING SOLUTIONS
Multi-Purpose Grease
With the exception of the Central Automatic Lube system and the Rotary Head, the following
grease can be used:
Table 27: MULTI-PURPOSE GREASE

MULTI-PURPOSE GREASE SPECIFICATION
Descriptions
Specifications
Manufacturer:
Amalie Oil Company
Type:
Multi-purpose Grease, EP1 (#673-6819)
Quantity:
120 lb. Drum (54.4 kg.)
Soap Type:
LI-12-OH
Color:
Light Brown
NLG1 Grade:
Work Penetration
D17 77F (25C)
265-295
Dropping Point:
0-2265C
177
0-2265F
350
Rust, D-1743 (max):
Timken, D-2905, OK Load:

Filler, WT.
Oxidation, D-942 (100 hrs.):
Base Oil Properties:

VIS @ 100C (212F) cSt
VIS @ 210F (99C) SUS
15.5
82
Pour Point:
-15C
Degree Celsius:
Degree Fahrenheit:
Product Number:
DRILLING SOLUTIONS
+5F
5819
6-31
Rotary Head Grease

Atlas Copco recommends using Exxon Mobil Ronex Extra Heavy Duty Moly 2 grease in the
rotary head. The following shows the specifications.
Table 28: ROTARY HEAD GREASE

ROTARY HEAD GREASE SPECIFICATION
Descriptions
Specifications
Manufacturer:
Exxon Mobil
Type:
Ronex Extra Heavy Duty Moly 2
Quantity:
1 lb. (.45 kg)
Thickener Type:
Lithium Complex
Pumpable Down To:
-10C (14F)
NLGL Grade:
Color:
Gray-Black
Base Oil Viscosity, ASTM D

CST @ 40C
SUS @ 100F
460
2500
Dropping Point, ASTM D 225:
250+C (480+F)
Rust Protection, ASTM D 1743:
Pass
Texture:
Smooth
Moly Percentage:
Note 1:
MOLY 2 is compound with special

extreme pressure and anti-wear additives
to protect bearing surfaces at high loadcarrying capability.
Note 2:
For applications requiring lower pumpable

temperatures, contact engineering.

For latest applicable engine lubricating oil specifications, contact the engine manufacturer,
your distributor or your local Drilling Solutions distributor. Drills leave the factory with SAE
15W40 OIL. The following shows the specifications.
6-32
DRILLING SOLUTIONS
Table 29: ENGINE LUBRICATING OIL

ENGINE LUBRICATING OIL SPECIFICATION
Descriptions
Specifications
Manufacturer and Type:
AMOCO 300
SAE Viscosity Grade:
15W-40
API Service Category:

Approved Oils:
Pennzoil Long Life 15W-40

Texaco Ursa Super Plus 15W-40
Engine Coolant Specifications

Coolant is normally composed of three elements: water, additives and glycol.
Coolant is normally composed of three elements: water, additives and glycol.

Water is used in the cooling system to transfer heat. Distilled or deionized water is
recommended for use in the engine cooling systems. DO NOT use the following types of water
in cooling systems: hard water, softened water that has been conditioned with salt, and sea
water. If distilled water or deionized water is not available, use water with the properties that
are listed in the following table.
Table 30: WATER REQUIREMENTS

MINIMUM ACCEPTABLE WATER REQUIREMENTS
Property
Maximum Limit
Chloride (CI):
40 mg/L (2.4 grains/US gallon)
Sulfate (SO4):
100 mg/L (5.9 grains/US gallon)
Total Hardness:
170 mg/L (10 grains/US gallon)
Total Solids:
340 mg/L (20 grain/US gallon)
Acidity:
pH of 5.5 to 9.0
Additives
Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives
or insufficient amounts of additives enable the following conditions to occur: corrosion,
formation of mineral deposits, rust, scale, pitting and erosion from cavitation of the cylinder
liner and foaming of the coolant. Additives must be added at the proper concentration. Over
concentration of additives can cause the inhibitors to drop out-of-solution. The deposits can
DRILLING SOLUTIONS
6-33
enable the following problems to occur:

1. Formation of gel compounds
2. Reduction of heat transfer
3. Leakage of the water pump seal
4. Plugging of radiators, coolers and small passages.
Glycol
Glycol in the coolant helps to provide protection against the following conditions: Boiling,
Freezing and Cavitation of the water pump and the cylinder liner. For optimum performance,
use a 1:1 mixture of a water/glycol solution.
Fuel Oil
Cummins Fuel Oil
WARNING
Do not mix gasoline, alcohol or gasohol with diesel fuel. This mixture can
cause an explosion.
Cummins Engine Company recommends the use of ASTM No. 2D fuel. The use of No. 2
diesel fuel will result in optimum engine performance. At operating temperatures below 32F
(0C), acceptable performance can be obtained by using blends of No. 2D and No. 1D. The
use of lighter fuels can reduce fuel economy.
The viscosity of the fuel must be kept above 1.3 cSt at 212F (100C) to provide adequate fuel
system lubrication.
Cummins diesel engines have been developed to take advantage of the high energy content
and generally lower cost of No. 2 Diesel Fuels. Experience has shown that a Cummins diesel
engine will also operate satisfactorily on No.1 fuels or other fuels within the specifications
shown in following table.
Table 31: CUMMINS FUEL OIL

CUMMINS FUEL OIL SPECIFICATION TABLE
6-34
Viscosity (ASTM D-445)
1.3 to 5.8 centistokes per second at 104F (1.3 to

5.8 mm per second at 40C)
Cetane Number (ASTM D-613)
40 minimum (exception: in cold weather or in

service with prolonged idle, a higher cetane
number is desirable)
DRILLING SOLUTIONS
CUMMINS FUEL OIL SPECIFICATION TABLE

Sulfur Content (ASTM D-129 or
1552
Not to exceed 1 percent by weight
Water and Sediment (ASTM D1796)
Not to exceed 0.1 percent by volume
Carbon Residue (Ramsbottom,

ASTM-D-524 or Conradson,
ASTM D-189)
Not to exceed 0.25 percent by weight on 10

percent volume residue
Flash Point
At least 125F (52C) or legal temperature if

higher than 125F (52C)
Density (ASTM D-287)
30 to 42F ( -1 to 6C) API gravity at 60F (16C)

(0.816 to 0.876 Sp. Gr.)
Cloud Point (ASTM D-97)
10F (6C) below lowest ambient temperature at

which the fuel is expected to operate
Active Sulfur
Copper strip corrosion not to exceed No. 2 rating

after 3 hours at 122F (49C)
Ash (ASTM D-482)
Not to exceed 0.02 percent by weight
Distillation (ASTM D-86)
The distillation curve must be smooth and

continuous. At least 90 percent of the fuel must
evaporate at less than 725F (385C).
Cat Fuel Oil

Diesel engines have the ability to burn a wide variety of fuels. These fuels are divided into two
general groups. The two groups are called the preferred fuels and the permissible fuels. The
preferred fuels provide maximum engine service life and performance. The preferred fuels are
distillate fuels. These fuels are commonly called diesel fuel, furnace fuel, gas oil or kerosene.
The permissible fuels are crude oils or blended fuels. Use of these fuels can result in higher
maintenance costs and in reduced engine service life. Diesel fuels that meet the specifications
in the following table will help to provide maximum engine service life and performance. In
North America, diesel fuel that is identified as No.1D or No. 2D in ASTM D975 generally meet
the specifications. Specifications and requirements shown in the table are for diesel fuels that
are distilled from crude oil. Diesel fuels from other sources could exhibit detrimental properties
that are not defined or controlled by this specification.
Table 32: CAT FUEL OIL

Caterpillar Specifications for Distillate Diesel Fuel
Specifications
Requirements
ASTM Test
Aromatics
35% maximum
D1319
DRILLING SOLUTIONS
6-35
Caterpillar Specifications for Distillate Diesel Fuel

Ash
0.02% maximum (weight)
D482
Carbon Residue on
10% Bottoms
D524
Cetane Number
40 minimum (DI engines)
D613
35 minimum (PC engines)

Cloud Point
The cloud point must not exceed the

lowest expected ambient temperature
Copper Strip Corrosion

Distillation
No. 3 maximum
D130
10% at 282C (540F) maximum
D86
90% at 360C (680F) maximum

Flash Point
legal limit
D93
API Gravity
30 minimum
D287
45 maximum
Pour Point
6C (10F) minimum below ambient

temperature
D97
3% maximum
D3605 or
D1552
Kinematic Viscosity
1.4 cSt minimum and 20.0 cSt

maximum at 40C (104F)
D445
Water and Sediment
0.1% maximum
D1796
Water
0.1% maximum
D1744
D473
10 mg per 100 mL maximum
D381
3100 g minimum
D6079
Sulfur
Sediment
Gums and Resins
Lubricity
0.45 mm (0.018 inch) maximum at 60C

(140F)
0.38 mm (0.015 inch) maximum at 25C
(77F)
6-36
DRILLING SOLUTIONS
6-4 MAINTENANCE AS REQUIRED

General Information
WARNING

before you operate or perform any maintenance, service or repair on the
drill.
and understand Section 4 - Operating Controls.
includes an approved hard hat, safety glasses, steel toe shoes/boots,
that can become caught on rotating components.
overturning.
crushing risk.
DRILLING SOLUTIONS
6-37

Service As Required
The following maintenance in this MAINTENANCE AS REQUIRED section requires attention
on an as needed basis before, during and after the drill operation shift. This is in addition to
the 8-10 hour daily routine maintenance procedures. Performance of this inspection can result
in longer life and maximum productivity from the drill.
Air Cleaners
The following are detailed instructions for performing routine maintenance procedures on
engine air cleaners and compressor air cleaner. Note: Cat engines require two air cleaners .
WARNING
Air born dust may be hazardous. Wear proper personal protective

equipment while handling air cleaners and elements.
CAUTION
Raw, unfiltered air can cause compressor damage. Never service the air
cleaner while the drill is running.
6-38
DRILLING SOLUTIONS
Air Cleaner Indicators
1. Check the air cleaner visual restriction indicators before every shift during
every shift and after every shift.
2. Clean and inspect both the engine and compressor air cleaner visual restriction
indicators. They should be GREEN. If the indicators are RED, indicating a
plugged air cleaner, clean or replace the filter elements.
3. After servicing the element, reset the restriction indicator to GREEN when the
element is replaced in the air cleaner housing.
4. The engine and compressor air cleaners must be checked to verify the
restriction indicators are not sticking. Check by pressing in the rubber boot. The
internal green and red indicator should move freely.
Connections and Ducts
Check air cleaner connections and ducts for leaks before every shift, during every shift and
after every shift. Ensure all connections between the engine air cleaners and engine are tight
and sealed. Ensure all connections between the compressor air cleaner and air compressor
are tight and sealed.
DRILLING SOLUTIONS
6-39
NOTE: Dust that gets by the air cleaner system can often be detected by
looking for dust streaks on the air transfer tubing or just inside the intake
manifold inlet.
Empty Dust Cups

As daily routine maintenance, and as required in extremely dusty conditions, the dust cup on
the air cleaner must be emptied of accumulations.
On air cleaners equipped with dust cups, the cup must be emptied when it becomes 2/3 full.
The frequency of dust cup servicing varies with the operating conditions. It may be necessary
to empty the dust cup daily.
1. Loosen the dust cup clamps and remove the dust cups on both the compressor
and engine air cleaner.
2. Empty any accumulations of dust and dirt and replace the dust cup. Secure the
dust cup clamps.
3. When reinstalling the dust cup, make sure it seals all the way around the air
cleaner body.
4. Inspect the o-ring between the dust cup and the air cleaner body. If it is
damaged in any way, it must be replaced.
5. On filters equipped with a quick release dust cup, simply release the latch on
the dust cup and allow it to swing down and empty. When it is empty, close the
dust cup and lock it in place with the latch.
6. On filters equipped with vacuator valves, the dust cup service is cut to a
minimum. A quick check to see that the vacuator valve is not inverted,
damaged or plugged is all that is necessary.
Air Cleaner Pre-Cleaner

The Donoclone tubes in the air cleaner pre-cleaner may become lightly plugged with dust
which can be removed with a stiff fiber brush. If heavy plugging is evident, remove the lower
body section and clean with compressed air or water not to exceed 160F (71C).
6-40
DRILLING SOLUTIONS
CAUTION
Never clean Donoclone tubes with compressed air unless both the safety
and primary elements are installed in the air cleaner. Do not steam clean
the tubes in the pre-cleaner.
Air Cleaner Rain Guard

1. Check the bolts fastening the rain guard around the pre-cleaner body and make
sure they are secure.
2. If the bolts become loose, it will allow the rain guard to fall down over the
openings in the pre-cleaner and restrict the flow of air into the air cleaner.
Air Cleaner Elements
The air cleaner is the dry type with two elements: A primary element that is replaceable and
can be cleaned, and a safety element that should only be replaced and never cleaned.
DRILLING SOLUTIONS
6-41
When the visual restriction indicator is RED, clean and replace the air cleaner elements. The
following maintenance procedure must be followed.
1. Unclip the three clamps holding the dust cover.
2. Remove the dust cover.
3. Remove the wing nut and washer. Carefully withdraw the primary air cleaner
element.
4. Inspect the safety element restriction indicator. If the indicator is RED, replace
the safety element.
NOTICE
Make sure new elements arrive enclosed in plastic or in a protective
membrane. DO NOT install elements that have been sitting on the shelf
unprotected. This is a dust hazard.
NOTICE
Make sure that the safety element wing nut is tight. Never attempt to clean
a safety element. You must change the safety element after three primary
element changes or as indicated by the safety service indicator.
5. Clean the inside of the cover and the housing with a clean, damp cloth.
6. To clean the primary element, perform the following:
a. To dry clean the element, carefully direct compressed air (not to exceed
100 psi or 5 bar pressure) at an angle onto the inside surface from no closer
than 1 inch (25.4mm) from the filter.
b. To wet clean the element, soak for 15 minutes in lukewarm water, not
exceeding 160F (71C), mixed with a commercially available detergent.
Rinse until water runs clear (40 psi maximum).
c. After the cleaning, the element must be thoroughly dry before using. Do not
use compressed air to dry the element.
6-42
DRILLING SOLUTIONS
NOTICE
Replace the primary element after six cleanings or annually, whichever
comes first.
7. Examine the new or newly cleaned primary element for torn or damaged pleats,
bent end covers, liners and gaskets.
8. Ensure the primary element wing nut and washer are not cracked or damaged.
Replace if necessary.
9. The safety element should be replaced at this time if:
a. Examination of the primary element reveals a torn or perforated element.
b. Change safety element after three primary element changes or 1 year
duration.
c. Change safety element as indicated by the safety element restriction
indicator.
d. Change safety element if the air cleaner visual restriction indicator is RED
after servicing the primary element.
10. Clean the inside of the air cleaner housing before removing safety element.
11. To replace the safety element, remove the cotterpin and restriction indicator.
Carefully remove the safety element. Dispose of the used element properly.
12. Install new safety element and secure it with the restriction indicator and
cotterpin.
13. Carefully install the cleaned or new primary element and secure it with the wing
nut and washer.
14. Install the dust cover.
15. Inspect all air intake piping and joints between the air cleaner and inspect the
compressor air inlet to ensure that no dusty air can enter.
16. Ensure all clamps are tight.
After servicing the elements, reset the restriction indicator to GREEN when the element is
replaced in the air cleaner housing.
The compressor air cleaner must be checked to verify the restriction indicator is not sticking.
Check by pressing in the rubber boot. The internal green/red indicator should move freely.
NOTICE
Never leave the air cleaner open longer than necessary.
DRILLING SOLUTIONS
6-43
NOTICE
The two most common servicing problems are over servicing and
improper servicing.
1. Over Servicing - New filter elements increase in dust cleaning efficiency as
dust builds up on the media. It will trap smaller particles by closing the area
between particles. Remember that if the filter is working properly, it will look
dirty. Also, if a filter looks clean, it may not be serviceable. The operator display
will indicate when the filters require servicing.
2. Improper Servicing - Your compressor is very vulnerable to abrasive
contaminants during the service process. The most common cause of
compressor damage is due to careless servicing procedures. A handful of dust
introduced into the inlet of the compressor can cause a catastrophic failure of
the compressor. Be very careful when replacing elements not to introduce dirt
into the inlet tube.
Air Cleaner Service Tips

Follow these simple service tips. Youll keep your air cleaners working at their best to protect
your compressor continuously.
1. To begin with, let restriction levels be your guide. Use a restriction indicator.
2. Service elements only when the restriction reaches the service level
recommended by the compressor or equipment manufacturer. Its only above
that point that air cleaner restriction begins to reduce performance levels.
3. If the compressor performance is poor, but restriction is still within limits, do not
change that element! The air cleaner is probably not at fault.
4. To get extra service hours out of each filter element, make sure the air inlet is
away from any heavy dust clouds caused by operation. And make sure exhaust
carbon cannot enter the air cleaner.
5. Check to see that all connections are tight and leak free and that breakaway
joints, both intake and exhaust, are aligned and sealing.
6. Make sure that the vacuator valve, on air cleaners so equipped, is not plugged.
Is the cup joint sealing? This should take care of most of the air cleaner related
performance problems.
7. When restriction readings finally indicate a change, remove the primary
element very carefully. Use a damp cloth to wipe out all excess dust in the air
cleaner.
8. If you reuse the elements, clean them with care. Rapping, tapping or pounding
dust out of them is dangerous. Severe damage to the filter will result.
6-44
DRILLING SOLUTIONS
9. A thorough cleaning with air or water is recommended in many cases. But be

careful. Too much pressure can break the filter paper and destroy the element.
10. Carefully check new or properly cleaned elements for damage before installing.
11. Never attempt to clean a safety element. Change safety elements only after
three primary element changes or as indicated by a SafetySignalTM Service
indicator.
12. Make it a habit not to disturb the element until restriction again reaches the
service limit.
Clean the Drill

The complete drill must be given a weekly cleaning. Daily cleaning will be required if material
is adhering to the tower or track working parts.
1. Make sure that the inside of the operators cab, decking, steps and grab rails
are clean. Oil, grease, snow, ice or mud in these areas can cause you to slip
and fall. Clean your boots of excess mud before getting on the drill.
2. Check that no material or debris is jammed between track sprockets and track
tensioners.
3. Check the tower feed installation for debris buildup around the sheaves.
4. Thoroughly wash all fittings, caps, plugs, etc. with a nonflammable, nontoxic
the service.
NOTICE
Protect all electric components and control panels against entry of water
or steam when using high pressure cleaning methods. Cover the fuel and
hydraulic fill cap breathers located on each tank.
5. After cleaning, check for defects in the air cleaner ducts.
a. Check intake for accumulation of debris that could restrict air flow.
b. Check air cleaner mounting hardware for security.
c. Check all hoses for cracks, chafing or deterioration and replace at the first
sign of probable failure.
Loose Bolted Connections

If any loose nuts or bolts are found during the frequent walk-around and the daily inspections,
ensure they are properly torqued. Refer to Torque Specifications for the required torque for
all bolt sizes and grades. Always replace self-locking nuts if they have been loosened.
DRILLING SOLUTIONS
6-45
FEED CABLE & WIRE ROPE

The wire rope industry recognizes the ASME (American Society for Mechanical Engineers)
standards for the criteria to set the end of the service life of wire ropes on cranes and towers,
based on visible indicators of wire rope deterioration.
Cable Tensioning Procedure (PV-271 & PV-275)

Preliminary Adjustments (Engine Running)
1. The upper cable tensioner counterbalance valve is factory pre-set at 3000-psi.
Adjustment of a new or replacement part should not be required. For reference,
the valve adjustment range is 1000-4000-psi in 3 turns. To set at 1000-psi turn
the adjustment fully counter-clockwise* until it stops (1000-psi).
2. The sequence valve cartridge must be set at 500-psi inlet pressure while its
outlet is being directed to tank. To adjust:
a. Attach a 1000-psi gauge or transducer to the test fitting in the sequence
valve inlet.
b. Hold the upper tensioner solenoid valve open by supplying 24 VDC to the
valve coil.
c. Adjust the sequence valve until the gauge reads 500-550-psi.
d. Remove power from the valve coil and the upper tensioner cylinders will
retract and tension the upper cables.
3.
Cable Adjustment (Machine Running)
1. After the upper and lower power head stops are stoutly welded into position and
feed system is completely assembled, fully retract the feed cylinders. Before
proceeding, it is assumed the feed cylinders have been stroked several times
to purge all air from the feed system. The next two steps can be made with the
tower vertical or horizontal.
2. Fully extend the feed cylinders to move the power head to the bottom of the
tower until the head guides make contact with the lower stops. If the head
guides will not reach the stops, release the upper tensioning cylinders so that
contact can be made. Use the lower cable jackscrews to pull the head guides
to the stops. Reactivate the upper tensioning cylinders and verify the head
guides are not lifted up off of the stops. Move the power head up and down the
tower several times to verify the head guides will return to contact the lower
stops.
3. Move the power head to the top of the tower by fully retracting the feed
cylinders until the power head guides contact the upper stops.
4. With the tower down (horizontal), the sag in the pulldown cables will be
measured to determine the correct cable adjustment.
5. With the power head guides against the upper stops, use the Cab Side (CS)
6-46
DRILLING SOLUTIONS
cable tension jack screw to tension the CS lower cable until the cable sag
(measured at the midpoint of the longest span) is 6.0-6.5 inches. This
measurement is typically taken from the centerline of the front tower tubing (i.e.,
Chord) to the centerline of the cables.
6. Using the Dust Collector Side (DCS) cable tension jack screw, tension the DCS
lower cable until the cable sag (measured at the midpoint of the longest span)
is the same as the CS lower cable 6.0-6.5 inches. Both cables must be adjusted
for the identical amount of sag in order to have the same pre-load.
7. With requirements of identical sag met, the cable adjustment procedure is
completed.
NOTE: The adjustment direction of this valve is opposite to that of
conventional pressure control valves. Clockwise adjustment decreases
valve setting.
Replacement Guideline
The standards for cranes and towers allow six (6) broken wires in a wire rope lay length, or
three (3) broken wires in one strand, in a wire rope lay. The lay length is 5.5 times the wire
rope diameter (B30.4-B30.8).
The overhead hoist standard criteria is twelve (12) broken wires in a wire rope lay length, or
four (4) broken wires in one strand per lay length (B30.2 and B30.16).
There is no industry wide recognized standard for wire rope on drills, but the above standards
can be used as a guide to determine a safe practical point for wire rope replacement. Cable
feed on the pullback side on a drilling derrick, as the cables support the drill pipe string and
the rotary transmission devise. The cable feed on the pulldown side of the drill does not reflect
any of the ASME standard conditions. The only load these cables see is the hydraulically
applied loads. There is no dead weight being supported and no component free fall will occur
due to complete failure of the rope. However, a tension rope failure is possible, so replacement
should not be delayed beyond the above determined replacement point.
Also, note that any broken wires protruding from the wire rope create a snagging hazard.
These wires should be trimmed flush to the wire rope diameter. These trimmed broken wires
need to be recorded and logged as to their exact locations as part of the broken wire count
DRILLING SOLUTIONS
6-47
criteria for determining wire rope replacement.
The drawing shows the wire rope broken down. The wire rope is made up of strands woven
around a core. Each strand is made up of individual wires. If a rope breaks four (4) wires from
the same strand within the lay length, it should be replaced according to ASME standards.
One lay length is the distance along the wire rope that it takes one strand to make one
revolution. The diameter of a wire rope is taken at the highest points. It is NOT taken across
the flats of the strands.
Cable Lubrication
Lubrication of the wire ropes and cables should be included in the maintenance schedule. Wire
ropes and cables should be cleaned with a wire brush and solvent and lubricated about every
500 hours with one of the following or equivalent:
1. Texaco Crater A
2. Brooks Klingfast 85 (Brooks Oil Co.)
3. Gulf Seneca 39
4. Whitmores Wire Rope Lubricant (Whitmore Manufacturing Co.)
The lubricant can be applied with either a spray or a brush and is recommended for protection
against corrosion only.
Feed Cable Replacement

Refer to the parts manual for your specific rig serial number to ensure the correct feed cables,
anchors, clamps and hardware are used. Do not substitute. Do not reuse cable anchors or
clamps.
Replace wire rope when any of the following conditions are met:
1. Six randomly distributed broken wires are found in one lay
6-48
DRILLING SOLUTIONS
2. The outside wires are worn more than one third (1/3) of their original diameter
3. There is evidence of heat damage of any kind
4. The wire rope is kinked or damaged.
Wire Rope
Winch ropes, including their anchorage and other load carrying components of the winch
system, e.g. sheave bearings, rope sheaves and drill hooks, shall be checked at least once a
week.
Wire ropes shall be examined and discarded in accordance with 3.5 of ISO 4309:1990. In table
3.5 of ISO 4309:1990, classification groups M1 and M2 shall be used. On drill rigs with normal
hook load of more than 1000KN, the winch rope shall be regularly paid out and shortened
according to a plan laid down by the manufacturer on basis of experience.
Wire rope used in drilling operations becomes unusable because of wear and wire breakage
and should be discarded according to certain criteria.
1. Replace when four (4) randomly distributed broken wires are found in one lay.
2. Replace when wire rope shows wear of one third (1/3) of the original diameter
of the outside wire.
3. Replace when evidence of any heat damage from any cause is found.
4. Replace when any kinking or cracking occurs.
Wire Rope Clamps

Incorrect installation of the rope clamps can cause premature rope failure and/or possible
DRILLING SOLUTIONS
6-49
bodily injury.
1. Nuts should always be retightened after the initial load has been applied.
2. A termination made in accordance with the following instructions and using the
number of clips shown has an approximate 80% efficiency rating. This rating is
based upon the catalog breaking strength of wire rope. If a pulley is used in
place of a thimble for turning back the rope, add one additional clip.
3. The number of clips shown is based upon using right regular or Lang lay wire
rope, 6 x 19 Class or 6 x 37 Class, fibre core or IWRC, IPS or XIPS.
4. The number of clips shown also applies to right lay wire rope, 8 x 19 Class, fibre
core, IPS, sizes 1-1/2 inch and smaller; and right regular lay wire rope, 18 x 7
Class, fibre core. IPS and XIPS, SIZES 1-3/4 inch and smaller.
5. The important things are using proper thimble size, number of clamps and size,
and installing them properly. Refer to drawing and Wire Rope Clamp chart.
6-50
DRILLING SOLUTIONS
Table 33: Correct Usage of Wire Rope Clips
Clip Size Inches
Minimum
Number of Clips
Amount of Rope
to Turn Back in
Inches
Torque in Foot
Pounds
Dimensions are in inches and are approximate

1/8
3-1/4
3/16
3-3/4
1/4
4-3/4
15
5/16
5-1/2
30
3/8
6-1/2
45
7/16
65
1/2
11-1/2
65
9/16
12
95
5/8
12
95
3/4
18
130
7/8
19
225
26
225
1-1/8
34
225
1-1/4
37
360
1-3/8
44
360
1-1/2
48
260
1-5/8
51
430
1-3/4
53
590
71
750
2-1/4
73
750
2-1/2
84
750
2-3/4
10
100
750
10
106
1200
DRILLING SOLUTIONS
6-51
Wire Rope Installation
WARNING
The cable clamp is not designed to hold the full load alone. NEVER
attempt to lift a load with less than five (5) wraps of cable on the drum.
Unless a revolving stand is available, we recommend unwinding the cable coil prior to
installing on winch drum. This prevents the cable from becoming twisted during the winding
operation.
Take the free end of the wire rope and insert it through the small opening of the anchor pocket.
Loop the wire rope and push the free end about 3/4 of the way back through the pocket. Install
the wedge, then pull the slack out of the wire rope. The wedge will slip into the pocket and
secure the wire rope into the drum. The anchor is designed to accommodate several sizes of
wire rope. You may anchor 3/8 inch and 7/16 inch (10mm and 11mm) wire rope by inserting
the wedge large end first. You may anchor 1/2 inch and 9/16 inch (13mm and 14mm) wire rope
by inserting the wedge small end first.
1. Wind cable onto the drum.
a. Leather gloves should be used when handling winch cable.
b. The cable winds in on TOP of the winch drum. Care should be taken to wind
the cable on the winch drum as evenly and as tight as possible.
2. Always use two persons when winding the cable onto the winch drum; one
person to operate the controls and the other to guide the cable from a safe
distance to obtain as level a winding job as possible.
3. When winding the winch cable on the winch drum, never attempt to maintain
tension by allowing winch cable to slip through hands. Always use hand-overhand technique.
6-52
DRILLING SOLUTIONS
Grease Drum Option

On drills equipped with a central lubrication systemoption, changing the 55 gallon (208.20 liter)
grease drum is an As Required maintenance item.
WARNING
Electrical shock hazard. Turn off and lock out power before opening
enclosure. Do not subject sensor bodies to pressure greater than 6000
PSIG.
Change Grease Drum
WARNING
Do not attempt to service the lubrication system when the drill is running.
Shut off the engine and relieve air pressure.
1. Undo the drum tie downs.
2. Remove the pump and cover.
3. Replace the used grease drum with a new grease drum. Dispose of the used
grease drum in accordance with local guidelines and regulations.
4. Reattach the drum cover and pump.
5. Start the engine. When the compressor is turned on, the lube cycle will begin.
Compressor Air Hoses and Clamps

1. Periodic clamping bolts re-tightening is necessary due to Cold-Flow present
in all rubber hoses. Tighten to recommended torque value listed on BOSS
CLAMPS chart in Section 7 SYSTEMS & TROUBLESHOOTING.
DRILLING SOLUTIONS
6-53
2. Examine for and change out worn hoses and weakened Boss clamps. If the
hoses are to be changed out, change the Boss clamps also. These Boss
clamps hold the hose connections under a large amount of pressure.
Remember, Boss clamps (including the nuts and bolts) are for single use only.
Do not reuse! Once removed, discard.
3. Refer to the Dixon Boss Clamp Selection and Installation instructions shown
in Section 7
4. SYSTEMS & TROUBLESHOOTING for the proper way to select and install
Dixon Boss Clamps.
6-54
DRILLING SOLUTIONS
6-5 MAINTENANCE (8-10 Hours)

General Information
WARNING

drill.
includes an approved hard hat, safety glasses, steel toe shoes/boots,
that can become caught on rotating components.
overturning.
crushing risk.
DRILLING SOLUTIONS
6-55

Overpressure Control System Test
WARNING
The Over Pressure Control does not relieve the operator from the
responsibility of having control of the drill at all times. While the Over
Pressure Control reduces the chance of a tip over, the operator must see
that he does not over feed the drill to this extent.
NOTICE
The operator must ensure the jacks are located on firm ground. Nothing
can prevent the drill from upsetting if the ground or shoring under the
jacks gives way.
NOTICE
LIABILITY FOR TIPPING A UNIT OVER LIES SOLELY WITH THE DRILLER.

Do not test the Overpressure Control System with a drill pipe in the rotary head. 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 (50.8mm) off the ground. The drill
weight must be fully supported by the leveling jacks.
Step Two:
Step Three:
Step Four:
Slowly increase pulldown pressure to maximum down pressure.
6-56
DRILLING SOLUTIONS
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, reduce system pressure with the feed controls, level
the drill and contact your supervisor for system repairs immediately.
Step Six:
Repeat steps 4 and 5, this time raising the dust collector side jack slightly. If pressure
vents when the jack pad is lifted slightly off the ground, the system is working.
If it does not vent pulldown pressure, shut down the drill immediately and report any
problems encountered to your supervisor.
Air Cleaners
The following are detailed instructions for performing routine maintenance procedures on
engine air cleaners and compressor air cleaners. Performance of this inspection can result in
longer life and maximum productivity from the drill.
WARNING
Air born dust may be hazardous. Wear proper personnel protective

equipment while handling filters.
CAUTION
Raw, unfiltered air can cause engine and compressor damage. Never
service the air cleaners while the engine is running.
Air Cleaner Indicators

Check the air cleaner visual restriction indicators before every shift, during every shift and after
every shift. The indicator measures the restriction of the air cleaner and alerts the operator
when filter replacement is required.
DRILLING SOLUTIONS
6-57
1. Clean and inspect the compressor air cleaner visual restriction indicator. It
should be GREEN. If the indicator shows RED, indicating a plugged air cleaner,
clean or replace the filter elements.
2. After servicing the element, reset the restriction indicator to GREEN when the
element is replaced in the air cleaner housing.
3. The engine and compressor air cleaner must be checked to verify the
restriction indicator is not sticking. Check by pressing in the rubber boot. The
internal green/red indicator should move freely.
Connections and Ducts
Check air cleaner connections and ducts for leaks before every shift, during every shift and
after every shift. Ensure all connections between the air cleaner and engine are tight and
sealed. Ensure all connections between the air cleaner and air compressor are tight and
sealed.
NOTE: Dust that gets by the air cleaner system can often be detected by
looking for dust streaks on the air transfer tubing or just inside the intake
manifold inlet.-
Empty Dust Cups

As daily routine maintenance, and as required in extremely dusty conditions, the dust cup on
the air cleaner must be emptied of accumulations.
6-58
DRILLING SOLUTIONS
On filters equipped with dust cups, the cup must be emptied when it becomes 2/3 full. The
frequency of dust cup servicing varies with the operating conditions. It may be necessary to
empty the dust cup daily.
1. Loosen the dust cup clamp and remove the dust cup on the compressor and
engine air cleaner.
2. Empty any accumulations of dust and dirt and replace the dust cup. Secure the
dust cup clamp.
3. When reinstalling the dust cup, make sure it seals all the way around the air
cleaner body.
4. Inspect the o-ring between the dust cup and the air cleaner body. If it is
damaged in any way, it must be replaced.
On filters equipped with a quick release dust cup, simply release the latch on the dust cup and
allow it to swing down and empty. When it is empty, close the dust cup and lock it in place with
the latch.
On filters equipped with vacuator valves, the dust cup service is cut to a minimum. A quick
check to see that the vacuator valve is not inverted, damaged or plugged is all that is
necessary.
Engine
WARNING
Hot oil or components can burn. Hot oil and hot components can cause
personal injury. Do not allow hot oil or hot components to contact the
skin.
The drawings shows a typical 32-CAT Engine. Due to individual applications, your engine may
appear different from the drawing.
DRILLING SOLUTIONS
6-59
WARNING
Hot oil or components can burn. Hot oil and hot components can cause
personal injury. Do not allow hot oil or hot components to contact the
skin.
The drawings show typical CUMMINS QSK19C Engine. Due to individual applications, your
engine may appear different from the drawing.
Engine Oil Level

Check the engine oil level daily by viewing the dipstick. Perform this maintenance with the
engine shut off.
1. The drill must be on a level and stable surface when checking the oil level to be
sure the measurement is correct.
2. Wait at least 5 minutes after shutting off the engine to check the oil level. This
allows time for the oil to drain into the oil pan.
3. Pull out the dipstick (oil level gauge), wipe it clean with a lint free dry cloth and
insert the dipstick back into the engine.
4. Pull out the dipstick again and check the oil level on the dipstick.
CAUTION
Never operate the engine with the oil level below the L (low) mark or above the H (high)
mark.
6-60
DRILLING SOLUTIONS
NOTICE
Operating the engine when the oil level is above the FULL mark could
cause the crankshaft to dip into the oil. The air bubbles created from the
crankshaft dipping into the oil reduces the oils lubricating
characteristics and could result in the loss of power.
5. Cummins Engine
Maintain the oil level between the L (low) mark and H (high) mark on the oil
level gauge (dipstick). Do not fill the crankcase above the HIGH mark.
Cat Engine
Maintain engine oil level between the ADD mark and FULL mark on the oil
level gauge (dipstick). Do not fill the crankcase above the FULL mark.
6. Remove the oil filler cap and add oil, if necessary. (Refer to 6.3 Lubricant
Specifications in this section for details on engine oil.)
7. Clean the oil filler cap and reinstall.
8. Repeat the process and check oil level again after engine has run for about 1
minute.
Engine Belts & Tensioner

Under normal operating conditions, the engine drive belts should be inspected daily. Belt
damage can be caused by incorrect tension, incorrect size or length, pulley misalignment,
incorrect installation, severe operating environment and oil or grease on the belts.
Drive Belts Inspection
To maximize the engine performance, visually inspect the belts for tension, wear, breaks,
cracks or other damage. Replace belts that are cracked or frayed. Adjust belts that have a
glazed or shiny surface which indicates belt slippage. Correctly installed and tensioned belts
will show even pulley and belt wear.
1. Remove the belt guard to check the belt tension or to replace belts.
2. Check belt tension. Adjust the belt tension in order to minimize belt slippage.
Belt slippage will decrease the life of the belts.
DRILLING SOLUTIONS
6-61
3. To check belt tension, apply 25 lbs (111 N) of force midway between the
pulleys. A correctly adjusted belt will deflect 1/2 to 3/4 (13mm to 19mm).
Belt Adjustment
Every three months, or as necessary, adjust the belt tension in order to minimize belt slippage.
Belt slippage will decrease the life of the belts. If the belts are too loose, the belts will vibrate.
This vibration is enough to cause unnecessary wear on the belts and on the pulleys. If the belts
are too tight, unnecessary stresses are placed upon the pulley bearings and upon the belts.
These stresses will shorten the life of the belts and of the pulley bearings. If new belts are
installed, check the tension again after 30 minutes of engine operation at the rated rpm.
Cat Engines
1. Remove the belt guard to adjust belt tension.
2. Slightly loosen mounting bolt and adjusting nuts.
3. Turn the adjusting nuts in order to increase or decrease the belt tension.
Tighten adjusting nuts. Tighten mounting bolt. Refer to the Torque
Specifications in this section for proper torques.
4. To check the belt tension, apply 111 N (25 ft./lb). of force midway between the
pulleys. A correctly adjusted belt will deflect 0.35 inch (9mm) to 0.59 inch
(15mm).
5. Ensure that the belt guard is replaced and secured.
Cummins QSK19C Engines

1. Remove the belt guard to adjust belt tension.
2. Measure the belt tension in the center span of the pulleys.
6-62
DRILLING SOLUTIONS
NOTE: Refer to Belt Tension Chart in the OEM Engine Operation and
Maintenance Manual for the correct gauge and tension value for the belt
width used.
3. An alternate method (deflection method) can be used to check belt tension by
applying 25 lbs. (111 N) forcemidway between the pulleys on v-belts. If the
deflection ismore than one (1) belt thickness per foot of pulley center distance,
the beltmust be adjusted. As a general rule, a correctly adjusted belt will deflect
0.35 inch (9mm) to 0.59 inch (15mm).
4. Ensure that the belt guard is replaced and secured.
Belt Replacement
For applications that require multiple drive belts, replace the belts in matched sets. Replacing
only one belt of a matched set will cause the new belt to carry more load because the older
belt is stretched. The additional load on the new belt could cause the new belt to break. Note:
When a drive uses two or more belts, replace the belts as a complete set.
1. Loosen up adjusting mechanism and move pulley centers as close together as

possible. The belts can then be installed without excessive force.
2. To prevent damage, do not roll a belt over the pulley or pry it on with a tool.
NOTE: Refer to the Belt Tension Chart in your OEM Engine Operation and
Maintenance Manual for the correct gauge and tension value for the belt
width.
3. Pulley misalignment must not exceed 1/16 inch for each 12 inches (6mm for
each meter) of distance between pulley centers.
DRILLING SOLUTIONS
6-63
4. Belts must not touch the bottom of the pulley grooves and they must not
protrude over 3/32 inch (2mm) above the top edge of the groove.
5. When a drive uses two or more belts, the belt riding depth must not vary over
1/16 inch (2mm) between the belts.
6. Ensure that the belt guard is replaced and secured properly.
7. If new belts are installed, check the tension again after 30 minutes of engine
operation at the rated rpm.
QSK19C Engine Alternator Belt

Follow the instructions below to adjust the engine alternator drive belt. (QSK19 engine is
shown).
1. Loosen the alternator and adjusting link mounting capscrews. Note: The lower
jam nut has left-hand threads.
2. Loosen up the jam nuts on the adjusting screw.
3. Turn adjusting screw clockwise to tighten the belt tension.
4. Tighten the jam nuts on the adjusting screw. Note: The lower jam nut has lefthand threads.
5. Tighten the adjusting link and alternator mounting capscrews to a torque value
of 40 ft/lbs. (54Nm).
6-64
DRILLING SOLUTIONS
6. Check the belt tension again to be sure it is correct. Note: Belt tension must
be 150 ft/lb. (203Nm).
Water Pump Drive Belt

1. Loosen the locknut which secures the idler pulley to the water pump.
2. Turn the adjusting screw to adjust the belt tension.

NOTE: Do not adjust belt tension to full value with the adjusting screw.
Belt tension can increase when the lock nut is tightened and, therefore,
reduce belt and bearing life.
3. Secure the idler pulley in position by tightening the lock nut to 50 ft/lb (68Nm) .
4. Loosen up the adjusting screw 1/2 turn to prevent breakage.
5. Measure the belt tension again. Adjust if necessary.
6. Ensure that the belt guard is replaced and secured properly.
Engine Fuel/Water Seperators

Engine manufacturers require that a fuel-water separator or fuel filter and water separator be
installed in the fuel supply system. The fuel filter/water separator should be monitored daily for
signs of water and sediment. If water is present, drain the water and sediment from the filters/
separators.
NOTE: Water and sediment may contain petroleum products. Consult
with your local environmental agency for recommended disposal
guidelines.
DRILLING SOLUTIONS
6-65
WARNING
extinguish all open flames and do not smoke while draining fuel filters.
Always wipe up any spilled fuel immediately. Fuel leaked or spilled onto
hot surfaces or electrical components can cause a fire. To help prevent
possible injury, turn the start switch off when changing fuel filters or
water separator elements.
Cat Fuel/Water Separator

Water in the fuel can cause the engine to run rough. If the fuel has been contaminated with
water, the fuel/water separator element should be changed before the regularly scheduled
interval of 500 hours. (See 6.9 Maintenance 500 Hours).
Due to individual applications, your engine may appear different from the picture.
WARNING
6-66
DRILLING SOLUTIONS
The primary filter/water separator also provides filtration to help extend the life of the
secondary fuel filter. The element should be changed as part of the 500 hour routine
maintenance schedule. If a vacuum gauge is installed, the primary filter/water separator
should be changed at 50 to 70 kPa (15 to 21 inches of Hg.)
If the engine is equipped with a fuel-water separator, drain the water and sediment from the
separator daily.
WARNING
Fuel leaked or spilled onto hot surfaces or electrical components can

cause a fire. To help prevent possible injury, turn the start switch off
when changing fuel filters or water separator elements.
The bowl should be monitored daily for signs of water. If water is present, drain the water from
the bowl.
1. Shut off the engine.

2. Open the self-ventilated drain. Catch draining water in a suitable container and
dispose of the water properly.
3. Close the drain.
NOTE: Water and sediment may contain petroleum products. Please
consult local environmental agency for recommended disposal
guidelines.
CAUTION
Do not overtighten the valve. It can damage the threads.
DRILLING SOLUTIONS
6-67
NOTICE
The Water Separator is under suction during normal engine operation.
Ensure that the drain valve is tightened securely to help prevent air from
entering the fuel system.
Cummins Fuel/Water Separator

water, the fuel/water separator element should be changed before the regularly scheduled
interval of 250 hours. (See 6.8 Maintenance 250 Hours).
WARNING
WARNING

when changing fuel filters or water separator elements.
1. Shut off the engine. Place a suitable container under the fuel filter/water
separator to collect any excess escaping fuel when draining. Do not allow fuel
to drain on the ground.
6-68
DRILLING SOLUTIONS
2. Use your hand to open the drain valve. Turn the valve counter clockwise about
2-1/2 turns until draining occurs. Drain the filter sump of water and any
sediment until the clear fuel is visible (about 1 cup).
3. Turn the valve clockwise approximately 2-1/2 turns to close the drain valve.
CAUTION
Do not overtighten the valve. It can damage the threads.
Cooling System Maintenance

Radiator Coolant Level
The coolant level must be checked daily as part of the 8-10 hour routine maintenance
procedure. Ensure the coolers are not too hot to touch.
WARNING
skin and eyes. Always shut down the engine and allow it to cool down
before removing the radiator cap. Remove the cap slowly to relieve
pressure. Avoid contact with steam or escaping fluid. Do not remove the
radiator cap from the cooler(s) while the engine is hot. Wait until the
temperature is below 120F (49C) before removing the pressure cap.
Failure to do so can result in personal injury from heated coolant spray
or steam. Remove the filler cap slowly to relieve coolant system pressure.
1. Check the engine coolant level. The coolant level should bemaintained so fluid
can be seen in the sight glass. If coolant is low, add through the quick fill station.
DRILLING SOLUTIONS
6-69
NOTE: If the coolant level is below the minimum level, the low level probe
will activate the engine shutdown. In the case of repeated low level
shutdowns, call for service to investigate the cause of coolant loss.
2. Makeup coolant added to the engine must be mixed with the correct
proportions of anti-freeze, supplemental coolant additive (SCA), and water to
avoid engine damage. It must be used year round in all climates. Note: Refer
to the Actual Manufacturers manual for more details on engine coolant.
NOTE: Refer to Cooling Recommendations and Specifications in this
section for more details on coolant. Also refer to the engine manual.
Cummins Engine Company, Inc. recommends using either a 50/50 mixture of
good quality water and fully formulated antifreeze, or fully formulated coolant
when filling the coolant system. The fully formulated antifreeze or coolant must
meet TMC RP329 or TMC RP330 specifications (Refer to 6.3 Refill Capacities/
Lubricants/Fuel for further recommended coolant specifications).
CAUTION
Do not add cold coolant to a hot engine. Engine castings can be

damaged. Allow the engine to cool to below 120F (49C) before adding
coolant.
Fully formulated antifreeze must be mixed with quality water at a 50/50 ratio (40
percent to 60 percent working range). A 50/50 mixture of antifreeze and water
gives a -34F(-37C) freezing point and a 228F (109C) boiling point, which is
adequate for locations in North America. The actual lowest freezing point of
ethylene glycol antifreeze is 68 percent. Using higher concentrations of
antifreeze will raise the freezing point of the solution and increase the possibility
of a silica gel problem.
1. A refractometer must be used to accurately measure the freeze point of the

coolant.
2. Do not use a floating ball hydrometer. Floating ball hydrometers give incorrect
readings.
6-70
DRILLING SOLUTIONS
Cooling System Sealing Additives
Never use a sealing additive to stop leaks in the coolant system. The use of sealing additives
will: (a) Build up in coolant low flow areas, (b) Clog coolant filters, (c) Plug radiator and oil
cooler. This can result in coolant system plugging and inadequate coolant flow causing the
engine to overheat.
Cooling System Soluble Oils

Do not use soluble oils in the cooling system. The use of soluble oils will: (a) Allow cylinder
liner pitting, (b) Corrode brass and copper, (c) damage heat transfer surfaces, (d) damage
seals and hoses.
Clean Radiator & Oil Coolers

If the drill has suffered leaks of oil or fuel, dirt will tend to adhere to the cooling fins of the
radiator and hydraulic oil cooler. This accumulation of dirt will reduce the cooling efficiency.
Therefore, any leaks of oil or fuel should be immediately repaired and cooling surfaces given
a thorough cleaning.
Check every 8-10 hours or daily for signs of clogging on the exposed cooling fins on the
combined radiator, compressor oil and hydraulic oil coolers as part of the routine maintenance
procedure.
Note:
Adjust the frequency of cleaning according to the effects of the operating environment. Inspect
the radiator for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator if necessary.
Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite
direction of the fans air flow. Hold the nozzle approximately 0.25 inch (6 mm) away from fins.
Slowly move the air nozzle in a direction that is parallel with the tubes. This will remove debris
that is between the tubes.
DRILLING SOLUTIONS
6-71
WARNING
When using compressed air, water jets or steam cleaning methods,

ensure that appropriate protective clothing is worn to protect eyes and
exposed parts of the body. Maximum air pressure at the nozzle must be
less than 30 psi (207 kPa) for cleaning purposes.
Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash
the core with detergent and hot water. Thoroughly rinse the core with clean water. After
cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the
removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in
order to inspect the core for cleanliness. Repeat the cleaning if necessary.
Inspect the fins for damage. Bent fins may be opened with a comb. Inspect these items for
good condition: welds, mounting brackets, air lines, connections, clamps and seals. Make
repairs if necessary.
1. If clogging is dried on dirt, use liquid or dry air to remove from the cooling fins.
If dry dust is present, use low pressure compressed air to clean.
2. In case of severe clogging, due to fluid leaks, apply diesel fuel or use a
commercial cleaning detergent. Let it soak in and then wash off with water jet.
Fuel Tank
WARNING
extinguish all open flames, and do not smoke while filling the fuel tank.
Always wipe up any spilled fuel immediately.
6-72
DRILLING SOLUTIONS
Fuel Level
Maintain fuel tank(s) at a high level to minimize water condensation inside the tank. This is
best accomplished by filling the fuel tanks at the end of each shift or day. Check fuel tanks and
fuel lines for possible leaks. Because of the potential fire hazard, leaks must be corrected as
soon as they are spotted. Select the proper grade of fuel in accordance with the information
given in 6.3 Fuel Specifications.
The fuel gauge monitors the level of fuel in the fuel tank. The tank should be refilled when the
indicator needle moves to below 1/4 tank.
1. Check the fuel level by reading the fuel level gauge on the operators console.
2. Never allow the fuel tank to completely empty, otherwise the entire fuel system
will require bleeding.
3. If the fuel level is low, add fuel through the Quick Fill Station.
4. Fill tank with the correct grade of fuel. Refer to 6.3 Fuel Specifications in this
section for more fuel details.
Receiver Separator
Water condenses and must be drained daily from the bottom of the separator tank. If water is
allowed to condense into the compressor oil, the bearing life will be considerably reduced.
Drain Water from Receiver Tank
WARNING

pressure before removing filler plug, drain valve, fittings or receiver
cover.
DRILLING SOLUTIONS
6-73
1. Locate and open the drain valve. Allow any of the accumulated water to drain
into a container.
2. When oil starts to flow, close drain valve.
3. Dispose of all accumulation in accordance with local regulations.
Compressor Oil Level
WARNING
Do not attempt to open the filler plug, any drain plugs or the drain valve
before making sure all air pressure has been relieved from the system.
High Pressure can cause severe injury or death
Periodically check the compressor oil level in the receiver tank. A loss of compressor oil could
be an indication of excess oil carry over with the compressed air and would require a separator
element change.
Check the receiver separator oil level at the sight glass oil level gauge on the receiver tank.
The procedure to check the fluid level is as follows:
1. The engine must not be running.
2. The fluid must be in the center of the oil level sight glass.
3. If necessary, add fresh, clean synthetic oil (filtered through a 10 micron filter)
through the fill cap area to bring level to FULL.
Note:
Low Pressure compressors (110 psi) use PROTEC Oil.
High Pressure compressors (350 psi) use XHP605 Oil.
For details on compressor oil, refer to 6.3-Refill Capacities/Lubricants/Fuel
Specifications.
6-74
DRILLING SOLUTIONS
Receiver Separator Element

Maintenance on the receiver separator element is on an as required basis. A change of the
receiver separator element is required when there is excessive oil carry over with the
compressed air.
WARNING
High pressure can cause severe injury or death. Do not attempt to remove
been relieved from the system. Completely relieve pressure before
removing filler plug, drain valve, fittings or receiver cover.
WARNING
components.
1. Park the drill on stable, level surface and shut down engine. Allow time for the
drill to cool.
2. Remove the receiver cover and remove the separator element.
3. Discard the used element in accordance with local guidelines.
4. When installing the new element, make sure that the gasket is equipped with a
staple. Also, install the element with the two drain holes located at the bottom.
5. Reattach the front cover and tighten bolts.
DRILLING SOLUTIONS
6-75
6. After startup, check the drill for any leaks at operating temperatures.
Hydraulic Reservoir
The hydraulic reservoir oil level must be checked daily as part of the 8-10 hour routine
maintenance procedure.
NOTICE
clean, contaminant free system is extremely important to the drills
system to ensure its complete cleanliness. When operating, the oil level
must be between the maximum and minimum levels.
CAUTION
Excessive hydraulic oil can rupture hydraulic tank and cause injury or
property damage. Do not fill hydraulic tank with cylinders extended.
Retract all cylinders and fill tank to indicated level.
WARNING
Liquid explosion can cause severe injury. Disconnect hydraulic tank high
voltage heater before draining or filling system.
Hydraulic Oil Level

The following procedure is proper for checking the hydraulic oil level in the reservoir. If the
hydraulic oil level is low, add hydraulic oil.
1. The drill must be level.
2. The tower must be horizontal, the power head at the top of the tower, and all
the leveling jacks fully retracted.
3. Check the reservoir oil level by viewing the sight gauge. Verify that fluid level is
near the maximum level indicated on the sight glass.
Add hydraulic oil through the quick-fill following the procedure below:
6-76
DRILLING SOLUTIONS
NOTICE
Do not use the quick-fill systemto drain or remove fluid. Use the fittings
at the bottom of the hydraulic tank.
1. The drill must be level.
2. The tower must be horizontal with the rotary head at the top of the tower and
all leveling jacks fully retracted.
3. The engine must not be running.
4. Ensure the breathers on top of the tank are clean and will allow the tank to
breathe.
5. Locate the proper port fitting in the quick-fill box for the hydraulic tank. Remove
cap and clean the fitting.
6. Locate the proper quick-fill hose. Clean hose fitting and connect to quick-fill
fitting.
7. Add or refill with new and clean oil.
8. Verify that the low hydraulic oil level operator alarm turns off when the float
reaches the safe level (bottom of the sight glass).
9. Verify tank has not been over filled. Fluid should not be over the top of the sight
glass.
10. Verify both of the main valves under the tank are fully open.
DRILLING SOLUTIONS
6-77

There are two system return hydraulic oil filters and two hydraulic drain filters on the drill.
The system main return filters are located on the side of the hydraulic tank. The main return
flow to the tank passes through these filters and into the supercharge manifold. The
supercharge provides supply to the piston pumps and minimizes cavitation problems.
The hydraulic drain filters are located on the other side of the hydraulic tank and filter the oil
prior to return into the hydraulic tank.
It is important to monitor the filters restriction indicator sight glass during the routine 8-10
hour walk around inspection by the operator. If the indicator window shows RED, then the
filter elements require replacement. If the window shows GREEN, the filters are satisfactory.
When restriction indicates that element servicing is required, follow the instructions shown in
6.10 Maintenance (1000 Hours). Under normal operating conditions, these filters are replaced
at the regular 1000 Hour service interval.
Rotary Head
WARNING
Riding the rotary head can can cause severe injury or death. Do not ride
rotary head.
WARNING
Climbing raised tower can cause severe injury or death. Do not climb
raised tower.
6-78
DRILLING SOLUTIONS
WARNING
Falling tower can cause severe injury or death. Ensure all locking pins are
in locked position.
WARNING
Rotating shafts or drill string can cause severe injury or death. Do not
service the rotary head with drill string in motion.
Rotary Head Oil Level

Check the rotary head oil level daily. Perform this maintenance with the tower up and the
rotary head at the bottom of the tower.
1. Level the drill.
2. With the tower vertical, bring the rotary head to bottom of the tower.
3. Inspect the case for leaks.
4. Inspect fluid level sight glass for damage.
5. Check the rotary head oil level. Oil must be showing in the sight glass.
If the fluid level is low, add fluid using the following procedure.
1. The drill must be level. The tower must be raised and the rotary head must be
at the bottom of the tower.
2. Clean area around fill plug.
3. Remove the fill plug.
DRILLING SOLUTIONS
6-79
4. Add SAE 90W Gear Oil through the fill port until the oil level is visible at the top
of the sight glass.
5. Clean and replace the fill plug.
Rotary Head Upper Bearing

There is a grease point on the top of the rotary head. Grease the rotary head upper bearing
daily at the grease point on the top of the rotary head.
Make sure the grease at the relief is free to move and the port is not plugged Remove the relief
fitting to perform this task. Then, add grease slowly until it is coming out the open port. Make
sure the relief fitting is operational. Replace the relief fitting and continue to add grease until
the relief indicator pops out. In a short period of time, if the relief has not popped out, stop and
determine where the grease is going. Use Exxon Mobil Ronex Extra Heavy Duty Moly 2
(#57818221) grease.
Gearbox Drive Shaft

The following grease procedures must be carried out as part of the 8-10 hour or daily routine
maintenance schedule.
Grease Gearbox Drive Shaft Universal Joints
WARNING
Rotating Shaft can cause severe injury or death. Do not operate with
guard removed.
1. Shut down engine.

2. Leave guard in place.
3. Reach in through the opening in guard to clean the drive shaft u-joint grease
nipples.
4. If necessary, (with everyone clear) momentarily press starter button (with key
ON/OFF switch in OFF position), to line up access to the grease nipples.
6-80
DRILLING SOLUTIONS
5. Inject 5 shots of MPG-EP1 grease into the drive shaft grease nipple. Wipe off
excessive grease.
Dust Collector
In order to insure that the dust collector system is operating to its design specifications, the
following visual inspections should be performed on a periodic basis.
Dropout Hose
Verify that the dropout hose located at the bottom of the dust collector is securely fastened to
the dropout cone. This hose should be free of any holes and should form a tight seal during
the period when the collector is pulling a vacuum. The hose will open momentarily during each
back-pulse of compressed air when the filter elements are being cleaned.
Suction Hose
The suction hose leading from the dust hood outlet to the dust collector inlet should be clear
of obstructions such as a build-up of dirt or mud. There should be no kinks or extremely sharp
bends in the suction hose.
Blower Assembly
Observe the discharge of the blower assembly. There should be no visible dust emerging from
the outlet of the blower housing. If there is, the filter elements and/or filter gaskets should be
replaced immediately to avoid damage to the blower wheel.
DRILLING SOLUTIONS
6-81
Filter Elements
Listen to the back-pulsing of the filter elements. There should be a sharp pulse of air every 23 seconds. If a pressure gauge is installed in the air supply line to the dust collector, verify that
the air is pulsed at a peak pressure of approximately 40 psi. The filters should be cleaned
whenever possible by pulsing the elements with the blower system turned off. This can be
done at the end of any drilling cycle, while changing drill rod and possibly between each hole.
Remove the dropout cone and inspect the filters. Replace them if they are worn, torn or
shredded. Remove the wing nut and the filter should drop out.
Rod Seal
Inspect the integrity of the rod seal attached to the bottom of the tower. Also give attention to
the dust curtains surrounding the hole.
Clean the Drill

The complete drill must be given a weekly cleaning. Daily cleaning will be required if material
is adhering to the tower or truck working parts.
1. Make sure the inside of the operators cab is clean. Make sure the operators
areas, steps and grab rails are clean. Oil, grease, snow, ice or mud in these
6-82
DRILLING SOLUTIONS
areas can cause you to slip and fall. Clean your boots of excess mud before
getting in the cab or on the drill.
2. Check the tracks. Make sure that no material is jammed between the track
sprockets and the track tensioners.
3. Check the tower feed installation for debris buildup around the sheaves.
4. Thoroughly wash all the fittings, caps, plugs, etc. with a nonflammable,
nontoxic cleaning solution before servicing to prevent dirt from entering while
performing the service.
Note:
Protect all electric components and control panels against entry of water or steam
when using high pressure cleaning methods. Cover the fuel and the hydraulic
fill cap breathers located on each tank.
5. After cleaning, check for defects in the air cleaner ducts.
a. Check intake for accumulation of debris that could restrict air flow.
b. Check air cleaner mounting hardware for security.
c. Check all hoses for cracks, chafing or deterioration and replace them at the
first sign of probable failure.
DRILLING SOLUTIONS
6-83
6-6 MAINTENANCE (50 Hours or Weekly)

General Information
WARNING

drill.
approved hard hat, safety glasses, steel toe shoes/boots, gloves, respirator and ear
protection. Do not wear loose fitting clothing that can become caught on rotating components.
overturning.
crushing risk.
6-84
DRILLING SOLUTIONS
Batteries
The following battery maintenance must be carried out as part of the 50 hour routine
WARNING
Batteries contain an acid and can cause injury. Battery fumes can ignite
and explode. Skin and eye contact with battery fluid can cause injury. Do
not smoke when observing battery fluid level. Avoid skin and eye contact
with battery fluid. If contact occurs, flush area immediately with water.
Electrolyte Level
1. Check the electrolyte level and keep the electrolyte level above the plates.
2. Refill with distilled water if necessary.
CAUTION
Over filling can cause poor performance or early failure.
DRILLING SOLUTIONS
6-85
Battery Terminals
Keep the battery terminals clean and the connections tight.
Pump Drive Gearbox

Oil Leaks
Inspect the hydraulic pump drive gearbox for leaks as part of the 50 hour maintenance
schedule. Follow the steps shown below.
1. Look for signs of oil on the case and around the bottom of the case.
2. If there are signs of oil leakage, clean the outside of the case and around the
bottom. Verify signs of oil are from the case and not another source.
3. If a leak is verified, contact maintenance and take corrective action.
Check Oil Level

The type of service and the operating conditions will determine the maintenance interval.
However, it is recommended that the oil level be checked as part of the 50 hour routine
maintenance schedule. At the same time, check for oil leaks. Because the lubricant system is
the heart of the unit, it is especially important that the oil be kept clean.
Note:
The oil in the pump drive gearbox should be changed whenever the oil shows traces of dirt or
the effects of high temperature, evidenced by discoloration or strong odor.
WARNING
Hot oil or components can burn. Oil must be at normal operating

temperature when draining. Avoid contact with hot oil or components. Do
not allow used oil to drain into the ground. Dispose of properly.
6-86
DRILLING SOLUTIONS
1. Move the drill to a level surface.

2. Stop engine before checking or adding oil.
3. Clean around the oil level and fill plug before checking or adding oil.
4. Check the oil level within the gearbox. The oil should be level with the oil level
plug.
5. If necessary, add 80W90 gear oil and fill to the correct level. Always use clean
oil from clean containers. Do not overfill. This will cause overheating. See 6.3
Lubricant Specifications for the recommended required oil specifications.
6. Check and clean the gearbox breather.
Undercarriage
Initial Break-In Maintenance
New equipment requires the following initial one time break-in maintenance after 50 to 100
hours of operation. After this initial phase, the regular intervals listed in the maintenance
schedule should be followed.
Final Drive Mounting Bolts
1. Check the torque of the final drive mounting bolts with a torque wrench. The
correct bolt torque is 420 50 ft/lbs (569 Nm).
NOTE:
If new wheel nuts have been recently installed, they may require frequent
checks until they seat properly.
2. Repeat same procedure for the other track drive.
Oil Leaks
Inspect the track final drives gearboxes for leaks. Look for signs of oil on the final drive gearbox
case and around the bottom of the case. If there are signs of oil leakage, clean the outside of
DRILLING SOLUTIONS
6-87
the gearbox case and around the bottom of the gearbox case. Verify that the signs of oil are
from the gearbox case and not another source. If a leak is verified, contact maintenance and
take corrective action.
Oil Level
The following gearbox maintenance must be carried out as part of the 50 hour routine
maintenance schedule. Follow the procedure below to check the fluid level and to add fluid if
level is low.
NOTICE
Care must be taken to ensure fluids are contained during any inspection
or work performed on this component. Handle and dispose of fluids
according to local regulations and mandates.
WARNING

1. Move the drill to a level surface and position the track final drive, with one port
at the 6:00 oclock position. Shut off the engine.
2. Be sure that the planetary housings are not too hot to touch. If they are hot, give
them time to cool down before proceeding.
3. Clean around the fill/level plug and remove it.
4. The final drive lubricant should be level up to the bottom of the fill/level plug
hole.
If the final drive gearboxes need oil, proceed with the following steps and
add lubricant:
WARNING
Do not overfill the final drive, damage may occur.

1. Add lubricant (ISO VG220) into the upper port until it is even with the threads.
2. Clean the port and plug threads, then replace the plug.
3. After all scheduled service is complete, start the engine and move the tracks to
check for leaks. Listen for any unusual noises that might need attention.
6-88
DRILLING SOLUTIONS
4. Repeat this procedure for the other track drive.
Tracks
Track Tension
The following track maintenance must be carried out as part of the 50 hour routine
One of the more critical factors in undercarriage wear is proper track adjustment.
1. Tracks that are too tight will put extra stress on both the undercarriage and the
drive train components, while wasting horsepower.
2. Tracks that are too loose create too much back bending, snaking and poor
footing which causes needless wear on the roller flanges, sprocket teeth and
track guides.
Proper track adjustment will vary with soil conditions and drill application. For example,
packing takes up slack, thus creating tight track. With excavator type chain, internal pin and
bushing wear causes track to loosen and offset the tight track caused by packing. Proper track
adjustment is important if long life and full track value are to be received.
1. The drill should be in its working environment. Propel the drill through mud and
allow dirt to pack the tracks.
2. Propel the drill in the direction of the idlers. Stop with one track pin directly over
the front carrier roller (the one closest to the idler).
3. Place a straight edge on top of the shoe grousers between the front carrier
roller and the idler.
DRILLING SOLUTIONS
6-89
4. The correct SAG (distance from the bottom of the straight edge to top of the
track shoe) is 3-4% of the distance between the top of the idler and the carrier
roller.
5. The track requires retensioning when the top of the track sag between the top
carrier rollers exceeds 1-1/2 (38 mm).
Track Adjustment
If the track is too loose, the track must be tightened by adding grease to the track adjuster. If
the track is too tight, grease must be removed from the track adjuster.
1. Clean the single grease fitting (A).
2. Inject MPG-EP2 grease,with a high pressure grease gun, until the required
track tension is obtained. See Refill Capacities/Lubricants/Fuel Specifications
for recommended grease requirements.
3. To reduce track tension, slightly unscrew the cover plug (B). The internal buffer
spring will relax and grease will be ejected.
4. To readjust, secure cover plug (B) and inject grease at grease point (A) until
correct track tension is effected.
5. Repeat the same procedure for the other track drive.
6-90
DRILLING SOLUTIONS
Auxiliary Hoist
WARNING
Do not climb a raised tower. Climbing a raised tower can cause severe
injury or death. Lower the tower to the horizontal position to service the
winch.
Never lift or transport personnel with the winch. Do not use the winch in
any manner of operation which may endanger any individual.
CAUTION
Stay at least 10 feet (304.80 cm) away from cable while it is under tension.
Cable should be inspected whenever unwound and replaced when
broken strands are noted.
WARNING
Cable clamps are not designed to hold rated winch load. At least 5 wraps
of cable must remain on the drum at all times.
Periodic Inspection
The following jib hoist maintenance must be carried out as part of the 50 hour routine
1. Inspect rigging, winch and hydraulic hoses at the beginning of each work shift.
Any defects should be corrected immediately.
DRILLING SOLUTIONS
6-91
2. Be certain that at least 5 full wraps of cable remain on the drum at all times;
otherwise, the cable clamps may not hold the load.
3. Replace cable that has kinked or broken strands because it may fail without
warning at low loads.
4. Inspect drive lugs on clutch and drum for rounding or cracking.
5. Inspect gear teeth for excessive wear. Wear should not exceed 1/16.
Refer to Feed Cable & Wire Rope information in 6.4 Maintenance As Required
for additional information on wire rope and wire rope clamps.
Wire Rope
Wire ropes, including their anchorage and other load carrying components of the traveling
block and winch system, e.g. sheave bearings, rope sheaves and drill hooks shall be checked
at least once a week.
and should be discarded in accordance with 3.5 of ISO 4309:1990. In table 3.5 of ISO 4309:
1990, classification groups M1 and M2 shall be used. On drills with normal hook load of more
than 1000KN, the winch rope shall be regularly paid out and shortened according to a plan laid
down by the manufacturer on the basis of experience.
2. Replace when the wire rope shows wear of one third (1/3) the original diameter
of the outside wire.
Refer to Cable & Wire Rope information in 6.4 Maintenance As Required for additional
information on wire rope and wire rope clamps.

Change the initial water injection pump oil after the first 50 hours of operation. Thereafter,
water injection pump oil change maintenance must be carried out as part of the 500 hour
routine maintenance schedule and every 500 hours thereafter.
WARNING
The water injection pump oil should be at operating temperature for

draining. Be careful. Hot oil and components can burn.
6-92
DRILLING SOLUTIONS
Change Initial Oil
1. Position the drill on stable, level surface.

2. Place a container with a capacity of at least 3 quarts (2.84 liters) under the drain
point to collect the used oil.
3. Remove both fill plug and drain plug. Allow oil to drain completely.
4. After oil has drained, clean and replace drain plug.
5. Clean and remove the level plug.
6. 12 gpm Cat Water Injection Pump - Refill the oil through the fill port
(approximately 40 ounces or 1.18 liters) or until oil appears at level plug. Fill
with ISO-68, SAE 40 (anti-rust) oil.
with ISO-68, SAE30 (anti rust) oil.
8. Clean and install fill plug and level plug.
9. Operate the drill and water injection and check for any leaks.
DRILLING SOLUTIONS
6-93
6-7 MAINTENANCE (100 - 150 Hours)

General Information
WARNING

drill.
overturning.
crushing risk.
6-94
DRILLING SOLUTIONS
Auxiliary Hoist
Oil Change
The initial gear oil should be changed after the first one hundred (100) hours of operation, then
every 1,000 operating hours or six (6) months, whichever occurs first. The gear oil must be
changed to remove wear particles that impede the reliable and safe operation of the brake
clutch and erode bearings, gears and seals. Failure to change gear oil at these suggested
minimum intervals may contribute to intermittent brake slippage which could result in property
damage, severe personal injury or death.
The gear oil should also be changed when ever the ambient temperature changes significantly
and an oil from a different temperature range would be more appropriate. Oil viscosity with
regard to ambient temperature is critical to reliable brake operation. Make certain that the gear
oil viscosity used in your winch is correct for your prevailing ambient temperature. Failure to
use the proper type and viscosity of planetary gear oil may contribute to brake slippage which
could result in property damage, severe personal injury or death.
WARNING
winch.
DRILLING SOLUTIONS
6-95
WARNING
components. Do not allow used oil to drain into the ground. Dispose of
properly.
The gear oil should be changed after the first one hundred (100) hours of operation, then at
every 1000 operating hours.
NOTICE
or work is performed on this component. Handle and dispose of fluids
Replace the lubricant using the following steps:

1. The winch must be removed from the tower in order to position the drain port
in the proper orientation.
2. Position the drum drain port at 6:00 oclock position, in line with the opening in
the housing.
3. Whenever gear oil is changed, remove the vent plug (located in the drum
support), clean in solvent and reinstall. Do not paint over the vent or replace
with a solid plug.
6-96
DRILLING SOLUTIONS
NOTICE
Do not paint over the vent, keep it clean and unobstructed.
4. Remove the center port plug and the drain port plug. Allow the old oil to drain
out of the drum into a suitable container. Dispose of the used oil in accordance
with local guidelines.
5. Clean the drain plug and reinstall it.
6. Refill the housing with Texaco MEROPA 150 or an equivalent API GL-2/3 gear
lubricant (with extreme pressure additives), through the fill hole, until oil is level
with the bottom of the fill/level hole. The winches being serviced may not
require as much oil due to incomplete draining of the original winch oil. Refer to
section 6.3-Refill Capacities/Lubricants/Fuel for further recommended oil
specifications.
7. Clean the center port plug and reinstall it.
Table 34: Temperature and Lubricant

Temperature Range
-30F to 80F (-34.44C to 26.67C)
Required Lubricant
Mobil SHC629 or Texaco Pinnacle 150
-10F to 80F (-23.33C to 26.67C)
Texaco Meropa 150 or equivalent

API GL-2/3
50F to 130F (10C to 54.44C)

AGMA #5EP
8. Reinstall the winch if it was removed and verify bolt torque. Use SAE grade 8
bolts.
Table 35: Thread Condition and Torque

Thread Condition
Torque
Dry Thread
205 to 220 ft/lbs. (278 to 298 Nm)
Lubed Thread
158 to 170 ft/lbs (214 to 231 Nm)
Mounting Bolts
Tighten all winch base mounting bolts to recommended torque after the first one hundred
(100) hours of operation, then every 1000 operating hours or six (6) months, whichever
occurs first.
DRILLING SOLUTIONS
6-97

Final Drive Mounting Bolts
The following maintenance must be carried out after 150 hours of operation:
1. Check the torque of the final drive mounting bolts with a torque wrench. The
correct bolt torque is 420 50 ft/lbs (569 Nm).
NOTE:
If new wheel nuts have been recently installed, they may require frequent checks
until they seat properly.
Change Initial Track Planetary Oil

The gear oil should be changed after the first one hundred fifty (150) hours of operation, then
at every 1500 operating hours. This maintenance is recommended by Caterpillar as part of
a lubrication and preventive maintenance schedule in order to help provide maximum
planetary gearbox life.
1. Move the drill to a level surface and position the track final drive with one port
WARNING

temperature when draining. Avoid contact with hot oil or components.
2. Be sure the oil is warm before draining but be sure that the planetary housings
are not too hot to touch. If they are hot, give them time to cool down before
proceeding.
3. Place container with a capacity of at least 25 quart (24 liter) under the track
drive drain point.
6-98
DRILLING SOLUTIONS
4. Clean the area around the fill/level plug and drain plug.
5. Removed the fill/level plug and drain plug and allow the oil to drain from the
drain port into the container. Do not allow the used oil to drain into the ground.
Dispose of properly.
6. Clean the port drain plug threads and then install it.
7. Refill the planetary through the oil fill/level plug hole with about 2.7 gallons (10.2
liters) per drive of ISO VG220 oil until the planetary is full and the oil overflows.
Allow the surplus oil to drain out until the oil level is up to the bottom of the fill/
level port. Do not allow the excess oil to drain into the ground. Dispose of
properly.
8. Clean the fill/level plug threads and then install it.
9. After scheduled service is complete, check the planetary track drive for leaks
at operating temperatures. Listen for any unusual noises that might need
attention.
DRILLING SOLUTIONS
6-99
6-8 MAINTENANCE (250 Hours)

General Information
WARNING

drill.
overturning.
crushing risk.
6-100
DRILLING SOLUTIONS
CAT Engine Maintenance

The following drawing shows a typical CAT 27 Engine. Due to individual applications, your
engine may appear different from the drawing.
Cat Engine Oil and Filters

Change the Engine Oil and Oil Filter(s) as part of the 250 Hour Routine Maintenance
Schedule or 6 months, whichever comes first.
DRILLING SOLUTIONS
6-101
WARNING
Some state and federal agencies in the United States of America have
determined that used engine oil can be carcinogenic and can cause
reproductive toxicity. Avoid inhalation of vapors, ingestion and common
prolonged contactwith used engine oil. Do not allow used oil to drain into
the ground. Always use proper procedures to dispose of the oil.
oil or hot components to contact the skin. Oil must be at normal operating
temperatures when draining. Do not allow used oil to drain into the
ground. Dispose of properly.
Drain Cat Engine Oil

Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle
on the bottom of the oil pan. The waste particles are not removed when draining cold oil. Drain
the crankcase with the engine stopped. Drain the crankcase with the oil warm. This draining
method allows the waste particles that are suspended in the oil to be drained properly.
Failure to follow this recommended procedure will cause the waste particles to be recirculated
through the engine lubrication system with the new oil.
1. Position the drill on a stable, level surface and shut off engine. Wait at least 5
minutes after shutting off engine to drain the oil. This allows time for the oil to
drain into the oil pan.
2. Ensure the oil is warm by viewing water temperature gauge. The temperature
should not exceed 140F (60C) before draining oil.
3. Place a container, with a capacity of at least 20 gallon (76 liter), under the drain
point.
4. Remove the drain plug and allow the engine oil and suspended contaminants
to drain from the drain hose into a container.
Replace Cat Engine Oil Filters

Change the engine oil filter(s) at the same time the engine oil is changed.
6-102
DRILLING SOLUTIONS
WARNING
Avoid contact with hot oil or components. Do not allow used oil to drain
into the ground. Dispose of properly.
Place a container with a capacity of at least 3 quarts (2.84 liter) under the engine oil filter(s).
1. Clean the area around the lubricating oil filter head. Remove the filter(s) with
an oil filter strap wrench assembly.
2. Cut the filter open with an oil filter cutter. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount of metal debris in the oil filter
may indicate early wear or a pending failure.
Due to normal wear and friction, it is not uncommon to find small amounts of
debris in the oil filter. Consult your Caterpillar dealer in order to arrange for a
further analysis if an excessive amount of debris is found in the oil filter.
3. Clean the sealing surface of the filter mounting base. Ensure that all of the old
gasket is removed before installing the new filter.
4. Apply a film of clean engine oil to the seal of the new oil filter gasket before
installing.
Note: Do not fill the oil filters with oil before installing them. This oil would not
be filtered and could be contaminated. Contaminated oil can cause accelerated
wear to engine components.
5. Install filter(s) as specified by the filter manufacturer. Most filters have
instructions printed on side of filter. Tighten the oil filter until the oil filter gasket
contacts the base. Tighten the oil filter by hand according to instructions shown
on the oil filter. Do not overtighten the oil filter.
6. After oil has completely drained and the filter(s) have been replaced, clean the
drain plug and install it securely.
7. Dispose of used filters and used oil properly and in accordance with local
regulations.
DRILLING SOLUTIONS
6-103
Fill Cat Engine Crankcase

The refill capacities for the Cat engine crankcase reflect the approximate capacity of the
crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil.
1. Remove the oil filler cap and fill the crankcase with the proper amount of oil.
Table 36: Engine Information

CAT Engine
Series
Oil Specification
C-27
SAE 15W40 (Refer

to OEM Engine
Manual)
C-32
Approximate Refill Capacities

Quarts
Liters
76
72
76
72
Refer to 6.3 Lubrication Specifications and Refill Capacities for more detailed
information.
NOTICE
If equipped with an auxiliary oil filter or remote oil filter system, follow the
OEM or filter manufacturers recommendations. Under filling or over
filling the crankcase with oil can cause engine damage.
6-104
DRILLING SOLUTIONS
NOTICE
To prevent crankshaft bearing damage, crank the engine with the fuel
OFF. This will fill the oil filter(s) before starting the engine. Do not crank
the engine for more than 30 seconds.
2. Start the engine and run at LOW IDLE for two minutes. Perform this
procedure in order to ensure that the lubrication system has oil and that the oil
filter(s) are filled. Inspect the oil filter for oil leaks.
3. Stop engine and allow oil to drain back to the crankcase for a minimum of ten
minutes.
4. Remove the oil level gauge in order to check the oil level. Maintain the oil level
between the ADD and FULL marks on the oil level gauge.
Cat Fuel Filters

Under normal operating conditions, the fuel filter(s) should be replaced every 250 hours as
part of routine maintenance.
WARNING

when changing fuel filters or water separator elements. Clean up any
spilled fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a suitable
cover over any disconnected fuel system components.
Use a suitable container to catch any fuel that might spill. Clean up any
DRILLING SOLUTIONS
6-105
1. It may be necessary to relieve residual fuel pressure from the fuel system
before removing the fuel filter. Loosen one of the fuel supply connections to
purge any residual pressure.
NOTICE
Do not loosen fuel lines or fittings at the fuel manifold or ECM. The engine
components may be damaged.
2. Remove and discard the used fuel filters in compliance with any local
regulations.
3. Clean the gasket sealing surface of the fuel filter base. Ensure that all of the old
gasket is removed.
4. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
In order to maximize fuel system life and prevent premature wear out from
abrasive particles in the fuel, use the correct filters.
Do not fill the fuel filters with fuel before installing. The fuel would not be
filtered and could be contaminated. Contaminated fuel will cause
accelerated wear to fuel system parts.
5. Install the new filter as specified by the filter manufacturer. Most filters have
instructions printed on the side of the filter. Spin the fuel filter onto the fuel filter
base until the gasket contacts the base. Use rotation index marks on the filters
as a guide for proper tightening. Tighten the filter for an additional 3/4 turn by
hand. Do not overtighten the filter.
6-106
DRILLING SOLUTIONS
6. When restarting the engine after replacing fuel filters, it is necessary to prime
the fuel system using the primer button switch on the console.
7. If fuel filters are changed according to these instructions, no manual bleeding
of fuel lines should be required. If necessary, refer to engine manufacturers
manual for the information on bleeding the system.
8. Check the fuel system for any leaks.
Replace CAT Coolant Filter

If your engine is equipped with an engine coolant filter, it must be replaced at every engine oil
and oil filter change interval as part of the 250 Hour routine maintenance. Refer to CAT Engine
Operators Instruction manual for details.
1. Clean area around water cooler filter.

2. Place a container under filter to collect any escaping coolant during removal.
3. Close coolant additive element inlet and outlet valve.
4. Unscrew and discard the used filter in full compliance with local guidelines.
5. Clean the sealing surface of filter head.
6. If necessary, replace O-ring on the filter head.
7. Lubricate O-ring seal with clean oil.
8. Install new filter as specified in parts manual.
9. Repeat this process for the other coolant filter
10. Check for leaks when engine is running at working temperature.
Engine SCA Level

Caterpillar engine cooling systems should be tested at 250 Hour intervals for the concentration
of Supplemental Coolant Additives (SCA). Refer to engine instruction manual for further
information and procedures on this important maintenance item.
DRILLING SOLUTIONS
6-107
NOTICE
Never use water alone without Supplemental Coolant Additives (SCA) or
without inhibited coolant. Water alone is corrosive at engine operating
temperature. Water alone does not provide adequate protection against
boiling or freezing.
Note:
The engine is protected against corrosion of the cooling system by adding corrosion inhibitor
to the coolant. If the engine radiator has been topped off using only water, the additive content
will become diluted and the risk of corrosion will increase.
Engine Valve Lash

The initial valve lash adjustment on new engines is recommended at the first scheduled oil
change (250 Hour Routine Maintenance). The initial adjustment is necessary due to initial
wear of the valve train components and seating of the valve train components. Thereafter,
inspect and adjust engine valve lash every 3000 Service Hours.
This maintenance is recommended by Caterpillar as part of a lubrication and preventive
maintenance schedule in order to help provide maximum engine life.
WARNING
Ensure that the engine can not be started while this maintenance is being
performed. To help prevent possible injury, do not use the starting motor
to turn the flywheel.
WARNING
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring/adjusting valve lash clearance.
NOTICE
Only qualified service personnel should perform this maintenance. Refer
to your Caterpillar dealer for the complete valve lash adjustment
procedure.
6-108
DRILLING SOLUTIONS
NOTICE
Operation of Caterpillar engines with improper valve adjustments can
reduce engine efficiency. This reduced efficiency could result in
excessive fuel usage and/or shortened engine component life.
Refer to your Caterpillar Operation and Maintenance Manual for specific
engine Maintenance Interval Schedule requirements.
Cummins Engine Maintenance

The following drawing shows a typical Cummins QSK19C engine. Due to individual
applications, your engine may appear different from the drawings.
Engine Lubricating Oil and Filters

Change the Engine Oil and Oil Filter(s) as part of the 250 Hour Routine Maintenance
Schedule or 6 months, whichever comes first.
WARNING
Some state and federal agencies in the United States of America have
determined that used engine oil can be carcinogenic and can cause
reproductive toxicity. Avoid inhalation of vapors, ingestion and common
prolonged contact with used engine oil. Do not allow used oil to drain into
the ground. Always use proper procedures to dispose of the oil.To avoid
personal injury, avoid direct contact of hot oil with your skin.
DRILLING SOLUTIONS
6-109
Drain Engine Oil

Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle
on the bottom of the oil pan. The waste particles are not removed with the draining cold oil.
Drain the crankcase with the engine stopped. Drain the crankcase with the oil warm. This
draining method allows the waste particles that are suspended in the oil to be drained properly.
Failure to follow this recommended procedure will cause the waste particles to be recirculated
through the engine lubrication system with the new oil.
1. Position the drill on a stable, level surface and shut off engine. Wait at least 5
minutes after shutting off engine to drain the oil. This allows time for the oil to
drain into the oil pan.
2. Ensure oil is warm by viewing the water temperature gauge. The temperature
should not exceed 140F (60C) before draining oil.
3. Place container, with a capacity of at least 20 gallon (76 liter), under the drain
point.
4. Remove the drain plug and allow the engine oil and suspended contaminants
to drain from the drain hose into a container.
Replace Engine Oil Filter(s)

Always change the engine oil filter(s) at the same time the engine oil is changed.
WARNING
Avoid contact with hot oil or components. Do not allow used oil to drain
into the ground. Dispose of properly.
6-110
DRILLING SOLUTIONS
Place a container with a capacity of at least 3 quarts (2.84 liter) under the engine oil filters.
1. Clean the area around the lubricating oil filter head. Remove the filter(s) with
an oil filter strap wrench assembly. Note: The O-ring can stick on the filter head.
Make sure it is removed.
Note:
If the lubricating oil filter head adapter comes off during the removal of the oil
filter, reinstall the oil filter head adapter. Use a small amount of loctite on the
threads of the oil filter head adapter and tighten to 150 ft/lb (203 Nm).
2. Discard the filter(s) if they are not needed for a failure analysis. Dispose of the
used filters in compliance with local regulations.
3. Cut all the way around the top of the oil filter(s) using a pipe cutter or hack saw.
Inspect the pleated paper element for metal debris. Metal debris in the filter can
reveal an impending engine failure. When debris is found, find the reason for
the debris and perform the needed repairs.
Due to normal wear and friction, it is not uncommon to find small amounts of
debris in the oil filter. Consult your Cummins dealer in order to arrange for a
further analysis if an excessive amount of debris is found in the oil filter.
DRILLING SOLUTIONS
6-111
4. Clean around the sealing surface of the filter mounting base. Again, ensure that
all of the old gasket is removed before installing the new filter.
5. Apply a film of clean engine oil to the seal of the new oil filter gasket before
installing.
CAUTION
Fill the oil filter(s) with clean lubricating oil before installation on the
engine. Lack of engine lubrication while the filter(s) are pumped full of oil
is harmful to the engine.
6. Install the filter(s) as specified by the filter manufacturer.
CAUTION
Mechanical overtightening can distort the threads or damage the filter element seal.
7. Tighten the oil filter an additional 3/4 of a turn after gasket contacts the filter
head surface, or as specified by the filter manufacturer. Most filters have their
instructions printed on the side of the filter. Tighten the oil filter by hand
according to the instructions that are shown on the oil filter. Do not overtighten
the oil filter.
8. After oil has completely drained and the filter(s) have been replaced, clean the
drain plug and install securely.
9. Dispose of used oil properly and in accordance with local regulations.
Fill Engine Crankcase

The refill capacities for the Cummins engine crankcase reflect the approximate capacity of the
crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil.
6-112
DRILLING SOLUTIONS
Table 37: Cummins Engine Information

Cummins Engine
Series
Oil Specification
QSK 19C Series
SAE 15W40 (Refer

to OEM Engine
Manual)
Approximate Refill Capacities

Quarts
Liters
72
68
Refer to 6.3 Refill Capacities/Lubricants/Fuel Specifications for more detailed engine oil
information.
1. Remove the oil filler cap and fill the crankcase with the proper amount of oil.
2. Operate engine at idle speed to inspect for leaks at the oil filter(s) and the drain
plug.
3. Shut off the engine. Wait approximately 15 minutes to let the oil drain from the
upper parts of the engine.
4. Check the oil level again. Add oil as necessary to bring the oil level to the H
(High) mark on the dipstick.
DRILLING SOLUTIONS
6-113
Replace Fuel Filters

Every 250 hours or 6 months (whichever occurs first), replace the fuel filter(s).
1. Clean the area around the fuel filter head.

2. Close the fuel line shutoff valve before changing fuel filter(s) or the overhead
tank can drain, causing a fuel leak.
3. Place a container under the fuel filter(s) to collect any escaping fuel when
removing them.
4. Unscrew the used fuel filter(s) using 75-80mm and 90-95mm filter wrenches.
Discard used filter(s) in accordance with local guidelines.
5. QSK19C Engine - Remove the thread adapter sealing nut.

6. Use a clean, lint-free towel to clean the surface of the filter head gasket.
7. If necessary, replace the O-ring in the filter head.
Note:
Use the correct filter(s) for your engine. Cummins requires that a fuel-water
separator or a fuel filter and water separator be installed in the fuel supply
system.
6-114
DRILLING SOLUTIONS
8. QSK19C Engine - Install a new thread adapter sealing ring supplied with the
new filter.
9. Apply a light coating of clean engine oil to the surface of the filter gasket.
10. Fill new filter(s) with clean fuel.
11. Install the new filters as specified by the manufacturer. Tightening instructions
are normally printed on the outside of the filter.
12. Install the filter on the filter head. Turn the filter until the gasket touches the
surface of the filter head.
13. Tighten the filter an additional 1/2 to 3/4 of a turn after gasket touches the filter
head surface. Do not overtighten the filter.
14. QSK19C Engine - Open the fuel line shutoff valve and check for leaks.
15. Check the engine and connections for leaks.
16. If fuel filters are changed according to these instructions, no manual bleeding
of the fuel lines should be required. If manual bleeding is necessary, refer to
engine manufacturers manual for information on bleeding the system.
Note:
When restarting the engine after replacing the fuel filters, it is necessary to
prime the fuel system using the primer button switch on the operators console.
Engine Coolant Filter

Replace the engine coolant filter at every engine oil and filter change interval as part of the 250
Hour routine maintenance schedule.
DRILLING SOLUTIONS
6-115
Note:
Use correct engine coolant filter to maintain correct SCA (Supplemental Coolant Additive)
concentration in the system. Maintain the correct concentration by changing the service filter
at each oil drain interval. Refer to Coolers Maintenance Procedures for further SCA
information.
Remove Engine Coolant Filter

Remove the coolant system pressure cap.
WARNING
Do not remove the pressure cap from a hot engine. Hot steam will cause
serious personal injury. Remove the coolant system pressure cap and
close the shutoff valve(s), if so equipped, before removing the coolant
filter. Failure to do so can result in personal injury from heated coolant
spray.
6-116
DRILLING SOLUTIONS
A manual shutoff valve is provided to prevent coolant leakage while changing the coolant filter.
With the valve in the vertical position, the coolant flows to and from the coolant filter. In the
horizontal position, the coolant flow is cut off to and from the coolant filter.
1. Turn the coolant shutoff valve to the OFF position.

2. Clean the area around water cooler filter.
3. Place a container under filter to collect any escaping coolant during removal.
4. Unscrew and discard the used filter in full compliance with local guidelines.
Install Engine Coolant Filter

1. Clean the sealing surface of filter head.
2. If necessary, replace O-ring on filter head.
3. Apply a light film of engine oil to the gasket seal before installing the new
coolant filter.
Note: Do not allow oil to get in the filter. It will break down the SCA.
4. Install the new filter as specified by the filter manufacturer. Turn the filter until
seal touches the filter head. Turn an additional 1/2 to 3/4 of a turn after contact.
DRILLING SOLUTIONS
6-117
CAUTION
Mechanical over tightening can distort the threads or damage the filter head.
5. Open the shut-off valve.
CAUTION
Engine damage will result if the shut-off valve is left closed.

6. Install the coolant system pressure cap.
7. Operate the engine and check for coolant leaks.
8. After the air has been purged from coolant system, check the coolant level
again.
Check Engine SCA Level

Cummins engine cooling systems should be tested at 250 Hour intervals for the concentration
of Supplemental Coolant Additives (SCA).
6-118
DRILLING SOLUTIONS
NOTICE
Never use water alone without Supplemental Coolant Additives (SCA) or
without inhibited coolant. Water alone is corrosive at engine operating
temperature. Water alone does not provide adequate protection against
boiling or freezing.
Note:
Engine is protected against corrosion of the cooling system by adding a corrosion inhibitor to
the coolant. If the engine radiator has been topped off using only water, the additive content
will become diluted and the risk of corrosion will increase.
Refer to engine instruction manual for further information and procedures on this
important maintenance item.
The engine manual gives full details of the procedures for checking and servicing the engine
cooling system.
Auxiliary Hoist
Wire Rope Condition

Winch ropes, including their anchorage and other load carrying components of the travelling
block and winch system,e.g. sheave bearings, rope sheaves and drill hooks, shall be checked
at least once a week.
Wire ropes shall be examined and discarded in accordance with 3.5 of ISO4309:1990. In table
3.5 of ISO 4309:1990, classification groupsM1 andM2 shall be used. On drill rigs with normal
hook load of more than 1000KN, the winch rope shall be regularly paid out and shortened
according to a plan laid down by the manufacturer on basis of experience.
and should be discarded according to certain criteria (Refer to Feed Cable &Wire Rope in 6.4
Maintenance As Required for additional information on wire rope and wire rope clamps.
DRILLING SOLUTIONS
6-119
2. Replace when wire rope shows wear of one third (1/3) the original diameter of
the outside wire.
6-120
DRILLING SOLUTIONS

General Information
WARNING

drill.
overturning.
crushing risk.
DRILLING SOLUTIONS
6-121
Cat Engine
Primary Fuel Filter/Water Separator
water, the element should be changed before the regularly scheduled interval of 500 hours.
The primary filter/water separator also provides filtration to help extend the life of the
secondary fuel filter. The element should be changed as part of the 500 hour routine
maintenance schedule. If a vacuum gauge is installed, the primary filter/water separator
should be changed if the pressure is at 50 to 70 kPa (15 to 21 inches of Hg.)
WARNING

NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any
The bowl should be monitored daily for signs of water. If water is present, drain the water from
the bowl.
6-122
DRILLING SOLUTIONS

2. Open the self-ventilated drain. Catch the draining water in a suitable container
and dispose of the water properly.
3. Close the drain.
NOTICE
The Water Separator is under suction during normal engine operation.
Ensure that the drain valve is tightened securely to help prevent air from
Replace Element
WARNING

Under normal operating conditions, the Cat engine primary filter/water separator element
should be replaced every 500 hours as part of routine maintenance. The following instructions
are specific to Cat engines:
1. Stop the engine.
2. Turn the start switch to the OFF position. Disconnect the battery.
3. Close the main fuel supply valve to the engine.
4. If the fuel filter/water separator is equipped with a drain valve, open the drain
valve in order to drain any fuel from the filter case. Close the drain valve.
NOTICE
Use a suitable container to catch any fuel that might spill. Immediately
clean up any spilled fuel.
5. Remove the element from the element mounting base while bowl is attached .
6. Dispose of the filter contents. Remove the bowl from element. The bowl is
reusable. Do not discard the bowl. Dispose of the used element in accordance
with any local regulations.
DRILLING SOLUTIONS
6-123
7. Remove the O-ring from the gland of the bowl. Clean the bowl, O-ring and
mounting base. Inspect the O-ring for damage and for deterioration. Replace
the O-ring, if necessary.
8. Lubricate the O-ring with clean diesel fuel.
9. Install bowl on a new element. Tighten the bowl by hand. Do not use tools in
order to tighten the bowl.
NOTICE
The primary filter/water separator may be prefilled with fuel to avoid
rough running/stalling of the engine due to air. Do not fill the secondary
filter with fuel before installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accelerated wear to fuel
system parts.
10. Lubricate the top seal of element with clean diesel fuel. The element may be
prefilled with fuel at this time. Install the new element on the mounting base.
Tighten by hand.
NOTICE
The water separator is under suction during normal engine operation.
Ensure that the vent plug is tightened securely to help prevent air from
11. Open the main fuel supply valve.
12. Start the engine and check for leaks. Run the engine for one minute. Stop the
engine and check for leaks again.
Batteries
Batteries, Clamps & Cables
The standard batteries supplied are heavy duty lead acid type, requiring the following
maintenance every 500 hours.
1. Keep the top of the batteries clean.
2. Clean the terminals.
3. Keep battery connections tight.
4. Apply a small amount of grease to the terminal connections to prevent
corrosion.
6-124
DRILLING SOLUTIONS
5. Inspect the cables, clamps and hold down brackets. Replace if necessary.
Fuel Tank
Fuel Tank Breather
The fuel tank breather should be replaced as part of the 500 hour routine maintenance
procedure.
1. Thoroughly clean the area around the fuel tank breather.
2. Remove the breather.
3. Until the new breather is installed, cover the breather port to ensure that
nothing can get into the housing.
4. Install the new breather.
Fuel Priming Pump

Clean the fuel priming pump during the 500 hour routine maintenance procedure.
1. Thoroughly clean the area around the fuel priming pump.
2. Carefully remove the spring loaded cover and remove the strainer.
DRILLING SOLUTIONS
6-125
3. Clean the strainer.

4. Replace the strainer and secure the cover.
Hydraulic Reservoir
Hydraulic Tank Breathers
The hydraulic tank breathers should be replaced as part of the 500 hour routine maintenance
procedure.
1. Thoroughly clean the area around the hydraulic tank breathers.

2. Remove the breathers.
3. Until the new breathers are installed, cover the breather ports to ensure that
nothing can get into the tank housing.
4. Install the new breathers.
Hydraulic Fluid Condition Limits

The following is for mineral based and synthetic fluids, excluding automatic transmission
fluids. Sample fluid from the return manifold every 500 hours. Change the fluid if any of the
following conditions occur:
1. Viscosity increases by 16% or decreases by 10% (compared to new fluid)*
2. Total Acid Number (TAN) increases by 2.5 or more (compared to new fluid)*
3. Water content exceeds .1% (1000 ppm)
4. The fluid becomes contaminated with any other unfilterable contaminant;
glycol, fuel, etc.
*
6-126
Oxidation of the fluid is usually indicated by an increase in viscosity and an

increase in TAN. If the fluid shows a TAN increase of 2.5 or more, and
DRILLING SOLUTIONS
especially if it corresponds to a viscosity increase of over 16%, the fluid should

be changed.
Notes:
1. High concentrations of soluble metals as indicated by a spectrochemical
analysis do not necessarily indicate a deterioration of the fluid.
2. A high particle count does not necessarily indicate deterioration of the fluid. A
filter bypass alarm or particle count exceeding ISO 18/15 indicates the need for
a filter change.
Change Hydraulic Oil

Change the hydraulic tank oil (and filters) after any major hydraulic system repair and if the oil
sampling results follow the hydraulic fluid condition limits shown above. Let the oil analysis
determine when to change the hydraulic oil. When changing the fluid, follow the procedure
below to do so.
NOTICE
clean, contaminant free systemis extremely important to the machines
Do not use the quick-fill systemto drain or remove fluid. Use the fittings
at the bottom of the hydraulic tank.
WARNING
Oil must be at normal operating temperature when draining. Hot oil or

components can burn. Avoid contact with hot oil or components.
Liquid explosion can cause severe injury. Disconnect high voltage tank
heater before draining or filling system.
Drain Hydraulic Reservoir

1. Position drill on stable, level surface and retract all hydraulic cylinders.
2. Lower the tower to the horizontal position, with the rotary head at the top of the
tower.
3. Make sure all of the leveling jacks are fully retracted.
DRILLING SOLUTIONS
6-127
4. The engine must be shut off and not running. The hydraulic fluid temperature
must be below 120F (49C).
5. Make sure the breathers on the top of the tank are clean and will allow the tank
to breathe. Replace any damaged breather before draining the tank.
6. Position a container with a capacity of at least 175 gallon (662.4 liter) under the
drain point to collect used oil. Do not allow used oil to drain into the ground.
7. Close the tank main valve located under the tank.

8. Connect a drain hose to the quick connection under the tank to facilitate
draining the oil into the container.
9. Allow the hydraulic fluid to drain into an appropriate and approved container.
Followall local standards and regulations for disposal of fluid.
NOTICE
10. When the tank is empty, disconnect the drain hose.
Refill Hydraulic Reservoir

Refill the hydraulic tank through the quick-fill station. When using the quick-fill station, follow
the procedure below.
1. The drill must be level and the engine must not be running.
2. Ensure the breathers on top of the tank are clean and will allow the tank to
breathe. Do Not Add Oil Thru The Breather Ports!
6-128
DRILLING SOLUTIONS
3. Locate the proper fitting on the quick-fill station for the hydraulic oil and then
connect the proper hose from the quick-fill station to the tank.
4. On the other side of the quick-fill station, remove the quick-fill cap and clean the
fitting for the hydraulic oil quick-fill.
5. Locate the proper quick-fill hose. Clean the hose fitting and connect to the
quick-fill fitting and hydraulic oil source.
Note:
Any contamination entering the hydraulic tank during filling will seriously risk
damage to the pumps and motors. The system uses filtration only on the return
oil and therefore oil in the tank must be free of contamination.
6. Fill with new, clean hydraulic oil. The tank holds approximately 157 gallon (594
liter) of grade ISO AW32 hydraulic oil.
7. Verify tank has not been over filled. Fluid should not be over the top of the sight
glass.
8. Open the main tank valve under the tank.
9. Check the reservoir oil level by viewing the sight gauge.
10. Remove the quick-fill hoses.
11. During operation, monitor the hydraulic oil temperature gauge.
12. Replace all hydraulic filters every time the hydraulic oil is changed.
Compressor
The following compressor system maintenance must be carried out as part of the 500 hour
routine maintenance schedule.
DRILLING SOLUTIONS
6-129
WARNING
Hot compressor oil or components can burn. Avoid contact with hot oil
or components. Do not allow used compressor oil to drain into the
ground. Dispose of used compressor oil properly.
WARNING
making sure all air pressure has been relieved from the compressor
system.
Compressor Oil Strainer

A 40 mesh, (150 micron) strainer is mounted before the inlet to the oil pump. It protects the
pump and catches any foreign debris, such as hose pieces and parts of the thermostat that
could damage the pump. The metal strainer should be removed, cleaned and re-installed
every 500 hours.
1. Thoroughly clean the entire area around the compressor oil strainer.
2. Remove the cover and remove the strainer element.
3. Clean the strainer and the magnetic plug.
4. Re-install the strainer element.
5. Replace and secure the cover.
6-130
DRILLING SOLUTIONS
Compressor Oil Filters

The following compressor oil filter maintenance must be carried out as part of the 500 hour
routine maintenance schedule.
WARNING
Hot compressor oil or components can burn. Avoid contact with hot
compressor oil or components. Do not let used oil drain into the ground.
Dispose of properly.
1. Wipe all external dirt and oil from filter housing and head area to minimize
contamination from entering the system.
2. Place a container under the oil filter to collect any oil escaping during removal
and prevent any oil spill from contaminating the ground.
3. Unscrew the used filter using a 90-95mm wrench. Discard used filters in
accordance with local guidelines.
4. Clean the sealing surface of dual filler head.
5. If necessary, replace the O-ring seals of the dual filter head.
6. Fill the new filters with clean compressor oil and lubricate the O-ring seal with
clean oil.
7. Install the new filter (as specified in the parts manual). Most filters will have
instructions included.
8. After startup, check the oil filter for any leaks at operating temperatures.
DRILLING SOLUTIONS
6-131
Pump Drive Gearbox

The type of service and the operating conditions will determine the maintenance interval.
However, it is recommended that the pump drive gearbox oil be changed after the first five
hundred (500) hours of operation, then at every 1000 operating hours. Because the
lubricant system is the heart of the unit, it is especially important that the oil be kept clean.
Note: The oil in the pump drive gearbox should be changed whenever the oil shows traces of
dirt or the effects of high temperature, evidenced by discoloration or strong odor.
WARNING
components. Oil must be at normal operating temperature when draining.
Do not allow used oil to drain into the ground. Dispose of properly.
Change Initial Oil
1. Move the drill to a stable, level surface and shut off the engine.
2. Place a container with a capacity of at least 4-1/2 quarts (4.3 liters) under the
drain point.
3. Clean around breather and fill plug and the drain plug areas.
4. Remove the drain plug and the breather.
5. Drain oil while the pump drive is still warm.
6. Examine the gearbox oil for any contamination or metal particles. Metal debris
can reveal an impending pump drive gearbox failure. If debris is found, find the
reason for the debris and perform the needed repairs. Allow the oil to drain from
the drain into a container.
7. Clean magnetic drain plug before installing.
8. Refill the pump drive gearbox through the breather port with 80W90 gear oil
until the oil level reaches the oil level port on the gearbox. The gearbox in
position 2 requires 2.75 quarts (2.6 liters) of oil. Do not overfill. This will result
in the over heating and the possible malfunction of the gearbox.
9. Clean the breather and install securely.
10. After startup, check the pump drive for any leaks at operating temperatures.
6-132
DRILLING SOLUTIONS
Auxiliary Hoist
Check Oil Level
The gear oil level should be checked every five hundred (500) hours of operation.
NOTICE
WARNING
winch.
properly.
1. Move the drill to a stable, level surface and lower the tower to the horizontal
position.
3. To check the oil level, remove the oil level plug. The oil should be level with the
bottom of this opening.
4. If additional oil is needed, add new fluid through the center port until it starts to
DRILLING SOLUTIONS
6-133
run out of the center port. Refer to section 6.3 Lubricant Specifications for
further recommended oil specifications.
6. Lubricate drum shaft bracket and clutch (if so equipped) with grease.
7. Oil the connections of operating linkages using SAE 30 oil.
Cable/Rope Lubrication
Lubrication of the wire rope should be included in the maintenance schedule. Cables should
be cleaned with a wire brush and solvent and lubricated approximately every 500 hours with
one of the following or equivalent:
1. Texaco Crater A
2. Brooks Klingfast 85 (Brooks Oil Co.)
3. Gulf Seneca 39
4. Whitmores Wire Rope Lubricant (Whitmore Manufacturing Co.)
The lubricant can be applied with either a spray or a brush and is recommended for protection
against corrosion only.
Automatic Tensioners
Tensioner Motor and Coupling
There are three grease fittings on the auto tensioner. Ten shots of grease from a grease gun
should be added to these points every 500 hours of service.
6-134
DRILLING SOLUTIONS

The following water injection pump maintenance must be carried out as part of the 500 hour
routine maintenance schedule and every 500 hours thereafter.
WARNING

draining. Be careful. Hot oil and components can burn.
Change Oil
DRILLING SOLUTIONS
6-135
Compressor Air Hose and Clamps

Refer to the Dixon Boss Clamp Selection and Installation instructions shown in Section 7
Systems & Troubleshooting for the proper way to select and install Dixon Boss Clamps.
Air Hose & Clamps

CLAMPS chart in Section 7 Systems & Troubleshooting.
2. Examine and change out worn hoses and weakened Boss clamps. If hoses are
to be changed out, change the Boss clamps also. Boss clamps hold the hose
connections under a large amount of pressure. Remember, Boss clamps
(including the nuts and bolts) are for single use only. Do not reuse. Once
removed, discard them.
Compressor Discharge hose and Clamps

Refer to the Dixon Boss Clamp Selection and Installation instructions shown in Section 7
Systems & Troubleshooting for the proper way to select and install Dixon Boss Clamps.
Discharge Hose & Clamps

CLAMPS chart in Section 7 Systems & Troubleshooting.
2. Examine and change out worn hoses and weakened Boss clamps. If hoses are
to be changed out, change the Boss clamps also. Boss clamps hold the hose
connections under a large amount of pressure. Remember, Boss clamps
(including the nuts and bolts) are for single use only. Do not reuse. Once
removed, discard them.

John Bean Water Injection Pump
After the initial water injection pump oil change after the first 100 hours of operation, the
following water injection pump maintenance must be carried out every 750 hours.
6-136
DRILLING SOLUTIONS
WARNING

draining. Be careful Hot oil and components can burn.

6. 18 gpm and 25 gpm Water Injection Pumps - Refill the oil through the fill port
(approximately 2 quarts or 1.89 liters) or until oil appears at the oil fill plug. Fill
with clean SAE 30 non-detergent oil.
7. 35 gpm Water Injection Pump - Refill the oil through the fill port
(approximately 2 quarts or 1.89 liters) or until oil appears at the oil level plug on
the back of the pump housing. Fill with clean SAE 30 non-detergent oil.
DRILLING SOLUTIONS
6-137

General Information
WARNING

drill.
7. If your drill is equipped with the remote control system option, always use it
from a safe location when propelling on unstable surfaces where there may be
overturning.
crushing risk.
6-138
DRILLING SOLUTIONS
Compressor Oil
Under normal operating conditions, the compressor oil must be changed every 1000 hours as
part of a routine maintenance program.
DANGER
any plugs or open the the drain valve before making sure all air pressure
has been relieved from the system. Completely relieve pressure before
removing filler plug, drain valve, fittings or receiver cover.
WARNING

1. Park the drill on stable, level surface and shut down engine. Allow time for the
drill to cool.
2. The best time to drain the receiver separator tank oil is when the oil is warm. At
that time the sediment in the receiver separator is in suspension and will drain
with the old oil. Temperature should not exceed 140F (60C) before draining
oil.
DRILLING SOLUTIONS
6-139
3. Place a container with a capacity of at least 38 gallon (144 liter) under the drain
point.
WARNING
making sure all air pressure has been relieved from the system.
4. The engine must not be running and all pressure relieved from the tank. The
gauge on the tank must read zero psi. Verify no pressure is in the system by
opening the service air valve and checking the gauge.
5. Open the drain valve and allow the compressor oil to drain into a container. Do
6. Close the drain valve and refill the receiver tank through the oil filler. Fill to the
full mark on the level gauge. See section 6.3 Refill Capacities/Lubricants/Fuel
Specifications for details on compressor oil. Clean and replace the oil filler cap.
Note: Low Pressure compressors (110psi / 7.58 bar) use PROTEC Oil.
High Pressure compressors (350 psi / 24.13 bar) use XHP605 Oil.

The hydraulic oil filters must be changed every 1000 hours as part of the routine maintenance
procedure. There are two system return hydraulic oil filters and two hydraulic drain filters on
the drill.
6-140
DRILLING SOLUTIONS
NOTICE
clean contaminant free system is extremely important to the machines
The system main return filters are located on the side of the hydraulic tank. The main return
flow to the tank passes through these filters and into the supercharge manifold. The
supercharge provides supply to the piston pumps and minimizes cavitation problems.
The hydraulic drain filters are located on the other side of the hydraulic tank and filter the oil
prior to return into the hydraulic tank.
It is important to monitor the filters restriction indicator sight glass during the routine 10 hour
walk around inspection by the operator. If the indicator window shows RED, then the filter
elements require replacement. If the window shows GREEN, the filters are satisfactory. When
restriction indicates that element servicing is required, proceed in the following manner. Under
normal operating conditions, these filters are replaced at the regular 1000 Hour service
interval.
WARNING
Do not attempt to service the filters before making sure all the hydraulic
pressure has been relieved from the system.
Replace Return/Drain Filters

1. Wipe all external dirt and oil from filter housing and the head area to minimize
contamination from entering the system.
2. Place a container under the oil filters to prevent any oil spill from contaminating
the ground.
3. Carefully remove the 4 bolts that secure the retaining ring to the filter head.
DRILLING SOLUTIONS
6-141
4. Remove elements from the filter housing.

5. Save the element connectors located between elements. Discard old elements
in accordance with any local guidelines.
6. Clean the filter housing and filter head with an approved cleaning solvent.
7. Lubricate grommets in the filter elements and install the compression spring
and the spring plate into the bottom of the element before inserting element into
the housing. On filters that use two elements or more, install the element
connector between the elements.
8. Attach the housing to the filter head and tighten the 4 bolts evenly and in
sequence.Caremust be taken not to damage the O-ring.
CAUTION
Over torquing bolts will cause damage to the housing and/or O-ring washer seal.
9. Pressurize the hydraulic system and check for leaks.
10. Repeat the procedure until all hydraulic fiilters are replaced.
Rotary Head
Change the rotary head oil as part of the 1000 hour routine maintenance schedule.
WARNING
Riding the rotary head can cause severe injury or death. Do not ride the
rotary head.
6-142
DRILLING SOLUTIONS
WARNING
Climbing a raised tower can cause severe injury or death. Do not climb
raised tower.
WARNING
A falling tower can cause severe injury or death. Ensure all locking pins
are in a locked position.
WARNING
Rotating shafts or a rotating drill string can cause severe injury or death.
Do not service the rotary head with the drill string in motion.
Rotary Head Oil

To change the lubricant in the rotary head, follow the procedure below.
1. Position the drill on a stable, level surface and raise the tower.
2. If necessary, remove the drill rod and lower the rotary head to the bottom of the
tower.
4. Ensure oil is warm before draining oil.
5. Place a container with a capacity of at least 44 quart (42 liter) under the rotary
head drain point.
6. Clean around the fill port area to prevent debris from entering during oil change.
NOTE: Take care to prevent any contamination from entering the fill
ports.
7. Remove the drain plug and install a drain hose to the drain port.
8. Remove the fill plug to allowair into tank during draining. Allow the oil to drain
into a container. Dispose of the used oil in accordance with local guidelines.
DRILLING SOLUTIONS
6-143
NOTICE
or maintenance on this component. Handle and dispose of fluids
9. After the case is drained, clean the drain plug and install. Torque to 60 ft/lbs (81
Nm).
10. Refill the rotary head gearbox through the fill port with 90W gear oil until the
fluid is near the top of the fluid level sight glass. The rotary head gearbox will
hold approximately 7.5 to 8 gallons (28 to 30 liter) of gear oil.
11. Clean and install the fill plug.
12. After startup, check the rotary head for any leaks while at operating
temperatures.
Pump Drive Gearbox

It is recommended that the pump drive gearbox oil be changed as part of the 1000 hour
routine maintenance schedule. Because the lubricant system is the heart of the unit, it is
especially important that the oil be kept clean. Note: The oil in the pump drive gearbox should
be changed whenever the oil shows traces of dirt or the effects of high temperature, evidenced
by discoloration or strong odor.
Change Oil
1. Move the drill to a stable, level surface and shut off the engine.
2. Place a container with a capacity of at least 4-1/2 quarts (4.3 liters) under the
drain point.
6-144
DRILLING SOLUTIONS
WARNING

3. Clean around breather and fill plug and the drain plug areas.
4. Remove the drain plug and the breather.
5. Drain oil while the pump drive is still warm.
6. Examine oil for any contamination or metal particles. Metal debris can reveal
an impending pump drive gearbox failure. If debris is found, find the reason for
the debris and perform the needed repairs. Allow the oil to drain from the drain
into a container.
7. Clean magnetic drain plug before installing.
8. Refill the pump drive gearbox through breather port with 4-1/2 quarts (4.3 liters)
of 80W90 gear oil or until the oil level reaches the oil level port on the gearbox.
Do not overfill. This will result in the over heating and the possible malfunction
of the gearbox.
9. Clean the breather and install securely.
10. After startup, check the pump drive for any leaks at operating temperatures.
Auxiliary Hoist
Change Oil
The auxiliary hoist gear oil should be changed every 1,000 operating hours or six (6) months,
whichever occurs first. The gear oil must be changed to remove wear particles that impede the
reliable and safe operation of the brake clutch and erode bearings, gears and seals. Failure to
change gear oil at these suggested minimum intervals may contribute to intermittant brake
slippage which could result in property damage, severe personal injury or death.
The gear oil should also be changed whenever the ambient temperature changes significantly
and an oil from a different temperature range would be more appropriate. Oil viscosity with
DRILLING SOLUTIONS
6-145
regard to ambient temperature is critical to reliable brake operation. Make certain that the gear
oil viscosity used in your winch is correct for your prevailing ambient temperature. Failure to
use the proper type and viscosity of planetary gear oil may contribute to brake slippage which
could result in property damage, severe personal injury or death.
WARNING
winch.
properly.
NOTICE
6-146
DRILLING SOLUTIONS
Replace the lubricant using the following steps:

1. Winch must be removed to position drain port in the proper orientation.
2. Position the drum drain port at 6:00 oclock position, in line with the opening in
the housing.
3. Remove vent plug, clean in solvent and reinstall.
NOTICE
Do not paint over the vent, keep it clean and unobstructed.
4. Remove the center port plug and the drain port plug. Allow the old oil to drain
out of the drum into a container.
5. Clean the drain plug and reinstall it.
6. Add new fluid through the center port until it starts to run out of the center port.
Winch capacity is 6 pints (2.8 liter).
Table 38: Temperature and Lubricant

Temperature Range
Required Lubricant
-30F to 80F (-34.44C to 26.67C)
Mobil SHC629 or Texico Pinnancle 150
-10F to 80F (-23.33C to 26.67C)

API GL--2/3
50F to 130F (10C to 54.44C)

AGMA #5EP

8. Reinstall the winch if it was removed and verify bolt torque. Use SAE grade 8
bolts.
Table 39: Thread Condition and Torque

Thread Condition
Torque
Dry Thread
205 to 220 ft/lbs. (278 to 298 Nm)
Lubed Thread
158 to 170 ft/lbs (214 to 230 Nm)
Water Injection Pumps

The following Cat water injection pump maintenance must be carried out as part of the 500
hour routine maintenance schedule and every 1000 hours thereafter.
DRILLING SOLUTIONS
6-147
Refer to Maintenance (50 Hours) for the procedure and instructions to change oil in the Cat
water injection pumps. Refer to Sec. 6-6 for further instructions.
The following John Bean water injection pump maintenance must be carried out as part of the
750 hour routine maintenance schedule and every 1000 hours thereafter.
Refer to Maintenance (100 Hours) for the procedure and instructions to change oil in the John
Bean water injection pumps. Refer to Sec. 6-7 for further instructions.
6-148
DRILLING SOLUTIONS
6-11 MAINTENANCE (1500-2000 Hours)

General Information
WARNING

drill.
Always wear the correct safety gear while working on or around the drill. This includes an
overturning.
crushing risk.
DRILLING SOLUTIONS
6-149

Change Planetary Gearbox Oil
The gear oil should be changed every 1500 operating hours. This maintenance is
recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in
order to help provide maximum planetary gearbox life.
WARNING

1. Move the drill to a level surface and position the track final drive,with one port
2. Be sure the oil is warm before draining but be sure that the planetary housings
are not too hot to touch. If they are hot, give them time to cool down before
proceeding.
3. Place container with a capacity of at least 25 quart (24 liter) under the track
drive drain point.
4. Clean the area around the fill/level plug and drain plug.
5. Removed them and allow the oil to drain from the drain port into the container.
Do not allow the used oil to drain into the ground. Dispose of properly.
6. Clean the port drain plug threads and then install it.
7. Refill the planetary gearbox through the oil fill/level plug hole with about 2.7
gallon (10.2 liters) of ISO VG220 oil until the planetary is full and the oil
overflows. Allow the surplus oil to drain out until the oil level is up to the bottom
of the fill/level port. Do not allow the excess oil to drain into the ground. Dispose
of properly.
6-150
DRILLING SOLUTIONS
8. Clean the fill/level plug threads and then install it.

9. After scheduled service is complete, check the planetary track drive for leaks
at operating temperatures. Listen for any unusual noises that might need
attention.
Air Cleaners
The air cleaner is the dry type with two elements: a primary element that is replaceable and
can be cleaned, and a safety element that should only be replaced and never cleaned.
Primary and Safety Elements

The primary and safety element must be replaced as part of the 2000 hour routine
maintenance schedule. The following maintenance procedure must be carried out.
1. Unclip the three clamps holding the dust cover.

2. Remove dust cover.
3. Remove wing nut and washer. Carefully withdraw the primary air cleaner
element.
4. To replace the safety element, remove the cotterpin and the restriction
indicator. Carefully remove the safety element. Dispose of the used element
properly.
5. Clean the inside of the cover and the housing with a clean, damp cloth.
6. Install new safety element and secure it with the restriction indicator and
cotterpin.
DRILLING SOLUTIONS
6-151
7. Examine the new primary element for torn or damaged pleats, bent end covers,
liners and gaskets.
8. Ensure the primary element wing nut and washer are not cracked or damaged.
Replace if necessary.
9. Carefully install the new primary element and secure it with the wing nut and
washer.
10. Install the dust cover.
11. Inspect all air intake piping and joints between the air cleaners and the engine
air and the compressor air inlets to ensure that no dusty air can enter.
12. Ensure all clamps are tight.
Compressor Discharge Hose

The yellow and black striped air hose between the compressor and the receiver tank should
be changed every two (2) compressor oil changes or once every 2000 hours, whichever
occurs first.
This hose is subject to the highest temperatures in the compressor system and is in contact
with synthetic oil at all times. If the hose is not replaced periodically, the inner lining will begin
to break down. Lining material can clog the cooler and damage the compressor lubrication
pump.
6-152
DRILLING SOLUTIONS
Compressor
Compressor Fire Prevention
A fiber gasket is installed between the outside cover of the receiver tank and the metal tube
holding the separator element in place. This gasket prevents oil from leaking around the metal
tube and down the hole.
When air and oil flow through the filter media, static electric charges are created. If these
charges are allowed to build up, a spark similar to a lightning flash will occur. This will set the
oil and the media on fire. The fire will burn from the inside of the element through the standpipe
hose and will follow the air flow until it burns through the air hose, This is NOT a fire caused
by the compressor flashing.
To prevent this from happening, several metal staples have been installed THROUGH the
gasket so each side comes in contact with the metal. This bridge serves to allow the static
charge to drain off outside the receiver tank and not cause a static buildup.
CAUTION
When replacing the separator element, be sure there is at least one staple
that shows through on both sides of the gasket and is not covered with
glue.
Receiver Separator Element

Maintenance on the receiver separator element is on an as required basis. A change of the
separator element is required when there is excessive oil carryover with the compressed air.
Otherwise, change the separator element at 2500 hours.
DRILLING SOLUTIONS
6-153
WARNING
been relieved from the system. Completely relieve pressure before
opening the drain valve or removing the filler plug, fittings or removing
the receiver cover.
WARNING
components.
The following maintenance procedure must be followed:
1. Park the drill on a stable, level surface and shut down the engine. Allow time
for the drill to cool.
2. Remove the receiver cover and remove the separator element.

3. Discard the used element in accordance with local guidelines.
4. When installing the new element, make sure that the gasket is equipped with a
staple. Also, install the element with the two drain holes located at the bottom.
6-154
DRILLING SOLUTIONS
5. Re-attach the cover and tighten the bolts.

a. Vertical tank - torque bolts to 353-380 ft/lbs. dry (478-515 Nm).
6. After startup, check the drill for any leaks at operating temperatures.
Engine Belts and Tensioners

Refer to Engine Belts information in 6.5 - Maintenance (8-10 Hours or Daily). Also refer to
actual manufacturers manual for maintenance instructions.
DRILLING SOLUTIONS
6-155
6-12 - MAINTENANCE (3000 HOURS)

General Information
WARNING

drill.
overturning.
crushing risk.
6-156
DRILLING SOLUTIONS
CAT Engine Maintenance

Engine Valve Lash
This maintenance is recommended by the engine manufacturer as part of a lubrication and
preventive maintenance schedule in order to help provide maximum engine life.
Inspect and adjust engine valve lash every 3000 Service Hours.
WARNING
Ensure that the engine can not be started while this maintenance is being
performed. To help prevent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring/adjusting valve lash clearance.
NOTICE
Only qualified service personnel should perform this maintenance. Refer
to your OEM dealer for the complete valve lash adjustment procedure.
Operation of diesel engines with improper valve adjustments can reduce
engine efficiency. This reduced efficiency could result in excessive fuel
usage and/or shortened engine component life.
Refer to your OEM Operation and Maintenance Manual for specific engine
Maintenance Interval Schedule requirements.
DRILLING SOLUTIONS
6-157
6-13 - MAINTENANCE (6000 HOURS)

General Information
WARNING

drill.
overturning.
crushing risk.
6-158
DRILLING SOLUTIONS
Engine Coolant
The coolant system of any engine should be drained and flushed out after 6000 hours, or 2
years of service, whichever comes first. Unless the coolant has a corrosion preventive in it,
rust and scale will eventually clog up the system.
Clean the cooling system and flush the cooling system before the recommended maintenance
interval if the following conditions exist:
1. The engine overheats frequently.
2. Foaming is observed.
3. The oil has entered the cooling system and the coolant is contaminated.
4. The fuel has entered the cooling system and the coolant is contaminated.
NOTICE
Use of commercially available cooling system cleaners may cause
damage to cooling system components. Therefore:
Caterpillar Engines - Use only cooling system cleaners that are approved for Caterpillar
engines. Contact your nearest CAT dealer or refer to your CAT Operation and Maintenance
Manual for specifics.
Cummins Engines - Use only cooling system cleaners that are approved for Cummins
engines. Contact your nearest Cummins dealer or refer to your Cummins Operation and
Maintenance Manual for specifics.
NOTE: Inspect the water pump and the water temperature regulator after
the cooling systemhas been drained. This is a good opportunity to
replace the water pump, the water temperature regulator and the hoses,
if necessary.
WARNING
Pressurized System: Hot coolant can cause serious burns. To open the
cooling systemfiller cap, stop the engine and wait until the cooling
system components are cool. Loosen the cooling system pressure cap
slowly in order to relieve the pressure.
DRILLING SOLUTIONS
6-159
WARNING
skin and eyes. Avoid all contact with steam or escaping fluid.
Drain Cooling System
1. Stop the engine and allow the engine to cool.

2. Place a container under the drain points to collect used coolant.
3. Loosen the cooling system filler cap slowly in order to relieve any pressure.
Remove the cooling system filler cap.
4. Open the drain valve located at the base of the radiator, and remove the drain
plug on the engine block. Allow coolant to drain into a container. (Refer to
engine manufacturers manual for the recommended procedure.)
NOTICE
Engine coolant must be disposed of in a responsible manner. Please
consult the local environmental agency for recommended disposal
guidelines.
Flush Cooling System

1. Flush the cooling system with clean water in order to remove any debris.
2. Close the drain valve. Clean and install the engine drain plug.
6-160
DRILLING SOLUTIONS
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid
air locks.
3. Fill the cooling system with a mixture of clean water and cooling system
cleaner.
Caterpillar Engines - Use a mixture of clean water and Cat Fast Acting Cooling
System Cleaner. Add 1 pint (0.5 L) of cleaner per 4 US gallon (15 L) of the
cooling systemcapacity.
Cummins Engines - Use a mixture of 1 US gallon (3.8 liters) of Fleetguard
RESTORE, RESTORE PLUS (or equivalent) for each 10 to 15 gallons (38-57
liters) of cooling system capacity and fill the system with water.
4. Turn on the heater temperature switch to high to allow maximum coolant flow
through the heater core. The blower does not have to be on.
5. Operate the engine at lowidle and normal operating temperatures of at least
185F (85C) for 1 to 1-1/2 hours.
6. Shut the engine off and drain the cooling system.
7. Fill the cooling system with clean water to flush the cooling system.
8. Operate the engine at high idle for 5 minutes with coolant temperature above
185F (85C).
9. Shut off the engine and drain the cooling system.
NOTE: If the water being drained is still dirty, the system must be flushed
again until the water is clean.
10. Stop the engine and allow the engine to cool. Loosen the cooling system filler
cap slowly in order to relieve any pressure. Remove the cooling system filler
cap. Open the drain valve located at the base of the radiator and remove the
drain plug on the engine block. Allow coolant to drain. Flush the cooling system
with clean water. Close the drain valve. Clean and install the engine drain plug.
Fill the Cooling System

1. Refill the radiator with a 50-50 mixture of engine manufacturers recommended
antifreeze and quality water. Install the correct coolant filter. Do not use any
lubricant or corrosion inhibitor. Fill cooling system no faster than 19 L (5 US
gallon) per minute to avoid air locks.
DRILLING SOLUTIONS
6-161
2. When refilling cooling system, refer to engine manufacturers Operation and

Maintenance Instruction manual where full information is given on how obtain
and to check the correct SCA level in the engine and on cooling system
specifications. Do not install cooling system filler cap at this time.
3. Start and run the engine at low idle. Increase the engine rpm to 1800 rpm. Run
the engine at high idle for one minute in order to purge the air from the cavities
of the engine block. Stop the engine.
4. Check the engine coolant level on the radiator. The coolant level should be
maintained so fluid can be seen in the sight glass. If the coolant level is low,
add more coolant through the filler cap.
5. Clean the cooling system filler cap. Check on the condition of the filler cap
gaskets. Replace the cooling system filler cap if the filler cap gaskets are
damaged. Now reinstall the cooling system filler cap.
6. Start the engine. Inspect the cooling system for any leaks and check for proper
operating temperature.
6-162
DRILLING SOLUTIONS
6-14 Torque Specifications

Standard Torque Values
General Information
CAUTION
Use only the proper tools (inch or metric) on hardware. Other tools may
not fit properly. They may slip and cause injury.
Head Markings
Fasteners should be replaced with the same grade or a higher grade. If higher grade fasteners
are used, these should only be tightened to the strength of the original grade fastener.
Do not use these values if a different torque value or tightening procedure is listed for a specific
application. Torque values listed are for general use only. All values are suggested maximum
with dry plated hardware.
Make sure fastener threads are clean and you properly start thread engagement. This will
prevent them from falling when tightening.
The following pages list the recommended tightening torques for the various size bolts used
by Drilling Solutions. Proper torque specifications should be used at all times.
The head of grade five (5) is marked with three (3) short lines. The head of a grade eight (8)
is marked with six (6) short lines.
In the following tables, DRY means clean dry threads and LUBE means a light film of oil.
Excess oil in a threaded dead end hole can create a hydraulic lock giving a false torque
reading.
DRILLING SOLUTIONS
6-163
Recommended Torques in Foot Pounds (ft/lbs.)

This page lists the recommended tightening torques, in foot pounds (ft/lbs.), for the various
size bolts and nuts that are used. Proper torque specifications should be used at all times. The
head of a grade five (5) bolt is marked with three (3) short lines. The head of a grade eight (8)
bolt is marked with six (6) short lines. Dry means clean dry threads and LUBE means a light
film of oil. Excess oil in a threaded dead end hole can create a hydraulic lock giving false
torque readings.
Table 40: Recommended Torques in Ft/Lbs.

SIZE
6-164
SAE GRADE 5
TIGHTENING TORQUE
SAE GRADE 8
TIGHTENING TORQUE
DRY
LUBE
DRY
LUBE
5/16 - 18 NC
5/16 - 24 NF
16 - 17
18 - 19
12 - 13
13 - 14
23 - 25
17 - 18
19 - 20
3/8 - 16 NC
3/8 - 24 NF
28 - 30
33 - 35
21 - 23
23 - 25
42 - 45
47 - 50
33 - 35
7/16 - 14 NC
7/16 - 20 NF
47 - 50
51 - 55
33 - 35
37 - 40
65 - 70
74 - 80
51 - 55
56 - 60
1/2 - 13 NC
1/2 - 20 NF
70 - 75
84 - 90
51 - 55
61 - 65
102 - 110
112 - 120
74 - 80
84 - 90
9/16 - 12 NC
9/16 - 18 NF
102 - 110
112 - 120
74 - 80
84 - 90
140 - 150
158 - 170
102 - 110
121 - 130
5/8 - 11 NC
5/8 - 18 NF
140 - 150
158 - 170
102 - 110
121 - 130
205 - 220
223 - 240
158 - 170
167 - 180
3/4 - 10 NC
3/4 - 16 NF
242 - 260
279 - 300
186 - 200
205 - 220
353 - 380
391- 420
260 - 280
298 - 320
7/8 - 9 NC
7/8 - 14 NF
400 - 430
437 - 470
298 - 320
326 - 350
558 - 600
614 - 660
428 - 460
465 - 500
3/4 - 10 NC
3/4 - 16 NF
242 - 260
279 - 300
186 - 200
205 - 220
353 - 380
391 - 420
260 - 280
298 - 320
7/8 - 9 NC
7/8 - 14 NF
400 - 430
437 - 470
298 - 320
326 - 350
558 - 600
614 - 660
428 - 460
465 - 500
1 - 8 NC
1 - 12 NF
595 - 640
651 - 700
446 - 480
493 - 530
837 - 900
930 - 1000
632 - 680
688 - 740
1-1/8 - 7 NC
1-1/8 - 12 NF
744 - 800
818 - 880
558 - 600
614 - 660
1190 - 1280
1339 - 1440
893 - 960
1004 - 1080
1-1/4 - 6 NC
1-1/4 - 12 NF
1042 - 1120
1153 - 1240
781 - 840
856 - 920
1693 - 1820
1860 - 2000
1255 - 1360
1395 - 1500
DRILLING SOLUTIONS
SIZE
SAE GRADE 5
TIGHTENING TORQUE
SAE GRADE 8
TIGHTENING TORQUE
DRY
LUBE
DRY
LUBE
1-3/8 - 6 NC
1-3/8 - 12 NF
1358 - 1460
1562 - 1680
1023 - 1100
1172 - 1260
2213 - 2380
2530 - 2720
1655 - 1780
1897 - 2040
1-1/2 - 6 NC
1804 - 1940
1358 - 1460
2939 - 3160
2195 - 2360
Recommended Torques in Nm
This page lists the recommended tightening torques, in newton-meters (Nm), for the various
size bolts and nuts that are used. Proper torque specifications should be used at all times. The
head of a grade five (5) bolt is marked with three (3) short lines. The head of a grade eight (8)
bolt is marked with six (6) short lines. Dry means clean dry threads and LUBE means a light
film of oil. Excess oil in a threaded dead end hole can create a hydraulic lock giving false
torque readings.
Table 41: Recommended Torques in Nm

SIZE
SAE GRADE 5
TIGHTENING TORQUE
SAE GRADE 8
TIGHTENING TORQUE
DRY
LUBE
DRY
LUBE
5/16 - 18 NC
5/16 - 24 NF
22 - 27
24 - 26
16 - 17
17 - 19
31 - 33
23 - 24
26 - 27
3/8 - 16 NC
3/8 - 24 NF
37 - 40
44 - 47
28 - 31
31 - 33
56 - 60
63 - 67
44 - 47
7/16 - 14 NC
7/16 - 20 NF
63 - 67
68 - 73
44-47
49 - 53
87 - 93
97 - 107
68 - 73
75 - 80
1/2 - 13 NC
1/2 - 20 NF
93 - 100
112 - 120
68 - 73
81 - 87
136 - 147
149 - 160
99 - 107
112 - 120
9/16 - 12 NC
9/16 - 18 NF
136 - 147
149 - 160
99 - 107
112 - 120
187 - 200
211 - 227
136 - 147
161 - 173
5/8 - 11 NC
5/8 - 18 NF
187 - 200
211 - 227
136 - 147
161 - 173
273 - 293
297 - 320
281 - 227
223 - 240
3/4 - 10 NC
3/4 - 16 NF
323 - 347
372 - 400
248 - 267
273 - 293
471 - 507
521 - 560
347 - 373
397 - 427
7/8 - 9 NC
7/8 - 14 NF
533 - 573
583 - 627
397 - 427
435 - 467
744 - 800
819 - 880
571 - 613
620 - 667
1-8 NC
1-12 NF
793 - 853
868 - 933
595 - 640
657 - 707
1116 - 1200
1240 - 1333
843 - 907
917 - 987
DRILLING SOLUTIONS
6-165
SIZE
6-166
SAE GRADE 5
TIGHTENING TORQUE
SAE GRADE 8
TIGHTENING TORQUE
DRY
LUBE
DRY
LUBE
1-1/8 - 7 NC
1-1/8 - 12 NF
992 - 1067
1090 - 1173
774 - 800
819 - 880
1587 - 1707
1785 - 1920
1191 - 1280
1339 - 1440
1-1/4 - 7 NC
1-1/4 - 12 NF
1389 - 1493
1537 - 1653
1041 - 1120
1141 - 1227
2257 - 2427
2480 - 2667
1687 - 1813
1860 - 2000
1-3/8 - 6 NC
1-3/8 - 12 NF
1811 - 1947
2083 - 2240
1364 - 1467
1563 - 1680
2951 - 3173
3373 - 3627
2207 - 2373
2529 - 2720
1-1/2 - 6 NC
2405 - 2587
1811 - 1947
3917 - 4213
2927 - 3147
DRILLING SOLUTIONS
Section 7 - Troubleshooting
DRILLING SOLUTIONS
7-1
7-1 SYSTEM & TROUBLESHOOTING

Troubleshooting Information
Improper operation and maintenance is the most frequent cause of drill failures and problems.
In the event of a failure, it is recommended that you read through this manual. Problems will
be related to defects occurring in the following areas: electrical, operator observed problems,
pneumatic and mechanical/hydraulic.
WARNING

drill.
General Information
1. Do not speed engine when it is cold
5. Do not control propel speed using the engine speed control (throttle).
safe location when propelling the drill on unstable surfaces where there may be
overturning.
crushing risk.
7-2
DRILLING SOLUTIONS
11. Always sound the horn, before moving the drill in either direction, to alert
WARNING
When carrying out trouble shooting procedures, it is important to strictly

observe the safety precautions and guidelines in Section 2 of this
manual.
Electrical Controls
These are problems related to the electrical systems which control the engine, hydraulically
operated controls and the compressor controls. Refer to 7.2 Electrical System for further
information on the electrical systems used on this drill.
A bank of seven (7) circuit breakers protect the drills electrical circuits. The circuit breakers,
located on the control console, are mounted between the current producer, batteries or
alternator and the devices they are protecting. In the event of an overload of a circuit, it is
necessary to press in the tripped circuit breaker.
NOTE: If there is a recurrence, call for service assistance to correct the
cause of the overload in the circuit.
Operator Observed Problems

During operations, the operator may observe some problems which may be defined in 7.3
Operator Observed Problems Trouble Shooting Chart.
The trouble shooting chart is limited to machine control operational problems which will guide
the operator to rectify the cause of the failure.
Pneumatics
During operations, the operator may observe some problems which may be defined in 7.4 LP
Compressor and 7.5 HP Compressor.
Trouble shooting and repairs of defects in the mechanical functioning of the compressor
systems requires specialist knowledge. All compressor related problems should be referred to
your local service support for assistance and are not considered part of operator maintenance
covered in this manual. If you are unable to determine the cause of the problem, contact your
local Atlas Copco Drilling Solutions service office.
DRILLING SOLUTIONS
7-3
Mechanical Hydraulic Components

Trouble shooting and repairs of defects in the mechanical functioning of the hydraulic systems
requires specialist knowledge. All mechanical problems should be referred to your local
service support for assistance and are not considered part of operator maintenance covered
in this manual. If you are unable to determine the cause of the problem, contact your local Atlas
Copco Drilling Solutions service office.
Mechanical Engine
Trouble shooting and repairs of defects in the mechanical functioning of the engine systems
requires specialist knowledge and test equipment. All engine problems should be referred to
covered in this manual.
If you are unable to determine the cause of the problem or are unable to find a solution when
following the trouble shooting chart, contact your local Atlas Copco Drilling Solutions service
office.
7-4
DRILLING SOLUTIONS
7-2 ELECTRICAL
General Information
WARNING

drill.
approved hard hat, safety glasses, steel toed shoes/boots, gloves, respirator and ear
protection. Do not wear loose fitting clothing or damaged garments that can become caught
on rotating components.
General Information
of overturning and when loading onto a transporter where there is a risk of
overturning.
crushing risk.
DRILLING SOLUTIONS
7-5

Electrical System Information

The following information is provided to give an understanding of the electrical system and the
relation to the operators control console described in Section 4 Operating Controls. Note:
There are wiring schematics shown at the end of this section which also relate to the
information provided here.
Cummins Engines
Drills equipped with Cummins engines have an electrical system with computer controls for all
engine functions. The engine protection system will be explained in detail to give the operator
an understanding of the system and to emphasize the need to call for specialist assistance in
the event the engine system warning lights signal problems during operation.
Note that on a Cummins QSK19C/755HP engine, there are two starter motors used. Each
starter motor uses two 12 volt batteries, connected in series, that provide 24 volt direct current
(DC) to the system. The batteries use a machine ground to complete the circuit. The battery
and starter ground cables are size 2/0. They are protected by four sections of fusible link. One
is attached to each starter and the other to the alternator. Current flows through the ammeter
to the number 2, 6 & 7 wires. Number 7 wire is the hot or (+) wire for the engine controls.
Number 2 wire is the hot or (+) wire for the drill lighting system. Number 6 wire supplies current
to the engine ECM.
When the engine is started, battery current is supplied to the starter motor through the starter
solenoid (S2) contacts on one starter motor and the starter solenoid (S3) contacts on the other
starter motor when they are closed. To close the contacts, the key switch must be turned to
7-6
DRILLING SOLUTIONS
the ON position and the starter button depressed. This activates the (S1) coil which, in turn,
closes contact (S1). Coil (S2) and coil (S3) are then powered and, in turn, activate (S2) and
(S3) contacts. This is what actually makes contact with the motor starter. NOTE: Relay S3 is
built into the second starter.
Note: Reference the wiring schematics at the end of this section which relate to the
information provided here.
Cat Engines
Drills equipped with Caterpillar engines have an electrical system with computer controls for
all engine functions. The Engine Monitoring System will be explained to give the operator an
understanding of the system and to emphasize the need to call for specialist assistance in the
event engine system warning lights signal problems during operation.
Note that on a Cat engines, there are two starter motors used. Each starter motor uses two 12
volt batteries, connected in series, that provide 24 volt direct current (DC) to the system. The
batteries use a machine ground to complete the circuit. The battery and starter ground cables
are size 2/0. They are protected by four sections of fusible link. One is attached to each starter
and the other to the alternator. Current flows through the ammeter to the number 2, 6 & 7
wires. Number 7 wire is the hot or (+) wire for the engine controls. Number 2 wire is the hot or
(+) wire for the drill lighting system. Number 6 wire supplies current to the engine ECM.
When the engine is started, battery current is supplied to the starter motor through the starter
solenoid (S2) contacts on one starter motor and the starter solenoid (S3) contacts on the other
starter motor when they are closed. To close the contacts, the key switch must be turned to
the ON position and the starter button depressed. This activates the (S1) coil which, in turn,
closes contact (S1). Coil (S2) and coil (S3) are then powered and, in turn, activate (S2) and
(S3) contacts. This is what actually makes contact with the motor starter. NOTE: Relay S3 is
built into the second starter.
NOTICE
Do not operate the starter motor for more than 30 seconds at a time. Let
the starter motor cool for at least 2 minutes before attempting to start
again. Overheating, caused by excessive cranking, will seriously damage
the starter motor.
Ether Injection is recommended by all engine manufacturers during cold weather starts and in
ambient temperatures below 50F (10C). To activate Ether Injection, simply push the Button
marked ETHER. It must be pushed each time you wish to inject ether into the engine. You
cannot over inject ether into the engine with the injection system supplied. It should be used,
as needed, until the engine temperature has reached 70F (21C).
Another device helpful in starting is the Fuel Primer Pump. It pumps fuel from the fuel tank into
the fuel filters or fills the fuel line with fuel after a fuel filter change. It is activated by pushing
the PRIMER button on the console. This supplies current to the primer motor that operates
the pump.
DRILLING SOLUTIONS
7-7
ELECTRICAL SYSTEM COMPONENTS

Batteries
Each starter motor uses two 8D type batteries rated at 12 volts each, connected in series, that
provide 24 volt direct current (DC) to the system (see figure 7.2-2). They should be checked
every 50 operating hours as part of routine maintenance. Refer to 6.6-Maintenance (50 Hours
or Weekly).
Fusible Links
The fusible links used on the drill are blue and are 9 inches (23cm) long. There is a ring
connector on one end of each link. Fasten one fusible link end ring connector to the starter and
fasten the other fusible link end ring connector to the alternator. The other end of each fusible
link is connected to the main hot wire #1 by a wire nut. The main hot wire (#1) is a red, 8 gauge
wire.
NOTICE
Fusible Links must be in place to operate the drill. If a short circuit
destroys a fusible link, it MUST be replaced before the drill goes back in
service.
7-8
DRILLING SOLUTIONS
Starter Motor
The starter motor contains the built in starter relay (Relay S2). The second starter motor used
on the engine contains the built in starter relay (Relay S3).
Alternator
The alternator is a 24 volt model. It is used to charge the batteries and provide current to the
electrical system and the night lights.
Key Switch
The key switch controls current to all functions but the night lights. When it is turned on it
supplies power through wire number 7 to the starter button, primer motor, tachometer and the
compressor shutdown switch. It also energizes the engine ECM (Cummins engines). Refer to
the electrical schematics for engine water temperature switch, fuel gauge and throttle switch.
Circuit Breakers
The bank of seven (7) circuit breakers, located on the control console, protect the drills
electrical circuits. The circuit breakers are mounted between the current producer, batteries or
alternator and the devices they are protecting. In the event of an overload of a circuit, it is
necessary to press in the tripped circuit breaker. Note: If there is a recurrence, call for service
assistance to correct the cause of the overload in the circuit.
The following is the identification of the circuit breakers on the console:
1. 5 amp= Engine Shutdown
2. 15 amp = Windshield Wipers and Washers
3. 20 amp = Power Distribution for OEM Controllers
4. 20 amp = Air Conditioner/Pressurizer System
5. 15 amp = Power Distribution for Engine
6. 20 amp = Drill Working Lights
7. 20 amp = Tram (Propel) Lights and Cab light
Push Buttons
The push buttons on the operators console enable the operator to:
a. Start the engine
b. Pump fuel from the fuel tank to prime the engine fuel system
c. Sound an audible warning (horn)
d. Inject ether into the engine intake (option)
DRILLING SOLUTIONS
7-9
These push buttons are spring loaded to disconnect power when they are
released.
Engine Shutdown Devices

The drill is equipped with several shutdown devices to prevent harm to the engine or
compressor in case of loss of fluids or other related problems. It has a compressor discharge
temperature switch, (on tier 1 and older) an engine coolant temperature switch and two engine
oil pressure shutdown switches.
Compressor Discharge Temperature Switch ( ECM Protects Later Engines)

This Murphy Switch gauge has a gauge on the operators console and a sensor located on the
compressor discharge piping of the compressor. It monitors the temperature coming out of the
compressor. When the temperature increases to 248F (120C), a contact inside the gauge
makes electrical contact with relay R1. This cuts the power to the engine.
Engine Water Temperature Switch (N/A on Tier 2)

This switchgage is also mounted in the console and the coolant temperature sensor, located
at the water manifold of most engines, monitors engine coolant temperature. Activation
temperature for the high coolant temperature fault is 224F (107C).
Engine Oil Pressure Switch (N/A on Tier 2)

This switchgage, mounted in the console, has two pressure limit switches that close when the
pressure falls below 27 psi and 10 psi. It does not have a capillary tube but uses a hose
connected to the engine to supply pressure to the switchgage. Both gages are normally closed
and rely on engine oil pressure to open them. They both work through the engine speed switch
and close when oil pressure falls below 27 psi or 10 psi, depending on the engine speed.
Tachometer / Magnetic Pickup (N/A on Tier 2)

The tachometer is driven by the magnetic pickup which receives its signal from the engine
flywheel. The pickup is a solid state device that counts the teeth on the flywheel and sends a
signal to the tachometer.
The wires between the pickup and tachometer are specially shielded wires to prevent
interference from outside signals.
The elapsed time meter records the number of hours the engine has operated. It only works
when the key is turned on.
Relays (Pre Tier 2)

A starter relay is connected between the starter button and the starter motor that energizes
the starter solenoid switch. The starter relay actually engages the starter motor. There are two
parts to any relay; a coil and at least one set of contacts (points). The coil physically changes
7-10
DRILLING SOLUTIONS
the condition of the contacts from normally open to closed or vice versa. There can be several
sets of contacts for one coil.
Relays are used in several circuits on the drills and the schematics do not always show how
they interact with each other.
A relay consists of a coil connected to one or more sets of contacts. When the coil is energized,
the solenoid pulls the other contacts downward. In some cases, this disconnects a circuit while
in others it makes a new circuit. For example, the shutdown relay R1 has a coil marked R1.
This coil is connected physically to R1A, a normally closed contact. R1B is a normally open
contact, connected physically, that becomes energized when R1 is energized. Even though
the schematic shows the elements in different places, they are actually made up of a single
device.
All shutdown devices are in the open mode during normal running conditions and are
connected to the R1 Relay coil.
Should an abnormal condition occur in any of these circuits, the appropriate monitoring device
will close and cause R1 relay coil to become energized.
When R1 coil is energized, it moves the R1A contacts from a normally closed position to an
DRILLING SOLUTIONS
7-11
open position. This interrupts the flow to the fuel solenoid and shuts down the engine. It also
cuts off current to the red light in the emergency stop button.
If the engine was at high idle (1800 RPM) when the shutdown occurred, the high pressure oil
switch may shut the engine down.
If the oil pressure remained higher than 10 psi, but lower than 27 psi, the engine would try to
restart at low idle. For this reason we added R1B. When current is interrupted to the fuel
solenoid, it must remain off until the engine stops. To insure this happens,R1B supplies current
to R1 coil continuously to keep it from cycling.
Emergency Engine Shutdown (Pre Tier 2)

The emergency engine shut down switch has a red light. Pushing the emergency engine shut
down switch in shuts off power to the fuel valve which stops fuel flow and shuts the engine
down. Turning the key switch does the same thing. All engines are energized to run, which
means the fuel system must be energized in order to pump fuel.
Cat Electronic Engine

The Caterpillar Engine is designed with electronic controls. The integral on board computer
controls the operation of the engine. Current operating conditions are monitored. The
Electronic Control Module (ECM) controls the response of the engine to these conditions and
to the demands of the operator. These conditions and operator demands determine the
precise control of fuel injection by the ECM. For more information on electronic engine
features, refer to the Caterpillar Operation and Maintenance Manual, Engine Features and
Controls topic (Operation Section).
7-12
DRILLING SOLUTIONS
Engine Electronics
WARNING
Tampering with the electronic system installation or the OEM wiring

installation can be dangerous and could result in personal injury or death
and/or engine damage.
The engine has a monitoring system with the following modes: OFF,WARNING, DERATE and
SHUTDOWN. Under the following operating conditions, the engine power and/or the engine
speed may be limited.
1. Very low oil pressure
2. High coolant temperature
3. Very high coolant temperature
4. Very low coolant level
Cat Monitoring System
WARNING
If the Shutdown mode has been selected and the warning indicator
activates, engine shutdown may take as little as 20 seconds from the time
the warning indicator is activated. Depending on the application, special
precautions should be taken to avoid personal injury. The engine can be
restarted following shutdown for emergency maneuvers, if necessary.
NOTICE
The Engine Monitoring System is not a guarantee against catastrophic
failures. Programmed delays and derate schedules are designed to
minimize false alarms and provide time for the operator to stop the
engine.
DRILLING SOLUTIONS
7-13
Warning/Derate/Shutdown
WARNING
If the Shutdown mode has been selected and the warning indicator
activates, bring the engine to a stop whenever possible. Depending on
the application, special precautions should be taken to avoid personal
injury.
The Diagnostic lamp turns ON and the warning signal on the console is activated. After the
warning, the engine power will be derated. The engine will continue to derate rpm until a
shutdown of the engine occurs. The engine can be restarted after a shutdown for use in an
emergency.
A shutdown of the engine may occur in as little as 20 seconds. The engine can be restarted
after a shutdown for use in an emergency. However, the cause of the initial shutdown may still
exist. The engine may shut down again in as little as 20 seconds.
If there is a signal for coolant loss, there will be a 10 second delay in order to verify the
condition. The system will derate the engine power for 40 seconds before the engine will shut
down if the engine has been programmed to shut down.
If there is a signal for low oil pressure or for coolant temperature, there will be a two second
delay in order to verify the condition. The system will derate the engine power for 30 seconds
before the engine will shut down if the engine has been programmed to shutdown.
Cat Diagnostic and Monitoring System

Monitoring System:
1. Engine Oil Pressure
2. Tachometer
3. Coolant Temperature
7-14
DRILLING SOLUTIONS
4. Fuel Pressure
5. Fuel Temperature
6. Engine Speed/Timing
7. Throttle Position
8. Overspeed
9. Atmospheric Pressure
10. Turbo Inlet Pressure
Cat Diagnostic Panel Information

1. ENGINE WARNING LAMP (YELLOW)
Warning Lamp - There is a general fault in the engine. Refer to the Messenger
display for additional information that may be available.
2. ENGINE DIAGNOSTIC LAMP (RED)
Diagnostic Lamp - The diagnostic lamp ia used to indicate the existence of a
fault by flashing a fault code. For a more detailed discussion of the diagnostic
lamp please see Diagnostic Lamp topic.
3. MAINTENANCE INDICATOR LAMP (BRIGHT WHITE)
Maintenance Indicator Lamp - The ECM records data that is related to
equipment maintenance. The ECM will activate the maintenance indicator lamp
when scheduled maintenance is due. The maintenance indicator lamp can be
reset by actuating the maintenance clear switch. The maintenance interval may
be based on operating hours or fuel consumption. The ECM provides
information that pertains to maintenance intervals and the last maintenance
that was performed.
4. MAINTENANCE CLEAR SWITCH
Maintenance Clear Switch - The maintenance clear switch is required to reset
the maintenance indicator lamp after maintenance on the engine is performed.
Warning Signals
Engines may be equipped with warning signals in order to alert the operator when undesirable
operating conditions occur. When a warning signal is activated, corrective measures must be
made before the situation becomes an emergency.
Warning signals are electrically operated. The operation of all electric warning signals utilize
components that actuate switches in a sensing unit. Warning signals are set for the following
parameters:
1. critical operating temperatures
2. operating pressures
3. operating levels
DRILLING SOLUTIONS
7-15
4. operating speeds
A history of all of the engine faults is maintained in the Electronic Control Module (ECM).
These faults can be either Active Codes or Logged Codes.
Cold Start Strategy

The cold start strategy utilizes the input from the oil temperature sensor to improve starting in
low temperatures. The cold start strategy helps to provide the following features:
1. Quicker cold starts
2. White smoke cleanup
3. Decreased deep cycling of the battery
4. Extended engine life
When the oil temperature is below 140F (60C), the cold start strategy is activated. The cold
start strategy deactivates under any of the following conditions:
1. The oil temperature reaches 140F (60C).
2. The engine has run for 14 minutes.
Engine Shutoff Controls

Secondary shutoff controls are electrically operated. Know the types and the locations of the
shutoff controls, the conditions which cause each control to function, and the resetting
procedure that is required to start the engine. Always determine the cause of the shutdown.
Before the engine is restarted, make the necessary repairs.
Engine Oil Pressure Sensor

The engine oil pressure sensor is an absolute pressure sensor that measures the engine oil
pressure in the main oil gallery. The engine oil pressure sensor detects engine oil pressure for
diagnostic purposes. The engine oil pressure sensor sends a signal to the ECM.
The ECM will detect failure of the engine oil pressure sensor. The diagnostic lamp warns the
user about the status of the engine oil pressure sensor. The engine oil pressure related
strategies will be disabled in the event of a failure of the engine oil pressure sensor. A failure
of the engine oil pressure sensor will not cause a shutdown of the engine or any horsepower
change.
Low Oil Pressure Warning

The set point is dependent upon the engine speed. The fault will be active and logged only if
the engine has been running for more than 15 seconds.
Tachometer
This gauge indicates engine speed (rpm). When the throttle control lever is moved to full
7-16
DRILLING SOLUTIONS
throttle position without load, the engine is running at high idle. The engine is running at full
load rpm when the throttle control lever is at full throttle position with maximum rated load.
Coolant Temperature Sensor

The coolant temperature sensor monitors engine coolant temperature. This feature is used for
engine system diagnostics with an output from the ECM. The output of the ECM can indicate
a high coolant temperature through a relay or a lamp. Activation temperature for the high
coolant temperature fault is 224F (107C).
A failure of the coolant level sensor will not cause a shutdown of the engine or any horsepower
change.
Fuel Pressure Sensor

The fuel pressure sensor monitors the fuel filter outlet pressure. Low fuel pressure or high fuel
pressure will not cause a shutdown of the engine. Low fuel pressure can result in low power.
Fuel pressure that is outside of the normal range will affect the engine performance. If the fuel
filter outlet pressure is low, the fuel filter may need to be replaced.
Fuel Temperature Sensor

The fuel temperature sensor monitors the fuel temperature. Fuel temperature is monitored in
order to adjust the fuel rate so that the engine will deliver consistent power. The fuel
temperature sensor can also be used to warn the operator of excessive fuel temperature. A
high fuel temperature can adversely affect the engine performance.
Engine Speed/Timing Sensor

If the primary speed/timing sensor (1) cannot sense engine speed, the DIAGNOSTIC lamp
will indicate a diagnostic fault code which will be logged in the ECM memory.
If the primary speed/timing sensor cannot sense engine speed, the automatic default will use
secondary speed/timing sensor. The secondary speed/timing sensor will be used until the
primary speed/timing sensor is replaced.
Throttle Position Sensor

The Throttle Position Sensor (TPS) sends a signal to the ECM. The signal from the TPS is
required in order to govern engine speed. The TPS signal is used by the ECM in order to
calculate the desired engine speed. The TPS is calibrated during the initial installation of the
engine. Note: Some installations of the TPS do not need calibration.
Failure of the Throttle Position Sensor
An intermittent failure in the TPS causes the engine speed to vary erratically. The ECM will
perform the following process:
1. The ECM will detect the failure of the TPS.
2. The ECM will warn the operator of the failure through the diagnostic lamp.
DRILLING SOLUTIONS
7-17
3. The ECM will set the desired engine speed to low idle.
Overspeed
An overspeed condition is detected by the primary speed/timing sensor. If the engine rpm
speed exceeds 2500 rpm, the Electronic Control Module (ECM) will shut off the electronic unit
injectors. The electronic unit injectors will be shut off until the engine speed drops below 2500
rpm. A diagnostic fault code will be logged into the ECM memory and the DIAGNOSTIC lamp
will indicate a diagnostic fault code.
Atmospheric Pressure Sensor

The atmospheric pressure sensor measures the atmospheric pressure in the crankcase. A
signal is sent to the Electronic Control Module (ECM).
Turbocharger Outlet Pressure Sensor

The turbocharger outlet pressure sensor provides a signal which corresponds to boost to the
ECM. The injection of fuel that is limited by the ECM is based on the boost pressure and the
fuel ratio control limit. This feature is called the FRC Fuel Limit on the Electronic Service Tool.
The ECM performs an automatic calibration of the turbocharger outlet pressure sensor
whenever the ECM is powered and the engine is off for at least five (5) seconds. During an
automatic calibration, the ECM calibrates the turbocharger outlet pressure sensor against the
atmospheric pressure sensor and an acceptable offset pressure range. If the FRC offset value
is not in the range, the previous calibration value is used. A manual calibration should be
performed if the turbocharger outlet pressure sensor is replaced.
Failure of the Turbocharger Outlet Pressure Sensor
The ECM will detect failure of the turbocharger outlet pressure sensor. The operator will be
warned of the problem through the diagnostic lamp. The strategies that are related to the boost
will be disabled. A failure of the turbocharger outlet pressure sensor will not cause a shutdown
of the engine.
Cat Engine Diagnostics

Caterpillar Electronic Engines have the capability to perform a self-diagnostics test. When the
system detects a problem, the DIAGNOSTIC lamp is activated. Diagnostic codes will be
stored in permanent memory in the Electronic Control Module (ECM). The diagnostic codes
can be retrieved by using the following components:
a. Caterpillar electronic service tools
b. DIAGNOSTIC lamp
Some installations have electronic displays that provide direct readouts of the engine
diagnostic codes.
Active codes represent problems that currently exist. These problems should be investigated
first. If a code is active, the DIAGNOSTIC lamp will flash the flash code at five (5) second
7-18
DRILLING SOLUTIONS
intervals.
Logged codes represent the following items:
a. Intermittent problems
b. Recorded events
c. Performance history
The problems may have been repaired since the logging of the code. These codes do not
indicate that a repair is needed. The codes are guides or signals when a situation exists.
Codes may be helpful to troubleshoot problems.
When the problems have been corrected, the corresponding logged fault codes should be
cleared.
Diagnostic Lamp
The DIAGNOSTIC lamp is used to indicate the existence of an active fault by flashing codes.
When the ignition switch is first turned on, the DIAGNOSTIC lamp will go through the
following procedure:
1. The DIAGNOSTIC lamp will come on and the DIAGNOSTIC lamp will
remain on for five (5) seconds.
2. The DIAGNOSTIC lamp will turn off.
3. The DIAGNOSTIC lamp will come on again and the DIAGNOSTIC lamp will
flash codes for any active diagnostic codes.
4. The DIAGNOSTIC lamp will turn off for five (5) seconds.
5. The DIAGNOSTIC lamp repeats all active diagnostic codes.
A fault diagnostic code will remain active until the problem is repaired. The electronic control
module will continue flashing the flash code at five (5) second intervals until the problem is
repaired.
Diagnostic Flash Code Retrieval

Use the DIAGNOSTIC lamp or a Caterpillar electronic service tool to determine the
diagnostic flash code. Use the following procedure to retrieve the diagnostic codes if the
engine is equipped with a DIAGNOSTIC lamp:
NOTE: Flash codes should only be used to indicate the nature of a
diagnostic condition. Do not use flash codes to perform detailed
troubleshooting
1. Turn the ignition key to the ON position. The engine does not need to be started
in order to view codes. The engine does not need to be running while the
ignition switch is in the ON position.
a. The DIAGNOSTIC lamp blinks on and off at five (5) second intervals.
DRILLING SOLUTIONS
7-19
b. When the ignition key is in the ON position, the lamp is checked for proper
operation. If there are any active codes except for Code 34, the codes are
displayed at this time.
Note: The DIAGNOSTIC lamp will illuminate for five (5) seconds. The lamp
will stay on if there is an active diagnostic code.
2. The diagnostic codes will always be flashed. There is no toggle switch that will
shut off the lamp.
3. The DIAGNOSTIC lamp will flash in order to indicate a two-digit code. The
sequence of flashes represents the system diagnostic message. Each digit of
the two-digit code is determined by counting the number of flashes. The lamp
flashes at a rate of two times per second. The lamp will pause for two seconds
between codes.
Diagnostic Flash Codes

The table below indicates the potential effect on the engine performance with active flash
codes. The table also forms a list of electronic diagnostic codes and descriptions.
7-20
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-21
1. Engine Monitoring must be programmed to Derate or Shutdown before the

power and engine rpm are reduced. Engine Monitoring must be programmed
to Shutdown before the engine will shutdown.
2. If both the primary speed/timing sensor and the backup speed/timing sensor
fail, a shutdown will occur.
For further information or assistance for repairs, consult your local Drilling Solutions distributor
or an authorized Caterpillar dealer.
Fault Logging
The system provides the capability of Fault Logging. When the Electronic Control Module
(ECM) generates a diagnostic code, the code will be logged in the memory of the ECM. The
codes that have been logged in the memory of the ECM can be retrieved with Caterpillar
electronic service tools. The codes that have been logged can be cleared with Caterpillar
electronic service tools. The codes that have been logged in the memory of the ECM will be
automatically cleared from the memory after 100 hours. The following faults can not be cleared
from the memory of the ECM without using a factory password: overspeed, low engine oil
pressure and high engine coolant temperature.
Engine Operation With Active Diagnostic Codes

If the diagnostic lamp starts to flash codes during normal engine operation, the system has
identified a situation that is not within the specification. Use Caterpillar electronic service tools
to check the active diagnostic codes.
Note: If the customer has selected DERATE and if there is a low pressure condition, the
Electronic Control Module (ECM) will limit the engine power until the problem is corrected. If
the oil pressure is within the normal range, the engine may be operated at the rated speed and
load. However, maintenance should be performed as soon as possible. Refer to Diagnostic
Flash Code Retrieval for more information on flash codes.
7-22
DRILLING SOLUTIONS
The active diagnostic code should be investigated. The cause of the problem should be
corrected as soon as possible. If the cause of the active diagnostic code is repaired and there
is only one active diagnostic code, the diagnostic lamp will turn off.
Operation of the engine and performance of the engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates may be significantly slower. Refer to the
Diagnostic Flash Codes for more information on the relationship between these active
diagnostic codes and engine performance.
Engine Operation With Intermittent Diagnostic Codes

If the diagnostic lamp starts to flash codes during normal engine operation and the diagnostic
lamp shuts off, an intermittent fault may have occurred. If a fault has occurred, the fault will be
logged into the memory of the Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine because of an intermittent code. However,
the operator should retrieve the codes and the operator should reference the appropriate
information in order to identify the nature of the event. The operator should note the
circumstances that are involved during the time that the lamp was on:
a. Low Power
b. Limits of the engine speed
c. Excessive smoke, etc.
This information can be useful to help troubleshoot the situation. The information can also be
used for future reference.
Cat Engine Protection

Troubleshooting a failure on an engine can be a difficult procedure. See the CAT Service
Manual for troubleshooting information. All repairs should be made by a properly trained
mechanic. Your Caterpillar dealer has the personnel and special tools needed to troubleshoot
and make repairs to your engine.
See the Troubleshooting Manual within the CAT Service Manual. The list of problems, causes
and corrections given in the CAT Service Manual will only give an indication of where a
possible problem can be, and what repairs may be needed. Remember that a problem is not
normally caused only by one part, but by the relation of one part with other parts.
The CAT Service Manual can not give all possible problems and corrections. The serviceman
must find the problem and its source, then make the necessary repairs. Your Caterpillar dealer
DRILLING SOLUTIONS
7-23
is equipped with the necessary tools and personnel to provide assistance when necessary.
7-24
DRILLING SOLUTIONS
Cummins Engine Electronics

Drills equipped with the Cummins QSK19 engines have an electrical system with computer
controls for all engine functions as defined in ECM Wiring Schematic. The QSK19 Engine
Protection System is explained in detail to give the operator an understanding of the system
and to emphasize the need to call for specialist assistance in the event of engine protection
systems warning lights signalling problems during operation.
The Cummins Quantum fuel system uses an ECM (Electronic Control Module) to operate the
devices needed to monitor and vary the operation of the QSK19 engine. It is equipped with an
engine protection fault code system and an electronic fuel system fault code system. The
system monitors critical engine temperatures, fluid levels, oil and fuel pressures. It will log
diagnostic faults when an over, or under, normal operating range condition occurs. If an outof-range condition exists, engine derate action will be initiated. The operator will be alerted by
the illumination of the Bright Red light. The warning lamp will start to flash as the out-of- range
condition gets worse and engine shut down will occur shortly thereafter.
DRILLING SOLUTIONS
7-25
Indicator Light System

There are three different colored lights on the operators console. Each light has its own
function:
Red Indicator Light
The red indicator light shows fault codes in the engine protection system. The red light signals
problems in the engine protection system. The red light will come on when an out-of-range
condition occurs. These include:
a. Coolant Temperature
b. Coolant Level
c. Oil Pressure
The red light will come on steady when the condition first appears but will change to a blinking
light if the condition continues. If the problem is not resolved, the engine will shut down when
the condition reaches the preset limit.
Yellow Indicator Light
The yellow indicator light signals In-Range failures of the engine protection system. The
engine can still be operated, but can lose some system features that can sometimes result in
a power loss. The failure must be repaired as soon as possible. In the diagnostic mode, the
yellow light flashes to indicate a fault code is about to be flashed by the red light. The yellow
light blinks before each fault code is signaled by the red light.
Bright White Indicator Light
The bright white Indicator light shows an out-of-range condition occurs.
QSK19 Diagnostic Fault Codes

If you have a laptop computer and the software program INSITE, you can plug into the
console Data Link socket and diagnose all the fault codes residing in the ECM. Every code is
recorded in the ECM until it is removed by the computer. There are two types of fault codes:
7-26
DRILLING SOLUTIONS
Active and Inactive.

Active fault code means the code is presently active on the engine, i.e., high engine
temperature.
Inactive fault code means the code was active at one time but is not active now. An example
would be: low coolant level fault code that the operator filled. It is no longer an active code but
it will be retained in the ECM.
Diagnostic Switch
The Diagnostic Switch must be in the OFF position for normal operation. It will not show fault
codes if it is left in the ON position.
Incremental Switch
The Incremental Switch is a spring centered switch that moves the ECM UP one fault code
every time it is toggled upward and it moves the ECM DOWN one fault code every time it is
pushed downward. When it is released, it moves back to the neutral position.
Finding Fault Codes

To check for active fault codes, first turn the engine key switch to the OFF position. Move the
diagnostic switch to the ON position.
Turn the engine key switch to the ON position. If no active fault codes are recorded, all three
lights will come on and stay on. If active fault codes are recorded, all three lights will come on
momentarily. The yellow (2) warning and red (1) stop lights will begin to flash the code of the
recorded fault. The bright white (3) light will not flash.
DRILLING SOLUTIONS
7-27
Reading Fault Codes

The fault code will flash in the following sequence. First, the yellow warning lamp will flash.
Then there will be a short, 1-second pause when both the yellow and red lights are off. Then
the numbers of the recorded fault code will flash in red. There will be a 1-second pause
between each number. When the number is done flashing, the yellow light will appear again.
The number will repeat in the same sequence.
The lights will continue to flash the same fault code until the system has advanced to the next
active fault code. To go to the second fault code, move the incremental switch to +, then
release it. You can also go back to the previous fault code by moving the switch to -, then
releasing it. To check the third or fourth fault code, move the switch to +, then release it when
all active codes have been viewed. Moving the switch to + will go back to the first fault code.
Fault Code Example

To show exactly what a sequence would look like, lets suppose that a Red light comes on and
after a few minutes, starts to blink. The operator should stop the engine as soon as possible
and determine the cause. He turns the key switch OFF and turns the diagnostic switch ON.
This starts the sequence of fault code lights flashing. The sequence for a Fault Code 235
would look like the sequence shown in the table below.
The yellow light comes on and flashes once. The red light flashes the first number, in this case
a two (2). Then the red light goes out for one second and starts the next number, a three (3).
Again a one second pause, then the final number five (5). The fault code is 235, or low coolant
level.
Since the fault code started as a Red light, the problem was an out-of-range condition, i.e., low
oil pressure, low coolant level, high temperature or high manifold temperature.
To stop the diagnostic system, move the diagnostic switch to the OFF position. Turn the
engine key switch to the OFF position.
7-28
DRILLING SOLUTIONS
QSK19 The explanation and correction of all fault codes is in the troubleshooting charts of the
QSK19 Operation and Maintenance manual, available from Cummins.
Electronic fault code troubleshooting trees are in ascending numerical order.
When a diagnostic fault code is recorded in the ECM, ECM input and output data are recorded
from all sensors and switches. Snapshot data allow the relationships between ECM inputs and
outputs to be viewed and used during troubleshooting.
Cummins Fault Code Tables

The fault codes for the Red light, which are the most common, are shown in the Red Light
(Engine Protection) Table. With the exception of code 432, most other codes can be acted on
by the operator.
Red Light (Engine Protection ) Fault Codes
Yellow Light Fault Codes

The failures caused by yellow (and red) lights indicate wiring problems or internal ECM
malfunctions that the operator cannot repair. Call your local dealer if a yellow (or red) light
comes on. Examples of the fault codes are shown tabulated in tables.
DRILLING SOLUTIONS
7-29
7-30
DRILLING SOLUTIONS
Red Light Fault Codes

The failures caused by red (and yellow) lights indicate wiring problems or internal ECM
malfunctions that the operator cannot repair. Call your local dealer if a red (or yellow) light
comes on. Examples of the fault codes are shown tabulated in tables.
DRILLING SOLUTIONS
7-31
No Fault Lamp
7-32
DRILLING SOLUTIONS
Murphy Link Powerview System
Description
The PowerView has been developed to meet the needs for instrumentation and control on
electronically controlled engines communicating using the SAE J1939 Controller Area
Network (CAN).
DRILLING SOLUTIONS
7-33
The PowerView is a multifunctional tool that enables operators to view many different engine
or transmission parameters and service codes. The PowerView includes a graphical backlit
LCD screen. The display can show either a single parameter or a quadrant display showing
four parameters simultaneously. Diagnostic capabilities include fault codes with text
translation for the most common fault conditions. The PowerView has four buttons using selfcalibrating charge transfer activation technology, which eliminates the concern for push button
wear and failure.
The enhanced alarm indication has ultra bright alarm and shutdown LRDs (amber & red). It
has a wide temperature range of -40F to +185F (-40C to +85C), display viewing -40F to
+167F (-40C to +75C), and increased environmental sealing to +/- 5 PSI (35kPa).
Other components in the system are microprocessor PowerView Gages for displaying critical
engine data broadcast by an electronic engine or transmissions Engine Control Unit (ECU):
engine RPM, oil pressure, coolant temperature, system voltage, etc. and a combination
audible alarm and relay unit for warning and shutdown annunciation.
Faceplate Features and Keypad Functions
7-34
DRILLING SOLUTIONS
The keypad on the PowerView is a capacitive touch sensing system. There are no mechanical
switches to wear or stick. It operates in extreme temperatures; with gloves, through ice, snow,
mud, grease, etc., and it allows complete sealing of the front of the PowerView. The key is
touched feedback is provided by the flashing screen. The keys on the keypad perform the
following:
Menu Key:
The menu key is touched to either enter or exit the menu screens.
Left Arrow Key:

The left arrow key is touched to scroll through the screen either moving the parameter
selection toward the left or upward.
Right Arrow Key:

The right arrow key is touched to scroll through the screen either moving the parameter
selection toward the right or downward.
Enter Key:
The enter key, also known as Enter Button, is touched to select the parameter that is
highlighted on the screen.
Mechanical Installation
Typical Quick-Connect Diagram
DRILLING SOLUTIONS
7-35
Electrical Installation
PowerView Unit Back View
Powerview Operation
1. When power is first applied to the PowerView, the Logo is displayed.
2. The Wait to Start message will be displayed for engines with a pre-startup
sequence. Once the Wait to Start message is no longer displayed the
operator may start the engine. Note: Displays only when SAE J1939 message
is supported by engine manufacturer.
3. Once the engine has started the single engine parameter is displayed.
Main Menu Navigation

1. Starting at the single or four engine parameter display, touch Menu.
2. The first seven items of the Main Menu will be displayed. Touching the Arrow
Buttons will scroll through the menu selection.
7-36
DRILLING SOLUTIONS
3. Touching the right arrow button will scroll down to reveal the last items of Main
Menu screen highlighting the next item down.
4. Touch the Arrows to scroll to the desired menu item or touch Menu to exit
the Main menu and return to the engine parameter display.
Selecting a Language
1. Starting at the main menu display use the Arrows to scroll to the Language
menu and once highlighted touch the Enter button.
2. Language choices will be displayed. Use the Arrow buttons to scroll through
selections and touch Enter to make a selection.
DRILLING SOLUTIONS
7-37
3. Now that you have selected the language, touch the Menu button to return to
the main menu display.
Stored Fault Codes

1. Starting at the single or the four engine parameter display touch the Menu
button.
2. The main menu will pop up on the display. Use the Arrow Buttons to scroll
through the menu until the Stored Fault Codes is highlighted.
3. Once the Stored Fault Codes menu item has been highlighted touch the
Enter Button to view the Stored Fault Codes (when applicable, consult
engine manufacturer for the SAE J1939 supported parameters).
7-38
DRILLING SOLUTIONS
4. If the word MORE appears above the Arrow Buttons there are more stored
fault codes that may be viewed. Use the Arrow Buttons to scroll to the next
Stored Diagnostic Code.
5. Touch the Menu Button to return to the main menu.

6. Touch the Menu Button to exit the Main menu and return to the engine
parameter display.
Engine Configuration Data

1. Starting at the single or the four engine parameter display touch the Menu
button.
DRILLING SOLUTIONS
7-39
through the menu until the Engine Configuration is highlighted.
3. Once the Engine Configuration menu has been highlighted touch the Enter
Button to view the engine configuration data.
4. Use the Arrow Buttons to scroll through the engine configuration data.
6. Touch the Menu Button to exit the Main menu and return to the engine
parameter display.
Faults and Warnings

Auxiliary Gauge Fault
1. During normal operation the single or four parameter screen will be displayed.
2. The PVA Series auxiliary gauges can be attached to the PowerView. These
auxiliary gages communicate with the Modbus master PowerView via a daisychained RS-485 port. If at any time during system initialization or normal
operation an auxiliary gauge should fail, the single or four parameter screen will
be replaced with the MLink Gauge Fault message.
3. To acknowledge and Hide the fault and return to the single or the four
parameter display, touch the Enter Button.
7-40
DRILLING SOLUTIONS
4. The display will return to the single or four parameter screen.
5. Touching the Enter Button will redisplay the hidden fault. Touching the Enter
Button once again will hide the fault and return the screen to the single or four
parameter display. Note: The fault can only be cleared by correcting the cause
of the fault condition.
Active Fault Codes

2. When the PowerView receives a fault code from an engine control unit the
single or four parameter screen will be replaced with the Active Fault Codes
message.
3. If the word MORE appears above the Arrow Buttons there are more active
fault codes that may be reviewed. Use the Arrow Buttons to scroll to the next
Active Fault Code.
4. To acknowledge and Hide the fault and return to the single or four parameter
display touch the Enter Button
5. The display will return to the single or four parameter display, but the display
will contain the Active Fault warning icon. Touching the Enter Button will
redisplay the hidden fault.
6. Touching the Enter Button once again will hide the fault and return the screen
to the single or four parameter display.
DRILLING SOLUTIONS
7-41
7. The single or four the parameter screen will display the fault icon until the fault
condition is corrected. Note: Ignoring active fault codes could result in severe
engine damage.
Shutdown Codes
2. When the PowerView receives a severe fault code from an engine control unit
the single or four paramenter screen will be replaced with the Shutdown
message.
3. To acknowledge and Hide the fault and return to the single or the four
parameter display, touch the Enter Button.
4. The display will return to the single or four parameter display, but the display
will contain the Shut Down icon. Touching the Enter Button will redisplay the
hidden fault.
5. Touching the Enter Button once again will hide the fault and return the screen
to the single or four parameter display.
6. The single or four the parameter screen will display the fault icon until the fault
condition is corrected. Note: Ignoring active fault codes could result in severe
engine damage.
7-42
DRILLING SOLUTIONS
Back Light Adjustment

1. Starting at the single or four engine parameter display touch the Menu Button.
through the menu until the Adjust Backlight is highlighted.
3. Once the Adjust Backlight menu has been highlighted touch the Enter
Button to activate the Adjust Backlight function.
4. Use the Arrow Buttons to select the desired backlight intensity.
6. Touch the Menu Button to exit the main menu and return to the engine
parameter display.
Contrast Adjustment
through the menu until Adjust Contrast is highlighted.
3. Once the Adjust Contrast menu has been highlighted touch the Enter Button
to activate the Adjust Contrast function.
4. Use the Arrow Buttons to select the desired contrast intensity.
parameter display.
Select Units
through the menu until Select Units is highlighted.
3. Once the Select Units menu has been highlighted touch the Enter Button to
access the Select Units function.
DRILLING SOLUTIONS
7-43
4. Use the arrows to highlight desired units. English for Imperial units i.e. PSI, F
or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, C.
5. Touch the Enter Button to select the highlighted units.

parameter display.
Setup 1-Up Display

1. Starting at the single engine parameter display, touch the Menu Button.
through the menu until Setup 1-Up Display is highlighted.
3. Once the Setup 1-Up Display menu item has been highlighted touch the
Enter Button to access the Setup 1-Up Display function.
4. Three options are available for modification of the 1-Up display.
a. Use Defaults - This option contains a set of engine parameters: Engine
Hours, Engine RPM, System Voltage, Battery Voltage, %Engine Load at
Current RPM, Coolant Temp., Oil Pressure.
b. Custom Setup - This option allows for the modification of what parameter,
the number of parameters, and the order in which the parameters are being
displayed.
c. Automatic Scan - Selecting the scan function will cause the 1-Up Display
to scroll through the selected set of parameters one at a time, momentarily
pausing at each.
5. Use Defaults - To select Use Defaults use the arrow buttons to scroll to and
highlight Use Defaults in the menu display.
6. Touch the Enter Button to activate the Use Defaults function.
7. A message indicating the Single Engine parameter display parameters are
reset to the factory defaults will be displayed, then the display will return to the
Custom Setup menu.
8. Custom Setup - To perform a custom setup of the 1-Up Display, use the arrow
buttons to scroll to and highlight Custom Setup on the display.
7-44
DRILLING SOLUTIONS
9. Touching the Enter Button will display a list of engine parameters.

10. Use the Arrow Buttons to scroll to and highlight a selected parameter
(parameter with a # symbol to the right of it).
11. Touch the Enter Button to deselect the selected parameter, removing it from
the list of parameters being displayed on the 1-Up display.
12. Use the Arrow Buttons to scroll and highlight the desired parameter that has
not been selected for display.
13. Touch the Enter Button to select the highlighted parameter for inclusion in the
Single Engine Parameter Display.
14. Continue to scroll and select additional parameters for the custom 1-Up
Display. Touch the Menu Button at any time to return to the Custom Setup
menu.
15. Automatic Scan - Selecting scan function will cause the 1-Up Display to scroll
through the selected set of parameters one at a time. Use the Arrow Buttons
to scroll to the Automatic Scan function.
16. Touching the Enter Button toggles the Automatic Scan function on.
17. Touching the Enter Button again toggles the Automatic Scan function off.
18. Once the Use Defaults, Custom Setup and Automatic Scan functions have
been set, touch the Menu Button to return to the main menu.
19. Touch the Menu Button to exit the main menu and return to engine parameter
display.
Setup 4-Up Display

1. From the single or four engine parameter display touch the Menu Button.
through the menu until Setup 4-Up Display is highlighted.
3. Once the Setup 4-Up Display menu item has been highlighted touch the
Enter Button to activate the Setup 4-Up Display menu.
4. Touch the Enter Button to deactivate the Use Defaults function. This action
will reset the unit to the factory default.
5. Use Defaults screen will be displayed during the resetting period then will
automatically return to the Setup 4-Up Display menu.
6. Select the 4-Up Custom Setup from the 4-Up Setup menu.
7. The quadrant with the backlit parameter value is the current selected
parameter. Use the Arrow Buttons to highlight the parameter value in the
quadrant you wish to place a new parameter.
8. Touch the Enter Button and a list of parameters will appear.
9. The quadrant that is highlighted is the selected parameter for the screen. Use
the Arrow Buttons to highlight the new parameter to be placed in the quadrant
DRILLING SOLUTIONS
7-45
that was selected in the previous screen. Note: The number to the right of the
parameter indicates the quadrant in which it is displayed (1 = Upper Left
Quadrant, 2 = Lower Left Quadrant, 3 = Upper Right Quadrant, 4 = Lower Right
Quadrant).
10. Touch the Enter Button to change the selected parameter in the quadrant to
the new parameter.
11. Use the Menu Button to return to the 4-Up Custom Setup screen.
12. The parameter in the selected quadrant has changed to the parameter that was
selected in the previous screen.
13. Repeat the parameter selection process until all spaces are filled.
15. Touch the Menu Button to exit the main menu and return to engine parameter
display.
Utilities (Information and Troubleshooting)

1. Starting at the single or four engine parameter display, touch the Menu
Button.
2. The main menu will be displayed. Use the Arrow Buttons to scroll through the
menu until the Utilities is highlighted.
3. Once the Utilities menu item has been highlighted touch the Enter Button to
activate the Utilities functions.
4. Touch Select to enter Gage Data display.When Gage Data is selected the
PowerView will communicate with the analog gages at a fixed rate of 38.4 k
Baud, 8 data bits, no parity check, 1 stop bits, half duplex.
5. Use the Arrow Buttons to scroll through the items or touch Menu to return to
the Utilities menu.
6. Touch the Menu Button to return to the Utilities menu.
7. Use the Arrows to highlight Remove All Gages. Touch Select to clear gage
data from memory. It takes a moment to clear all gages.
8. When the gage data has cleared, the display automatically returns to the
Utilities menu. Scroll to Software Version. Touch Select to view the
software version currently in the PowerView.
9. Touch Menu to return to Utilities. Highlight Fault Conversion using the
Arrows. Touch Select to enter the Fault conversion menu.
10. Use the Arrows to scroll and highlight the version, then touch Select and an
asterisk appears to the right of the selection.
Note: There are four (4) different methods for converting fault codes. The
PowerView always looks for J1939 Version 4 and can be set to use one of the
3 other J1939 versions. Most engine ECUs use Version 4, therefore in most
cases adjustment of this menu option will not be required.
7-46
DRILLING SOLUTIONS
Upon receiving an unrecognizable fault, change to a different J1939 Version. If the

fault SPN does not change when the version is changed, the ECU generating
the fault is using Fault Conversion method 4. If the SPN number does change
but is still unrecognizable, try changing to another J1939 Version not yet used
and continue to check the SPN number.
11. Touch the Menu button to return to Utilities menu. Touch the Menu button
again to return to the Main menu.
MODBUS Setup
1. Starting at the single or four engine parameter display, touch the Menu
Button.
2. The main menu will be displayed. Use the Arrow Buttons to scroll through the
menu until the Utilities is highlighted, then touch Enter.
3. Once in the Utilities menu use the Arrows to scroll through the menu until
the Modbus Setup menu is highlighted, then touch Enter.
4. Use the Arrows to scroll down to and highlight either the Slave Active or
Master Active modes. Touch the Enter button to toggle between master and
slave.
5. Use the Arrows to scroll to the Serial Port menu to highlight it, then touch
Enter.
6. Use the Arrows button to scroll to each selection to configure the MODBUS
values for your application.
7. When finished, touch Menu to return to the previous screen.
J1939 Parameters
DRILLING SOLUTIONS
7-47
Glossary
CANBUS FAILURE
PowerView has not received any CAN messages for at least 30 seconds.
7-48
DRILLING SOLUTIONS
NO DATA
PowerView has not received the particular message being displayed for at least 5 seconds.
NOT SUPPORTED
PowerView has received a message from the ECU stating the displayed message is not
supported.
DATA ERROR
PowerView has received an error message from the ECU for the displayed message.
EMPTY
No parameter selected for this 4-UP quadrant.
WAIT TO START PREHEATING
This is a message from the engine indicating it is in a preheating cycle. Wait until this message
clears before starting the engine.
TIMEOUT ECU NOT RESPONDING
The ECU did not respond to the PowerView request.
NO GAGE DATA
The PowerView has no record of connected gages to the RS485 bus.
Electric Ladder
The electric ladder schematic is a logical way to show how the current flows in the various
parts of the electrical circuits on a drill. The schematic is broken into seven (7) parts that are
different and serve different purposes.
The first part is the Power Supply. These are the Batteries that supply all the power to the
system. They are indicated by the two battery symbols.
The second part is the Fusible Link that protects against massive short circuit and fire. It is
always located in the main wiring just beyond the batteries. It is located beyond the batteries
and between the alternator and the batteries so any high flow of electricity is prohibited or
DRILLING SOLUTIONS
7-49
stopped from getting to the batteries and causing a fire. Remember that electricity flows out of
the batteries but back from the alternator to the batteries. Fuse links are blue colored and are
9 inches (23 cm) long. They have a ring connector on one end and use a wire nut to connect
to the main hot wire.
The third part is the Key Switch and the Circuit Breakers that protect each separate circuit and
control the power to the whole system.
The fourth part is the Main Power wire or Wires. These are the positive or plus (+) wires that
carry the current to each area. They are usually larger in size than the others so they can carry
more current without getting hot.
The fifth part is the Switch or Controller that allows current or disconnects it from the operating
system. These may be push button switches or remotely controlled switches that cause a
change in the system.
The sixth part is the actual Solenoid, Relay, Light or other device that is activated by supplying
power to it or removing power from it.
The last part is the Return or Ground Wire that makes a complete circuit and allows the system
to be a system. These wires dont always seem significant but without a good ground wire the
system will not function.
7-50
DRILLING SOLUTIONS
Remember that all power flows from the batteries to the main power line, usually through the
ammeter. You will notice several diodes in the circuits. The symbol is an arrow with a bar
across the end. These act the same as check valves in a hydraulic circuit. They allow current
to flow in one direction but not backwards.
24 volt battery power means that both 12 volt batteries add together to produce 24 volts.
Batteries in series produce whatever their voltages add up to. Thus, two 12 volt batteries will
produce 24 volts.
Electrical Symbols
* N O = Normally Open
** N C = Normally Closed
DRILLING SOLUTIONS
7-51
7-3 TROUBLESHOOTING (OPERATOR OBSERVED)

Troubleshooting (Operator Observed Problems)
Operator Observed Problems
During operations, the operator may observe some problems which may be defined in the
following Operator Observed Problems Trouble Shooting Chart.
The trouble shooting chart is limited to machine control operational problems which will guide
the operator to rectify the cause of the failure.
7-52
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-53
7-4.1 LOW PRESSURE COMPRESSOR
WARNING

drill.
GENERAL INFORMATION
overturning.
crushing risk.
7-54
DRILLING SOLUTIONS
Pneumatic System Information

All PV-270 Series drill air compressors are of the oil flooded asymmetrical rotary screw design.
Tapered roller bearings are used to handle thrust and radial loads.
Standard equipment for the air compressor includes a separate three stage inlet air cleaner
and full instrumentation and controls. The lubrication system includes an oil cooler, bypass
valve, oil filter, oil pump, and combination receiver and oil separator tank. A safety shutdown
system is also provided for high discharge air temperature.
Low Pressure compressors are those with discharge pressures of 100 to 150 psi. A
compressor is considered high pressure if the discharge pressure is 250 psi or greater. All
High Pressure compressors have discharge pressures of 350 psi. See Low Pressure
Compressor or High Pressure Compressor sections for specific detailed information.
There are three systems on a rotary screw compressor:
1. Lubrication System
2. Separation System
3. Regulation System
Each system is critical to the operation of the air end and the systems are all interrelated.
These systems will be described further in the appropriate areas of Low Pressure Compressor
or High Pressure Compressor sections

A fiber gasket is installed between the outside cover of the receiver and the metal tube holding
the separator element in place. This gasket prevents oil from leaking around the metal tube
and down the hole.
hose and will follow the air flow until it burns through the air hose.
To prevent this from happening, several metal staples have been installed THROUGH the
gasket so each side comes in contact with the metal. This bridge serves to allow the static
charge to drain off outside the receiver tank and not cause a static buildup.
CAUTION
When replacing the separator element, be sure there is at least one staple
glue.
DRILLING SOLUTIONS
7-55
Lubrication System
Low Pressure compressors are those with discharge pressures of 100 to 150 psi. These
compressors are of the single stage, oil flooded, asymmetrical screw design. They are listed
by the metric diameter of the rotors. The low pressure drills use a 285 mm air end.
The Lubrication System consists of the receiver, an oil pump, cooler, mixing valve, filters and
a manifold. When the compressor is compressing air, a minimum pressure valve in the
discharge line holds a certain pressure in the receiver tank to assist in pushing the oil through
the system. The minimum pressure valve is set at 65 psi.
Lubrication System Components

Receiver - Separator Tank
7-56
DRILLING SOLUTIONS
The receiver tank contains the compressed air and the lubricating oil for the compressor. The
oil is removed from the air by centrifugal force, gravity and velocity. The receiver tank has an
oil sight glass that shows the oil level at all times. The proper oil level is when the sight glass
shows 1/2 full while the drill is running.
Oil Pump
The oil pump is a gear type pump, driven from the rear of one of the compressor rotors. It
operates as long as the compressor is turning. It is speed sensitive and pumps at rated volume
when the compressor is at full RPM. The oil pump acts as a normal pump when the oil is cold
and becomes a restriction to hold back pressure on the receiver tank when the compressor is
operating at normal pressure and temperature. This prevents all the oil from being forced out
of the receiver tank at once and flooding the compressor rotors. There is no shaft seal in this
pump since it is being lubricated by the same oil it is pumping.
Strainer
A 40 mesh, 150 micron strainer is mounted just before the inlet to the oil pump. It protects the
pump and catches any foreign debris such as hose pieces and parts of the thermostat that
could damage the pump. The metal strainer should be removed, cleaned and reinstalled every
500 hours.
Temperature Bypass Valve

The Temperature Bypass Valve, also called a Mixing Valve or Amot Valve, contains a
thermostat that regulates oil flow between port B and port C. Cold weather causes the
thermostat to close, shutting off flow from C to A, and forcing all oil to pass from B to A.
As the oil temperature rises, the thermostat starts to open, allowing some oil from C to pass
through A.When the operating temperature is reached, the thermostat closes off the flow
through B and forces all oil through C. The temperature range of the thermostat is 140F
(60C) and 160F (71C).
DRILLING SOLUTIONS
7-57
Oil Cooler
The Compressor Oil Cooler is a single pass unit. Hot oil enters from the bottom of the cooler
and cool oil exits out the top. This prevents any air bubbles that may have been carried along
with the oil from being trapped in the top and creating a vapor barrier.
The cooler package is made up of four sections. The larger section is the compressor oil cooler
and the other sections are the hydraulic oil cooler, radiator and engine charge air cooler
(Cummins engines). Also included is the air conditioner cooler core when required).
Relief Valve
A 65 psi relief valve, which replaces the 50 psi relief valve and 75 psi relief valve, is connected
between the inlet and outlet of the oil cooler.
7-58
DRILLING SOLUTIONS
If the cooler becomes plugged and the inlet pressure becomes 65 psi higher than the outlet
pressure, the relief valve opens and allows oil to bypass the cooler. When the differential
pressure is reduced below 65 psi, the valve will close and normal flow resumes. The 65 psi
relief valve allows the oil cooler system to function properly.
Oil Filter
A 10 micron filter is installed at the outlet of the cooler before the oil reaches the compressor.
It catches any contaminants that may have been picked up in the circuit and prevents them
from plugging the orifices at the inlets to the bearings.
Discharge Check Valve

The Discharge Check Valve serves one purpose for two mediums: air and oil. It prevents air
and oil, under pressure, from backing up into the air end. When the drill is stopped, pressure
in the compressor drops to zero. There is still pressure in the receiver tank until it completely
blows down. If the check valve was not there, air pressure would force air and oil back through
the compressor housing and out the inlet valve, thus flooding the air cleaners.
DRILLING SOLUTIONS
7-59
The valve being held open, It has a single spring. The hinge must be mounted on top to
prevent the valve from staying open when the drill is shut down. Notice the white nylon ring
that forms a tight seal to prevent back flow when the drill is stopped.
Compressor Oil
The pressure and heat created in these air ends requires a special oil. This oil is not
compatible with certain types of O-rings. Therefore, we use Viton type O-rings in the air end
fittings and filters. The oil is also not compatible with other oils and should never be mixed with
other oil. For low pressure (XL) compressors, use PROTEC oil only. Be sure to change the
filters every 500 hours.
Oil Flow
The layout for the lubrication system is shown below in. Oil is stored in the receiver tank. At
startup, the oil pump must pull the oil from the receiver tank. When air pressure rises in the
receiver, oil is pushed by air pressure from the receiver tank to the oil pump. The pump then
moves the oil to the temperature bypass valve and/or the cooler. Depending on the oil
temperature, it either flows through the temperature bypass valve, to the oil filter and into the
compressor oil manifold or through the oil cooler and then to the temperature bypass valve, to
the oil filter and to the compressor oil manifold.
From the compressor manifold, oil passes into the air end. Oil is pumped to each bearing and
rotor and into the cavity of the air end to mix with the air being compressed. This controls the
temperature of the discharge air. When the air has been compressed, the oil/air mixture
passes into the receiver tank to be separated.
7-60
DRILLING SOLUTIONS
Separation System
Lubricating oil is forced through the air end to cool, seal and lubricate the rotors. When the
oil is pumped into the receiver-separator tank, it must be separated from the air going down
the hole. This is accomplished in three steps.
1. The air/oil mixture enters the receiver through the inlet pipe and splashes
against the inner walls. This forces the majority of oil to fall to the bottom of the
tank and remain there.
DRILLING SOLUTIONS
7-61
2. When the down stream air line is opened and air flows down the hole, some of
the oil that remains is carried along with it into the filter area. A metal canister
prevents oil from flowing through the filter directly. The air/oil mixture enters the
outer edge of the element and then moves towards the center. As the oil travels
through the element, it is slowed down by friction and gravity pulls it downward.
Most of the oil drops out the bottom of the element and falls into the reservoir.
3. The final step in the separation process is removing any remaining oil from the
element so it is not carried over into the down hole air stream. When enough
excess oil is carried into the center of the element, a series of holes in the end
of the filter element allow the oil to fill an area between the flange and the
element. The scavenger line is connected between the flange and the inlet of
the compressor. Since there is a differential pressure between the receiver tank
and the low pressure area of the compressor, oil and air are forced through the
scavenger line into the inlet area of the air end, thus removing the last of the oil
carryover. A 0.94 orifice in the line prevents excessive amounts of air loss.
It is important to note when changing separator elements that the element be

installed correctly. The word TOP should always be on top to insure that the
drain holes are at the bottom. This prevents excessive buildup in the scavenger
area.
7-62
DRILLING SOLUTIONS
Another item to watch when changing elements is to be sure that the staples in
the gaskets are left there to prevent a static electric charge from building up and
causing a fire.
Service Hint
When oil carryover is encountered, first check the orifice in the scavenge line for blockage
before condemning the separator element. A blocked scavenge line will prevent oil from being
drained, causing carryover. Replacing an element when the orifice is blocked will not solve the
problem.
Regulation System
The regulation system controls the pressure and volume of the air going down the hole to the
bit.
The butterfly valve (also called the inlet valve) is manually opened and closed by a handle in
the operators control console in the cab. Normal drilling is performed when the operator
pushes the handle away to open the inlet valve while the engine is at full RPM. This allows air
into the compressor inlet and it is compressed as it goes through the air end. The compressed
air is forced into the receiver tank and as long as the pressure is greater than 65 psi, air will
flow to the bit through the standpipe. A minimum pressure valve is mounted between the
receiver tank and the standpipe to insure there is always 65 psi in the tank. This pressure
forces oil into the oil pump to insure a positive flow to the lubrication system at all times.
DRILLING SOLUTIONS
7-63
A discharge check valve is located at the discharge of the air end to prevent any pressure from
returning to the air end when the drill is stopped. While the drill is running, there is a flow of oil
being pumped into the air end whether air is being compressed or not. This oil is forced out of
the air end into the receiver tank through the check valve. There is a scavenger line connected
from the base of the separator element to the inlet area on the air end. This line removes the
excess oil from the element and returns it to the air end. Refer to the previous SEPARATION
SYSTEM section for more information.
Regulation System Components

The 285 mm air end regulation system has one manual control to open and close the inlet
valve and several other automatic devices to operate the system.
Inlet Butterfly Valve
The inlet butterfly valve is an 8 round, wafer valve that sits on top of the compressor. It has a
shaft that is connected to the center of the valve. This is where the linkage for the control cable
and the air cylinder are attached.
There is a 3/8 orifice drilled in the inlet butterfly valve to allow outside air to enter the
compressor at all times. This opening allows enough air into the compressor to provide
pressure to the auxiliary functions such as the air pulse on the dust collector and to allow for
the airend to ingest enough air to charge the receiver tank. At startup, the inlet is closed. The
hole in the valve allows air to enter, limiting the rotor rumble until sufficient air is made to re-
7-64
DRILLING SOLUTIONS
circulate. The re-circulation of tank air greatly reduces the amount taken in through the
butterfly hole. This air mixes with the oil being pumped into the airend, providing a
compressible mixture, preventing excessive vacuum and preventing rotor rumble.
The butterfly valve is manually controlled. There is a lever on the operators panel that is
connected to the inlet (butterfly) valve by a cable. When ready to begin drilling, push forward
on the lever to open the compressor inlet. There is an air cylinder at the compressor inlet as
part of the automatic unloading circuit. The cylinder has an internal spring that assists in
opening the inlet when the lever is pushed forward.
When the inlet valve is opened, air is drawn into the compressor by the rotary motion of the
rotors. It is compressed and directed to the receiver tank where it is stored for use in drilling or
auxiliary functions.
The discharge check valve is located at the outlet of the compressor and prevents any oil or
air, under pressure, from backing up into the compressor housing. While the compressor is
running, oil and air are being forced out of the compressor housing and this keeps the
discharge check valve open. When the compressor is stopped nothing is coming from the
compressor side, but pressure is built up in the receiver. This would pressurize the compressor
housing if the discharge check valve were not there. The valve being held open, It has a single
spring. The hinge must be mounted on top to prevent the valve from staying open when the
drill is shut down. Notice the white nylon ring that forms a tight seal to prevent back flow when
the drill is stopped.
Blowdown Valve
When the drill is stopped, there is air under pressure trapped in the receiver tank. This air must
be exhausted before the drill is started again. An automatic blowdown valve is connected to
the receiver tank to relieve the pressure in the tank. As long as the compressor is running, pilot
pressure from the discharge end of the compressor prevents the valve from opening. When
the compressor is stopped, there is no pilot pressure available to keep the valve closed, and
the spring pressure opens the valve and allows tank air pressure to escape.
On the outlet side of the valve is an orifice and a silencer. The silencer is there to muffle the
noise of the escaping air. The orifice is there to provide back pressure to pilot the exhaust valve
closed.
DRILLING SOLUTIONS
7-65
Receiver Tank
The receiver tank serves several purposes. It contains the lubricating oil that is used to cool
and lubricate the compressor. It serves as a reservoir for the compressed air. Also, the
separator element helps to separate the oil from the air.
7-66
DRILLING SOLUTIONS
Minimum Pressure Valve
Located at the tank outlet is a 65 psi minimum pressure relief valve. This valve is used to
maintain a constant minimum air pressure within the tank. The purpose of the air pressure is
to assist oil to flow through the cooler and to the pump in cold weather. The air pressure is also
used to power various pneumatically operated systems such as the dust collector, Lincoln
Lube system and automatic thread lubricator.
Safety Relief Valve

All drills are equipped with safety valves. The setting on these valves is 25-50 psi higher than
the maximum working pressure. The only function of a safety valve is to prevent damage to
the receiver tank in case of other failures. It should never be used as a high pressure relief
valve for two reasons. One, the pressure setting is above the allowable working pressure of
the compressor. Two, the safety valve loses a small amount of spring tension every time it is
opened. Therefore, the pop off pressure will be reduced each time it is opened and will shortly
open below the normal operating pressure and will have to be replaced.
Automatic Inlet Unloading

In the event of a clogged bit or blocked drill pipe, the regulation system has an automatic
unloading circuit. This system is designed to shut the inlet valve at a predetermined receiver
tank pressure limit. Attached to the receiver tank air manifold is a 100 psi check valve, also
called a cigar valve. When tank pressure reaches 100 psi, air passes over the check valve and
into the air cylinder connected to the inlet valve linkage. At 110 psi, air pressure in the cylinder
overcomes the internal spring and extends the cylinder, closing the inlet.
DRILLING SOLUTIONS
7-67
Anti-rumble System
Rumble of the rotors within an airend is very detrimental to its life expectancy. If left
uncorrected, rumble will cause severe damage to the airend in a short while. Rumble is
defined as high frequency loading and unloading of the rotors of a compressor due to lack of
compressive material within the airend. To address this condition, an anti-rumble system has
been designed to eliminate it. The components of the anti-rumble system are:
1. Butterfly Valve with Hole.
2. Adjustable Electric Vacuum Switch
3. Vacuum Gauge
4. Anti-Rumble Valve
5. Hoses
An air re-circulation (anti-rumble) system has been developed to prevent rotor rumble. This
gives the rotors an air/oil mixture to compress when the inlet valve is closed.
7-68
DRILLING SOLUTIONS
The design of the compressor requires limited inlet vacuum. The maximum desired vacuum
must be limited to no more than 24 inches (610mm) of mercury at any time. When the inlet is
closed, the rotors are capable of pulling vacuum well above this figure. To limit the inlet
vacuum, the anti-rumble system takes air from the receiver tank and injects it into the inlet
housing. See schematic representation of the anti-rumble system.
Butterfly Valve
As stated earlier, the butterfly valve is an 8 wafer type valve that is manually operated by a
cable from the operators panel. The wafer has a 3/8 hole drilled in it to allow for the airend to
ingest enough air to charge the receiver tank. At start up, the inlet is closed. The hole in the
valve allows air to enter, limiting the rotor rumble until sufficient air is made to re-circulate. The
re-circulation of tank air greatly reduces the amount taken in through the butterfly hole. This
air mixes with the oil being pumped into the airend, providing a compressible mixture,
preventing excessive vacuum and preventing rotor rumble.
Electric Switch (Vacuum Actuated)

There is an electrical vacuum switch connected by a hose to the inlet housing. The switch is
adjusted to actuate its contacts when inlet vacuum reaches 15 Hg. The switch is used to
energize / de-energize the anti-rumble valve coil. Energizing the coil closes the normally open
anti-rumble valve. When vacuum falls below 15 Hg. under the inlet valve, the switch energizes
the coil, closing the anti-rumble valve. In other words, when the inlet is open the anti-rumble
valve is closed (coil energized). When inlet is closed the anti-rumble valve should be open
(Coil de-energized).
Typical adjustment of the vacuum switch is done as follows:
1. Holding the hex, turn the black portion of the switch clockwise. Screw it all the
way in.
2. Once it stops turning, back it out four (4) complete revolutions. This setting is
typically 15 Hg. to actuate the switch. The switch can be wired normally closed
or open. Vacuum actuates the contacts causing them to change state.
When the anti-rumble valve is open, it allows tank air to re-circulate to the airend inlet through
the -12 hose.
DRILLING SOLUTIONS
7-69
When excessive air is seen out the drill bit, it is a good indication that the vacuum switch is
inoperative. Failure of the vacuum switch usually results in loss of re-circulation. When this
happens, the tank pressure rises above 65 psi and excess air escapes over the minimum
pressure valve.
The installation of the vacuum switch and gauge inside a sealed electrical enclosure box. The
box is located on the side of the power pack base.
The vacuum gauge reading should be monitored periodically to insure the vacuum never
exceeds 24 Hg. Adjust the switch as required to maintain proper anti-rumble efficiency.
Anti-Rumble Valve
The anti rumble valve is a solenoid operated, normally open two way valve. It has a solenoid
coil on top that is used to power the valve closed against spring pressure. If the coil fails to
open, the two way valve will not close. Large amounts of air volume will be lost and poor hole
cleaning will result.
If the valve fails to open when the inlet is closed, the compressor will continue to pull air in
through the hole in the butterfly. This air will blow out the bit continually.
Compressor Related Problems

local Drilling Solutions service office.
7-70
DRILLING SOLUTIONS
7-4.2 LOW PRESSURE COMPRESSOR WITH EARS
WARNING

drill.
General Information
overturning.
crushing risk.
DRILLING SOLUTIONS
7-71

Low Pressure compressors are those with discharge pressures of 100 to 150 psi. A
compressor is considered high pressure if the discharge pressure is 250 psi or greater. All
High Pressure compressors have discharge pressures of 350 psi. See Low Pressure
Compressor or High Pressure Compressor sections for specific detailed information.
Electronic Air Regulation System (EARS)

1.1 Introduction
The following information is general for all Atlas Copco Drilling Solutions drills using Electronic
Air Regulation. Due to differences in drill models, there will be differences in electronic air
regulation components used. As an example, a TH60 model drill utilizes a single truck engine
and therefore would use a shaft speed sensor and an engagement sensor not used on other
drill models. Also, an engine oil pressure switch is required for some installations that do not
have J1939 equipped engines.
This information contains instructions for several Electronic Air Regulator systems used on
7-72
DRILLING SOLUTIONS
Atlas Copco Drilling Solutions drills. Therefore, you must refer to the parts book specific to your
drill for parts and schematics specific to your drill.
The Electronic Air Regulation System consists of fourteen general components. Some of the
components are only required on some of the applications.
1.2 Components
1. Flow sensor
2. Proportional Butterfly Valve and Actuator on the compressor inlet
3. Pressure Sensor on the receiver tank
4. Proportional Vent Valve and Actuator on the receiver tank
5. Electronic Controller
6. Flow Control Knob
7. Maximum Pressure control Knob
8. Compressor ON/OFF Switch
9. Diagnostic Light
10. Hardware Interface Board
a. Power Control Relay
b. Diagnostics Port
c. Fuse
d. Sensor Power Conditioning Circuits
e. Electrical Noise Suppression Circuits
11. Interconnect System
12. Oil Pressure Switch (Required on some installations)
13. Shaft Speed Sensor (Required on some installations)
14. Engagement Sensor (Required on some installations)
DRILLING SOLUTIONS
7-73
1.2.1 Flow Sensor
The Flow Sensor detects the volume of air the compressor is producing and sends this
information to the electronic controller. This sensor is actually a vacuum sensor.
1.2.2 Proportional Butterfly Valve and Actuator
The Proportional Butterfly Valve and Actuator are controlled by the electronic controller and
regulates the air flow into the compressor from fully closed (no air enters the compressor) to
fully open. It includes a visual position indicator. The indicator will be horizontal when the valve
is closed and vertical when the valve is full open.
7-74
DRILLING SOLUTIONS
1.2.3 Pressure Sensor
The Pressure Sensor detects the pressure in the receiver tank and sends this information to
the electronic controller.
1.2.4 Proportional Vent Valve and Actuator
The Proportional Vent Valve and Actuator are controlled by the electronic controller and can
release air from the receiver tank. The air is vented to atmosphere through an air silencer. The
proportional vent valve w a s previously called the blowdown valve. The indicator will be
horizontal when the valve is closed and vertical when the valve is full open.
DRILLING SOLUTIONS
7-75
1.2.5 Electronic Controller
The Electronic Controller monitors the flow and pressure inputs, operator inputs and engine
data. It controls the actuators so that compressor outputs the flow or pressure requested. It
also detects several fault conditions and alerts the operator by flashing an error code with the
diagnostic light. The controller is initially powered up with the key switch but then latches its
power on so that it can perform a shutdown sequence after the key switch is shut off.
1.2.6 Controls Located on Console

Flow Control Knob
The Flow Control Knob is a variable electronic input into the electronic controller. When the
compressor On/Off switch is on it adjusts the flow into the compressor between the minimum
flow (required to prevent damage to the compressor) and maximum flow (full open on the
butterfly valve).
Maximum Pressure Control Knob
The Maximum Pressure Control Knob is a variable electronic input into the electronic
controller. When the compressor On/Off switch is on it adjusts the maximum pressure in the
receiver tank between the minimum holding tank pressure and the maximum working pressure
of the compressor system.
7-76
DRILLING SOLUTIONS
Compressor On/Off Switch

The Compressor On/Off Switch is used to select the source of the flow and maximum pressure
commands. When the switch is On, the Flow Control Knob and Maximum Pressure Control
Knob are active and control the compressor. When the switch is Off, the Flow Control is set to
the minimum flow required to prevent damage to the compressor and the Maximum Pressure
Control pressure is set to the minimum holding tank pressure (setting the switch to Off has the
same effect as setting the flow and pressure knobs to the minimum positions).
Diagnostic Light
The Diagnostic Light (RED) is normally off but will blink out an error code if the controller
detects an error (See Error Code Indications and Priorities section). If this light is blinking, turn
off the engine.
DRILLING SOLUTIONS
7-77
1.2.7 Hardware Interface Board
The hardware interface board is a DIN rail mounted circuit board with terminal strips down
each side. It is not intended for exposure to wash down. This board contains circuits to perform
the following functions.
1. The Power Control Relay allows the electronic controller to latch on the supply
voltage to the EAR system. This allows the system to complete the receiver
tank bleed down after the key switch has been turned off.
2. The Diagnostic Port allows a lap top computer equipped with the correct
software to monitor the system via a USB port.
3. The Fuse protects the system in the event of a wiring short.
4. Sensor Power Conditioning Circuits provide correctly regulated power to the
sensors and operator inputs.
5. Electrical Noise Suppression Circuits prevent electrical noise from being
generated by the electric motors in the valve actuators.
7-78
DRILLING SOLUTIONS
1.2.8 Interconnect System
The Interconnect System includes harness split out boxes and cables sets that connect the
various components. Several variations of the Interconnect system are required to
accommodate the wide range of drills the system can be installed on.
1.2.9 Oil Pressure Switch

An Engine Oil Pressure Switch is required for some installations that do not have J1939
equipped engines. This switch should close when a hot engine is turning 75% of the idle
speed.
1.2.10 Shaft Speed Sensor

A Shaft Speed Sensor is required for some installations. It is used to determine the speed of
a shaft associated with compressor rotation. It can be used to determine the speed of the
compressor or to check for correct transmission gear selection.
1.2.11 Engagement Sensor

Engagement Sensors are used on some installations to detect if various compressor drive line
components are engaged.
DRILLING SOLUTIONS
7-79
1.3 Operation
1.3.1 Startup Operation
engine speed reaches the minimum RPM there is a factory set delay time to allow the engine
to stabilize after which the controller regulates the compressor.
1.3.2 Shut Down Operation

When the controller detects the key has turned off and the engine is stopping, it closes the
butterfly valve and bleeds down the pressure in the receiver tank through the vent valve.
Because the system is ramping down the pressure in the receiver normal system air leaks will
usually allow the pressure to drop fast enough during the early stages of the blow down without
the controller needing to open the vent valve. This results in what appears to be a delay in
venting the tank. However, the pressure is dropping at the correct rate during this time.
1.3.3 Flow Regulation

The controller is always regulating the flow into the compressor. If more flow is called for than
the compressor can make under the conditions, the butterfly valve is opened all the way. There
are three sources for the amount of flow that is called for:
1. The flow control knob (direct control).
2. The compressor On/Off switch (calls for minimum flow).
3. The controllers maximum pressure regulation system. When the maximum
pressure commanded by the maximum pressure knob is reached, the
controller overrides the flow knob command and reduces the commanded flow
to lower the pressure in the receiver.
1.3.4 Maximum Pressure Regulation

The Controller has two methods to control the maximum pressure in the receiver:
1. Override the Flow Knob and lower the commanded flow into the compressor.
2. Open the vent valve to let air out of the receiver tank.
Method 1: When the maximum pressure commanded by the maximum pressure knob is
reached, the controller enters the pressure control mode, overrides the flow knob command
and reduces the commanded flow to lower the pressure in the receiver. The controller then
regulates the flow up and down to maintain the maximum pressure but will not command more
flow than is called for by the flow control knob. If the pressure drops to a level where the
commanded flow would be more than commanded by the flow knob, the controller exits the
pressure control mode and returns control to the flow knob.
Method 2: The controller is constantly attempting to regulate the receiver tank pressure using
7-80
DRILLING SOLUTIONS
a command that is 20 PSI (1.38 bar) above the maximum pressure knob command. If the
pressure is below the command, the vent valve is moved in the close direction. If the pressure
is above the command, the vent valve is moved in the open (vent) direction. For most
conditions, the pressure is below the command and results in the vent being closed. It is the
vent valve regulation system that controls the pressure when the compressor On/Off switch is
in the Off position.
1.3.5 Emergency Venting

If the maximum system pressure is exceeded, the controller commands the butterfly valve
closed and opens the vent valve. This allows quick system reaction to over pressure spikes.
1.3.6 Compressor Turning

In order to control the compressor correctly, the system needs to know if the compressor is
actually turning and more importantly if it is in the process of shutting down. On directly
coupled drills, this is accomplished by monitoring the key switch and the J1939 engine bus.
For other non direct configurations and for drills without a J1939 bus, the system can be
configured to use two additional inputs to make the determination. The first additional input is
a frequency reading input designed to receive a shaft speed from a magnetic or other type
pickup. The second is an On/Off type input that can be configured to function as an engine
speed at minimum indicator, or an indication a compressor drive chain component is engaged.
1.3.7 Gear Selection Error Detection

On drill configurations that utilize a single truck engine, the system is capable of monitoring
the engine speed and the transmission tail shaft speed to determine if the operator has
selected the correct gear for PTO operation.
1.3.8 Temperature Regulation

The temperature regulation is set up to monitor various system temperatures and adjust the
cooling fan speed to prevent any of the four temperatures from exceeding their individual set
points. The four temperatures being monitored are as follows:
1. Engine Coolant
2. Hydraulic Oil Cooler
3. Compressor Oil Cooler
4. Charge Air Manifold
SECTION-2 Flow Chart

EAR-EFR Diagnostics
This quick find diagnostic procedure is primarily designed as a guide for diagnosing Electronic
Air and Fan regulation system problems on a machine that was working and has failed in the
DRILLING SOLUTIONS
7-81
field. It could lead to an incorrect diagnosis if the machine is incorrectly wired or assembled.
The procedure is structured as a set of questions that lead the tester through a path that will
find the problem in the minimum number of steps.
The questions are designed to be answered in sequence. Skipping a question will always lead
to an incorrect diagnoses.
These questions are designed to avoid rotating the compressor and engine where possible.
Things to remember:
Having two people a tester and a helper is strongly advised.
The following test can be preformed using a volt/ohm meter on the interface board terminal
strips, and observing the system behavior.
These tests are not intended to replace additional trouble shooting measures once the
problem is narrowed to a component or simple circuit.
The corrosion resistant coating on the interface board terminal strips can become oxidized and
interfere with meter readings. Make sure to use sharp tips and apply enough pressure and or
scraping action to get a good connection.
Note 1: The diagnostic lamp blinks 1 to 11 times with a pause at the end of the blink cycle.
The number of blinks is the error code
Note 2: The system outputs a two second blink immediately after it is powered up. This can
be checked by turning the key off for 6 seconds then back on.
Note 3: T Terminal.
7-82
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-83
7-84
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-85
7-86
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-87
7-88
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-89
7-90
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-91
7-92
DRILLING SOLUTIONS
3.1 Standard Test Conditions
EAR/EFR system is fully assembled with all connectors, actuators, and sensors
connected and tight. The system has a limited number of parts that can easily be
given a quick examination. This can save a lot of time.
The engine is not running
The engine ignition (Key Switch) is ON
Machines with the capability to select a drill mode should be pre-set to that mode
Machines that have an transfer case should have the box disengaged.
Receiver tank discharged
Compressor on/off switch set to off position
Flow or volume knob set to minimum (fully counter clockwise)
Maximum pressure knob set to minimum (fully counter clockwise)
The throttle valve should be open. (if equipped)
3.2 Error Code Meaning and Diagnostic Information

Table 1: Diagnostic Error Codes with Possible Faults
Listing of the diagnostic error codes along with the possible faults that could
cause the error
Code
1
Error Description
The vacuum sensor input has been below 1.05 Volts DC (2 PSIA )
and above 0.5 Volts DC (0 PSIA) for more than 30 seconds.
Possible non-rotating compressor causes include
Damaged vacuum sensor
Low vacuum sensor supply voltage
Partial short in vacuum sensor output signal wiring
Damage controller
Additional causes in a rotating compressor
The butterfly valve is not opening and the vacuum has remained
low for too long.
Interface board terminals for vacuum sensor
DRILLING SOLUTIONS
46 Vacuum Sensor Supply (20-30 Volts DC)
47 Vacuum Sensor Ground
7-93
cause the error
1
48 Vacuum Sensor Signal (Use section 3.7.3 to look up the

approximate voltage to expect for the current altitude of the
machine.)
The sensor supply voltage originates on the interface board it goes off the
interface board at terminals 46,49,71,69
2
The vacuum sensor input has been below 0.25 Volts DC Possible causes
include
Disconnected or damaged vacuum sensor wiring
Low Vacuum sensor wiring
Shorted Vacuum sensor wiring
Damaged controller

machine.)
3
The pressure sensor input has been below 0.25 Volts DC or Greater than
4.75 Volts
DC Possible causes include
Damaged pressure sensor
Disconnected or damaged pressure sensor wiring
Low pressure sensor supply voltage
Shorted Pressure sensor wiring
Damaged controller
Interface board terminals for pressure sensor
7-94
49 Pressure Sensor Supply (20-30 Volts DC)
50 Pressure Sensor Ground
51 Pressure Sensor Signal (0.48-0.51 Volts DC)
DRILLING SOLUTIONS
cause the error
3
The flow potentiometer input is below 0.25 Volts DC or Greater than 5.75
Volts DC
Possible causes include
Damaged flow potentiometer
Disconnected or damaged flow potentiometer wiring
Low flow potentiometer supply voltage
Shorted flow potentiometer wiring
Damaged controller
Interface board terminals for flow potentiometer
40 Flow Potentiometer Supply (4.6 Volts DC)
41 Flow Potentiometer Return (0.4 Volts DC)
42 Flow Potentiometer Signal (counter clockwise 0.4 Volts DC

clockwise 4.6 Volts DC)
Interface board terminals for the plus supply and ground used by the
Potentiometer circuits
7 Plus supply from the controller (5 Volts DC)
8 Ground from controller (ground)
The maximum-pressure potentiometer input is below 0.25 Volts DC or

Greater than 5.75 Volts DC Possible causes include
Damaged maximum-pressure potentiometer
Disconnected or damaged maximum-pressure potentiometer

wiring
Low maximum-pressure potentiometer supply voltage
Shorted maximum-pressure potentiometer wiring
Damaged controller
Interface board terminals for Max Pressure potentiometer
DRILLING SOLUTIONS
43 Max Pressure Pot Supply (4.6 Volts DC)
44 Max Pressure Pot Ground (0.4 Volts DC)
7-95
cause the error
5
45 Max Pressure Pot Signal (counter clockwise 0.4 Volts DC

The controller is not receiving the data from the engine. (J1939) Possible
causes include
Wiring problem in J1939 circuit
Damaged Power-view disrupting communications
Damaged Engine ECM
Damaged controller
Interface board terminals for J1939 Data from machine
34 Data Low (2-3 Volts DC)
35 Data High (2-3 Volts DC)
The regulated 5 volt supply the controller provides to the interface board is
below 4.8 Volts DC or above 5.2 Volts DC.
(This voltage should be measured from the ground on Pin 8 of the interface
board.) Possible causes include
Short on interface board or wiring between controller and interface

board
Damaged controller
Interface board terminals for the plus 5 volt supply and ground.
7 Plus supply from controller (5 Volts DC)
The Engine speed as reported by the J1939 data link and the Shaft speed
sensor do not agree when the drill mode is selected. Possible non-rotating
compressor causes include
7-96
Damaged controller
DRILLING SOLUTIONS
cause the error
8
Wiring shorted to Fan drive PWM output or some other device that
outputs a modulated voltage.
The tail shaft is not turning at the correct speed for the reported
engine speed. Possible causes include
1. A transmission or other drive line component is in the
wrong gear.
2. A drive line disengagement component such as a clutch
is not engaged.
Damaged Speed Sensor
Disconnected or damaged speed sensor wiring
Damaged controller
Interface board terminals for Shaft Speed Sensor
72 Shaft Speed Sensor Output signal

a.
Zero Volts DC on a non running machine.
b.
Approximately 5-6 VAC running at idle.
38 Shaft Speed Sensor Ground
The speed sensor is a conventional two wire magnetic pickup. The

resistance of the coil is approximately 2.5 k ohms.
9
The COC temperature sensor input is below 0.25 Volts DC or Greater than
4.75 Volts DC Possible causes include
Damaged COC temperature sensor
Disconnected or damaged COC temperature sensor wiring
Low COC temperature sensor supply voltage
Shorted COC temperature sensor wiring
Damaged controller
Interface board terminals COC temperature sensor
DRILLING SOLUTIONS
71 COC Temp Sensor Supply (20-30 Volts DC)
75 COC Temp Sensor Ground
7-97
cause the error
9
74 COC Temp Sensor Signal (Section 3.7.4 can be used to look up

the approximate voltage to expect if the temperature of the
Compressor discharge is known)
10
The hydraulic temperature sensor input is below 0.25 Volts DC or Greater

than 4.75 Volts DC Possible causes include
Damaged hydraulic temperature sensor
Disconnected or damaged hydraulic temperature sensor wiring
Low hydraulic temperature sensor supply voltage
Shorted hydraulic temperature sensor wiring
Damaged controller
Interface board terminals for Hydraulic temperature sensor
69 Hydraulic Temp Sensor Supply (20-30 Volts DC)
73 Hydraulic Temp Sensor Ground
70 Hydraulic Temp Sensor Signal (Section3.7.4 can be used to

look up the approximate voltage to expect if the temperature of the
11
One of the four temperatures monitored by the Electronic Fan Regulation

systems has exceeded its maximum temperature.
7-98
One of the temperatures is too hot.
Damaged hydraulic temperature sensor.
Damaged COC temperature sensor.
Damaged coolant sensor on the ECM system.
Damaged air intake sensor on the ECM system.
DRILLING SOLUTIONS
3.3 Blown Fuse Check List

1. Turn off the KEY input and verify the power to the controller is off.
Terminal 32 = Zero V
Terminal 78 = Ground
2. Use multi-meter to measure resistance between Terminal 32 and terminal 78 the resistance
should not be less that 20 Ohms.
3. If the resistance is less than 20 ohms there is a short in the system. Check the resistance
of every terminal to ground (Terminal 78) and eliminate the short.
Terminals 8 ,17, 33, N, 38, 47, 50, 53, 58, 64, 73 & 75
Are also ground and will always read zero ohms.
3.4 Actuator Diagnostics Table

The actuator is composed of the following components
24 volt DC motor.
Intergrated gear box with life time lubrication.
Two cam operated limit switches.
Thermostat and heater.
Clockwise rotation always closes the valve.

Counterclockwise rotation always opens the valve.
The actuator has 6 wires.
1. Clock Wise Supply
2. Counter Clock Wise Ground
3. Clock Wise Ground
4. Counter Clock Wise Supply
5. Heater Ground
6. Heater Supply
DRILLING SOLUTIONS
7-99
3.5 Actuator test using an actuator test box
Instructions
1. Make sure the white line on the actuator indicator knob is lined up with the scribed mark on
the actuator. (This requires removing the indicator knob).
2. Install the actuator test box in series with the actuator to be tested.
3. Set the speed switch to fast.
4. Use the Clock wise and counter clockwise switch to command the actuator and observe the
actuator response.
5. Set the speed switch to slow.
actuator operation at slow speed.
Results
7-100
The butterfly Valve should move in the direction commanded by the switch.
The actuator should have free travel from horizontal with the long edge of the
actuator to perpendicular to the same edge. (The actuator is stopped at the end of
travel by internal limit switches that can be heard as a faint click.) (The actuator
should not load up and stop.)
DRILLING SOLUTIONS
The actuator should stop in the horizontal position after moving clockwise and in the
perpendicular position after moving counter clockwise.
The actuator should move smoothly with a steady buzzing sound. (There should not
be any spots where the actuator loads up and slows down.)
If there appears to be a problem with the actuator.

Possible causes include.
If the actuator operates backwards of the indications on the tester there are two
possible causes.
1. The heater circuit is wired backwards. (Diagnose and repair.) (This problem
does not affect operation of the system. It should however be corrected.)
(Use the schematic and connector pin diagrams to diagnose and correct.)
2. The test box is wired incorrectly. (Use the tester schematic and connector
pin diagrams to diagnose and correct.)
If the actuator does not travel the full operating distance there are several possible
causes.
1. The limit switch or limit switch cam have come loose. (It will be necessary
Diagnose and repair. Remove the cover and correct the problem.)
2. Something inside the valve is stopping the actuator. (It will be necessary to
remove the actuator from the valve to isolate this cause, then diagnose and
repair the problem.)
3. The actuator has broken internal gears or other mechanical problems. (It
will be necessary to remove the actuator from the valve to isolate this
cause, then diagnose and repair the problem.)
If the actuator does not stop in the horizontal position after moving clockwise and in
the perpendicular position after moving counter clockwise. (the internal cams will
need to be adjusted.)
3.6 Potentiometer Testing using a multi meter

Instructions
1. Rotate the shaft to a position approximately have way between the mechanical stops.
2. Measure the resistance between the three Wires/Terminals until the pair with the greatest
resistance is found.
The resistance should correspond with the resistance marked on the pot.
The resistance between either one of these wires and the third wire should be
approximately half resistance marked on the pot.
3. This pair of Wires/Terminals are the two ends of the resistive element.
4. The third Wire/Terminal is the wiper.
DRILLING SOLUTIONS
7-101
5. Rotate the shaft fully in one direction and measure the resistance as the shaft is rotated
slowly in the other direction.
The resistance should change from approximately the resistance of the pot to near zero
ohms. (Depending on the direction you rotated the action could be reversed)
The resistance should change smoothly with to places where the resistance changes or
appears to be unstable.
The resistance should be stable when side loading is applied to the shaft. (provided the
shaft is not rotated)
Section 3.7 Tables

3.7.1 Voltage output for Vacuum Sensor
7-102
DRILLING SOLUTIONS
3.7.2 Voltage output for Pressure Sensor
3.7.3 Atmospheric Pressure to expect at various elevations and the Vacuum

sensor output for that pressure
DRILLING SOLUTIONS
7-103
3.7.4 Temperature Sensor voltage output at various temperatures
3.8 Summed On/Off Inputs Decode Table

The interface board sums (adds together) the three on/off inputs to create a single voltage that
the controller decodes to determine the status of these three inputs:
Key switch
Compressor on/off switch
Auxiliary on/off switch
This table can be used to determine if a specific input will be decoded as ON or OFF.
7-104
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-105
4.1 Schematics
7-106
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-107
7-108
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-109
7-110
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-111
7-112
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-113
7-114
DRILLING SOLUTIONS
7-5.1 HIGH PRESSURE COMPRESSOR
WARNING

drill.
General Information
overturning.
crushing risk.
DRILLING SOLUTIONS
7-115

A compressor is considered high pressure if the discharge pressure is 250 psi or greater. All
High Pressure compressors have discharge pressures of 350 psi.

A fiber gasket is installed between the outside cover of the receiver and the metal tube holding
the separator element in place. This gasket prevents oil from leaking around the metal tube
and down the hole.
hose and will follow the air flow until it burns through the air hose. This is not a fire caused by
the compressor flashing.
To prevent this from happening, several metal staples have been installed through the gasket
so each side comes in contact with the metal. This bridge serves to allow the static charge to
drain off outside the receiver tank and not cause a static buildup.
CAUTION
When replacing the separator element, be sure there is a least one staple
glue.
7-116
DRILLING SOLUTIONS
Overview
PV-270 Series high pressure compressors have discharge pressures of 350 psi. They are
designated either HR2 or HR2.5. These models describe the rotor sizes. For example, the
HR2 has two sets of rotors; a 226mm size and a 127.5mm size. The HR2.5 has two sets of
rotors; 226mm x 2\127.5mm. The size of the rotors and their speed determine the inlet volume
of the air end. The PV-270 Series drill has a 1450/350 compressor available that is suited for
DHD drilling. There are three systems on a rotary screw compressor: the lubrication system,
the separation system and the regulation system. Each system is critical to the operation of
the air end and the systems are all interrelated.
Lubrication System Components

The equipment used in the lubrication section includes the Receiver Tank, Mixing Valve, Oil
Cooler, Bypass Valve, Strainer, Filters, Oil Pump, Relief Valve, Discharge Check Valve and
special oil.
Receiver - Separator Tank

The receiver tank contains the lubricating oil for the compressor. The oil is removed from the
air by centrifugal force, gravity, velocity and filtration. The receiver tank has an oil level sight
glass that shows the oil level at all times. The proper oil level is when the sight shows 1/2 full
while the drill is running.
DRILLING SOLUTIONS
7-117
Oil Pump
The oil pump is a gear type pump, driven from the rear of one of the compressor rotors. It
operates whenever the compressor is turning. It is speed sensitive and pumps at rated volume
only when the compressor is at full RPM.
It acts as a normal pump when the oil is cold but becomes a restriction to maintain oil flow from
the receiver tank when the compressor is operating at normal pressure and temperature. This
prevents all the oil from being forced out of the receiver tank at once and flooding the
compressor rotors. There is no shaft seal in this pump since it is being lubricated by the same
oil it is pumping.
Strainer
A 40 mesh (150 micron) strainer is mounted just before the inlet to the oil pump. It protects the
pump and catches any foreign debris such as hose pieces and parts of the thermostat that
could damage the pump. The metal strainer should be removed, cleaned and reinstalled every
500 hours.
Oil Cooler
The cooler package is made up of three sections. The larger section cools the compressor oil,
the middle section cools the engine coolant and the smaller section cools the hydraulic oil.
7-118
DRILLING SOLUTIONS
The Compressor Oil Cooler is a single pass unit. Hot oil enters from the bottom of the cooler
and cool oil exits out the top. This prevents any air bubbles that may have been carried along
with the oil from being trapped in the top and creating a vapor barrier.
Compressor Oil
The very high pressure created in these air ends requires a special oil. This oil is not
compatible with certain types of O-rings. Therefore, we use Viton type O-rings in the air end
fittings and filters. The oil is also not compatible with other oils and should never be mixed with
other oil. High Pressure compressors use XHP605 oil. Be sure to change the filters every 500
hours.
Mixing Valve
The Mixing Valve contains a thermostat that stops oil flow in one direction when it is cold and
allows oil to flow from another direction when it reaches operating temperature. When the
temperature is below 145F (63C), oil flows from port B to port A, thus bypassing the oil
cooler altogether. When the temperature increases to 160F (71C), the thermostat is
completely opened and all the oil flows from port C to A and shuts off all flow to B. At
temperatures in between 145F (63C) and 160F (71C), some oil flows through port B to
A and some oil flows through the cooler and fromC to A. Under normal operation, some
oil is flowing through both B and C. The normal discharge temperature of the oil leaving the
air end should be between 180F (83C) and 220F (104C).
DRILLING SOLUTIONS
7-119
Relief Valve / Check Valve
A 65 psi relief valve is connected between the inlet and outlet of the oil cooler. If the cooler
becomes plugged and the inlet pressure becomes 65 psi higher than the outlet pressure, the
relief valve opens and allows oil to bypass the cooler. When the differential pressure is
reduced below 65 psi, the valve will close and normal flow resumes. The 65 psi relief valve
allows the oil cooler system to function properly.
Oil Filter
Two 10 micron filters are installed at the outlet of the pump before the oil reaches the
compressor bearings. They catch any contaminants that may have been picked up in the
circuit and prevent them from plugging the orifices at the inlets to the bearings.

The Discharge Check Valve serves one purpose for two mediums; air and oil. It prevents air
and oil, under pressure, from backing up into the air end. When the drill is stopped, pressure
in the compressor drops to zero. There is still pressure in the receiver tank until it completely
blows down. If the check valve was not there, air pressure would force air and oil back through
the compressor housing and out the inlet (butterfly) valve, thus flooding the air cleaners.
7-120
DRILLING SOLUTIONS
The valve being held open, It has a single spring. The hinge must be mounted on top to
prevent the valve from staying open when the drill is shut down. Notice the white nylon ring
that forms a tight seal to prevent back flow when the drill is stopped.
DRILLING SOLUTIONS
7-121
Lubricating System Operation
Use High Pressure Lube System schematic to follow the oil flow in the Lubricating and Cooling
system.
Oil is injected into the air end under pressure. The oil serves three purposes:
1. It cools the air end bearings and rotors.
2. It lubricates the moving parts
7-122
DRILLING SOLUTIONS
3. It seals the clearances between the male and female rotors, and between the
rotors and the housings and end plates.
The discharge check valve prevents air pressure and oil from re-entering the compressor
when the drill is stopped.
The Receiver Separator serves two purposes:
1. It stores compressed air for future use.
2. It separates the oil from the air.
Oil is forced from the receiver by air pressure flowing through the piping towards the oil cooler.
The oil has three paths it can follow at this point.
1. When the oil is cold, the mixing valve allows oil to bypass the cooler and go
directly to the oil pump (B to A).
2. As the oil warms up to 145F (63C), the thermostat in the mixing valve starts
to open and some oil flows up through the cooler. Most of the oil still flows
through the bypass (B to A and some C to A).
3. When the oil temperature reaches 160F (71C), the valve is closed completely
and all oil flows through the cooler (C to A). The valve stays partially open
during normal operation and the discharge temperature of the oil stays
between 145F (63C) and 160F (71C).
If the oil cooler becomes plugged and the differential pressure across the cooler builds up to
65 psi, the relief valve opens and allows oil to bypass the cooler. It still flows from (C to A)
in the mixing valve.
When the oil exits the mixing valve, it passes through a 40 mesh (150 micron) screen into
the inlet of the oil pump. When the oil is cold or the receiver is operating at low pressure, the
pump performs as a regular pump by forcing oil into the compressor. But as the temperature
and pressure increase, the pump acts to prevent excess oil from getting into the compressor
and flooding it.
Before the oil reaches the pump, it passes through a 40 mesh 150 micron strainer that keeps
larger debris from reaching the pump. After the oil passes the pump and before it gets to the
compressor bearings, it passes through two (2) 10 micron filters and then flows through a
metal manifold that sends oil to all areas of the compressor. Each bearing has its own supply
line. The balance of the oil goes into the low pressure area of the rotors.
A 425 psi relief valve is located between the oil pump and the compressor and bearings that
prevents damage to the system in case of a high pressure surge during cold starts and/or
blockage in the bearing lines. When the temperature of the oil warms up, the relief valve will
close.
Separation System
Lubricating oil is forced through the air end to cool, seal and lubricate the rotors. When the oil
is pumped into the receiver separator tank, it must be separated from the air going down the
hole. This is accomplished in three steps.
DRILLING SOLUTIONS
7-123
1. The Air/Oil mixture enters the receiver through the inlet pipe and splashes
against the inner walls. This forces the majority of oil to fall to the bottom of the
tank and remain there.
2. When the down stream air line is opened and air flows down the hole, some of
the remaining oil is carried along with it into the filter area. A metal canister
prevents oil from flowing through the filter directly. The air/oil mixture enters the
outer edge of the element and moves towards the center. As the oil travels
through the element, it is slowed down by friction and gravity pulls it downward.
Most of the oil drops out the bottom of the element and falls into the reservoir.
3. The final step in the separation process is removing any remaining oil from the
element so it is not carried over into the down hole air stream. When enough
excess oil is carried into the center of the element, a series of holes in the end
of the filter element allow the oil to fill an area between the flange and the
element. The scavenger line is connected between the flange and the inlet of
the compressor. Since there is a differential pressure between the receiver tank
and the low pressure area of the compressor, oil and air are forced through the
scavenger line into the inlet area of the air end, thus removing the last of the oil
carryover. A 0.94 orifice in the line prevents excessive amounts of air loss.
The HR2/HR2.5 air ends all have an anti-rumble valve connected in parallel with the
scavenger orifice. The anti-rumble valve is a pilot operated valve that opens when the
compressor is not making air. It allows a large volume of compressed air from the receiver
back into the air end to mix with the oil already being pumped into it. The air acts as a cushion
to prevent the rumbling sound caused by oil, in a vacuum, being forced through the rotors.
When the compressor inlet is opened, the anti-rumble valve closes and the scavenger orifice
operates in the normal fashion.
7-124
DRILLING SOLUTIONS
Regulation System-High Pressure

The regulation system controls the pressure and volume of the air going down the hole to the
bit. All high pressure compressors have discharge pressures of 350 psi. Certain types of drills
may operate at lower pressures than 350 psi. Drilling Solutions uses the UL88 unloader valve
to control the discharge pressure and volume.
REGULATION SYSTEM COMPONENTS
The regulation system on high pressure compressors is designed around the UL88
modulating valve and includes several other automatic devices to operate the system.
Inlet Butterfly Valve

The Inlet Butterfly Valve is a round, wafer valve that sits on top of the compressor. It has a
shaft that is connected to the center of the valve. This is where the linkage for the UL88
Unloader Valve is attached.
UL88 Unloader Valve

The regulation system on high pressure compressors is designed around the UL88
modulating valve. It controls the pressure and volume in the receiver by opening and closing
the inlet (butterfly) valve according to the discharge pressure in the receiver.
The UL88 consists of three chambers; the Power Chamber, the Metering Chamber and the
Pressure Chamber.
DRILLING SOLUTIONS
7-125
There are two diaphragms in the UL88. One is the Power diaphragm and the other is the
Metering diaphragm. Air pressure works on the Metering diaphragm to open it against spring
pressure in the Pressure Chamber and allow air to flow through the metering seat into the
Power Chamber.
When the air pressure becomes high enough in the Power Chamber, the diaphragm pushes
against the control arm which is held in place by the control spring. This pulls the linkage
connected to the inlet (butterfly) valve and closes it. This cuts off intake to the compressor.
When there is no pressure in the Power Chamber, control spring force holds the inlet valve
open. There must be air pressure in the Power Chamber to close the inlet valve.
There are several components needed to operate this system correctly. They include an ONOFF valve, a linkage control arm, inlet butterfly valve, receiver tank, 100 psi check valve and
a 50 psi relief valve.
7-126
DRILLING SOLUTIONS
ON-OFF Valve
This valve is located in the operators console and allows air pressure to flow into the Power
Chamber or it can stop the flow. When the ON-OFF switch is turned OFF, air flows through
it and pressurizes the Power Chamber Diaphragm. This pushes the control arm back and
closes the inlet valve. Thus when the ON-OFF switch is OFF, it is ON or actually flowing.
When the ON-OFF valve is turned ON, air is prevented from getting into the Power Chamber
and the inlet valve stays open, making air. There is a port in the ON-OFF switch for exhaust
and it must be plugged to operate correctly. On newer drills, there is a ball type valve without
the exhaust. Air bleeds out through the orifice in the 50 psi relief valve.
DRILLING SOLUTIONS
7-127
50 psi Relief Valve / Orifice
A 50 psi relief valve is located in the line between the ON-OFF switch and the UL88 Power
Chamber. There is a small orifice in the valve that allows a certain amount of air to
continuously blow through it. This relieves the pressure in the Power Chamber when the
switch is turned ON and lets the Power Chamber diaphragm return to its normal position. The
relief valve works only when a high pressure surge would damage the UL88.
100 psi Check Valve
The UL88 and the pressure regulator were designed to operate at 250 psi maximum pressure,
so a 100 psi check (cigar) valve, was installed in line from the receiver tank to reduce the final
discharge pressure from the check (cigar) valve from 350 psi to 250 psi. When a drill is first
started, air pressure in the receiver tank must increase above 100 psi before the check valve
opens and allows any air to the UL88.
Volume Control Valve
7-128
DRILLING SOLUTIONS
There may be times when the operator wishes to use a down hole device that uses less air
volume than the compressor is rated for. To prevent the compressor from hunting (opening
and closing the inlet valve rapidly), a volume control was added. It consists of a needle valve
that can be opened to allow a certain volume of air into the Power Chamber to assist in
modulating the UL88. It should be closed tight for full volume.
Operation
To use the volume control, turn the compressor switch to the ON position, then unscrew the
volume knob several turns counterclockwise until the hunting action of the engine slows to
an even RPM. When approaching this area, unscrew the handle slowly using only partial turns
to allow the inlet valve to balance the incoming flow with the actual usage. When the engine
remains at a steady RPM, dont move the handle any further. If two different sized DHDs are
used interchangeably , then the volume control should be monitored as to how many turns it
takes to get to the lower volume required so it can be set quickly the next time the smaller DHD
is used.
DRILLING SOLUTIONS
7-129
Pressure Regulator
Discharge pressure is set by the Pressure Regulator mounted on the control console. It can
be increased or decreased as the situation demands. A spring inside the pressure chamber
puts a minimum amount of pressure on the metering chamber diaphragm. The pressure
regulator increases that pressure up to the maximum psi allowed by the system.
NOTE: The regulator should not be decreased while the compressor is turned ON. Turn the
compressor OFF and bleed the system down, then back the regulator off. Otherwise, the
regulator diaphragm will be destroyed by excess pressure.
7-130
DRILLING SOLUTIONS
Anti-Rumble Valve
When the compressor inlet is closed, no air is flowing through the rotors but the oil pump is still
pumping the same volume of oil. This causes the rotors to try to compress oil. The result is
backlash by the rotors that causes a loud rumbling sound. To prevent this from doing any
damage to the air end, an anti-rumble valve has been installed.
This valve allows a measured volume of compressed air from the receiver tank back into the
rotor housing whenever the inlet valve is closed. This air mixes with the oil and cushions the
rotors. The valve is automatically turned off when the inlet valve is opened and all of the air
goes down the hole. The scavenger line is the tube that goes from the inlet to the outlet. An
orifice is mounted in the fitting. This carries the oil/air mixture back to the air end inlet.
DRILLING SOLUTIONS
7-131
Blow Down Valve

Without a shut off valve, there is still pressurized air trapped in the receiver tank when the drill
is stopped. This air must be exhausted before the drill is started again. An automatic blow
down valve is connected to the receiver tank, on the dry side of the separator element, to
relieve the pressure in the tank. A pilot line has been installed between the discharge of the
compressor and the discharge check valve. As long as the compressor is running, pilot
pressure prevents the valve from opening. When the compressor is stopped, there is no pilot
pressure available to keep the valve closed and the spring pressure opens the valve and
allows tank air pressure to escape.
On the outlet side of the valve is an orifice and a silencer. The silencer is there to muffle the
noise of the escaping air. The orifice is there to provide enough back pressure to pilot the shut
off valve or exhaust valve closed.
Shutoff Valve
When the drill is stopped, air pressure from the receiver can still flow through the lines and
pressurize the power chamber. This would close the inlet valve and trap air pressure inside
the air end, since the discharge check valve would prevent any air/oil from getting out of the
air end. This would cause a back pressure on the inlet valve and keep it closed. Oil and air
would still be entering the air end through the scavenger line and when the inlet valve finally
opens, oil under pressure will blow through the intake tubes and soak the air cleaners.
Therefore, a shut off valve is installed in line between the ON-OFF switch and the volume
control to shut off any air pressure from reaching the power chamber. The shutoff valve is
piloted by the back pressure caused by the orifice downstream from the blow down valve.
7-132
DRILLING SOLUTIONS
Quick Exhaust Valve

Some drills are equipped with a Quick Exhaust valve instead of a Shut Off valve.
The difference is that the shut off valve stops the flow of air to the UL88 and the exhaust valve
exhausts any air in the lines leading to the UL88. Either system will prevent air from reaching
the Power Chamber. The quick exhaust valve is piloted from the same connection on the
DRILLING SOLUTIONS
7-133
Blowdown Valve. When it receives pilot pressure, it opens and exhausts all the pressure in the
line leading to the Power Chamber, thus preventing the inlet valve from closing.
Minimum Pressure Valve

A minimum pressure valve is installed between the receiver and the main air hose which goes
to the tower air hard piping. Its only purpose is to maintain a minimum amount of pressure in
the receiver tank to force the oil into the lubrication system. On most high pressure drills, the
valve is set at 120 psi (140 psi on HR2.5 compressors). This means that the down hole
pressure may be 50 psi or 350 psi but the receiver tank never sees a pressure less than 120
(140) psi. It does not control the volume of air in CFM. It only restricts the outlet pressure. It
has nothing to do with the pressure shown on the pressure gauge at startup.
7-134
DRILLING SOLUTIONS
Safety Relief Valves

All drills are equipped with safety valves. The setting on these valves is 25-50 psi higher than
the maximum working pressure. The only function of a safety valve is to prevent damage to
the receiver tank in case of other failures. It should never be used as a high pressure relief
valve for two reasons. One, the pressure setting is above the allowable working pressure of
the compressor. Two, the safety valve loses a small amount of spring tension every time it is
opened. Therefore, the pop off pressure will be reduced each time it is opened and will shortly
open below the normal operating pressure and will have to be replaced.
Drill Air Throttle Valve

All high pressure drills are equipped with a drill air throttle valve to control the air flow down
the hole. These valves can be metered to prevent excess air flow from disturbing the
formation. The throttle valve is connected downstream from the minimum pressure valve. The
throttle valve should always be opened slowly to prevent premature damage to the
separator element.
The Drill Air Throttle Controller controls the drill air throttle valve which allows air flow to the
drill string and allows air flow down the hole to operate the DHD (Down Hole Drill) and clean
the hole. It is used to turn ON/OFF the drilling air during drill rod or hammer changes. It can
be adjusted to a lower setting while collaring the hole. This is an option for high pressure drills
only.
DRILLING SOLUTIONS
7-135
Service Connection
A ball valve and a pressure regulator are connected to the main discharge piping to
accommodate tools and equipment that use air power. The pressure regulator is used to lower
the high operating pressure to the tool operating pressure, usually around 100 psi. The ball
valve is there to reduce the load on the regulator when it is not being used.
NOTE: Do not operate the service air pressure at normal discharge
pressure, since most air tools are rated for no more than 100 psi.
Pressure Gauge
A pressure gauge is connected to the upper manifold on the receiver tank before the minimum
pressure valve. It reads tank pressure at all times. If a rotary bit or other device is being used
down hole that requires less than minimum pressure setting, the gauge will read only minimum
pressure. A second gauge must be installed in the standpipe to read actual down hole
pressure if you are operating below minimum pressure.
7-136
DRILLING SOLUTIONS
Regulation System Schematic
The drawing shows the basic layout of the regulation system for high pressure drills. Air
pressure is pumped into the receiver tank from the compressor. As the pressure reaches 100
psi, the check valve opens and allows air to flow through the metering line into the Metering
Chamber. At the same time, air flows through the ON-OFF switch into the Power Chamber.
When the pressure builds up past 100 psi enough to overcome the control spring (45 psi), the
inlet butterfly valve will close and the compressor will stop making air. This is why the
compressor inlet butterfly valve closes at 145 psi on start up.
DRILLING SOLUTIONS
7-137
The drawing shows the volume control, pressure regulator and scavenger line.
7-138
DRILLING SOLUTIONS
Shutdown System
The shutdown system, consists of a pilot operated blowdown valve and a shut off valve or a
quick exhaust valve. When the drill is stopped, pilot pressure is lost to the blowdown valve and
the spring opens the valve so the receiver tank blows down. There is an orifice between the
blowdown valve and the muffler that causes enough back pressure to activate the pilot on the
shut off or quick exhaust valve. This will either stop all flow to the Power Chamber of the UL88
or exhaust the pressure coming to the Power Chamber, thus preventing the inlet butterfly valve
from closing. At the same time, pilot pressure to the anti-rumble valve is lost and it closes. This
allows only scavenger air to enter the compressor cavity.
Operation
Starting
Before starting the drill, make sure the compressor ON-OFF Switch is OFF, the Drill Air
Throttle is closed and the Pressure Regulator is set properly. Once the drill has started and all
fluids are at operating temperatures, check the discharge pressure gauge on the operators
console. It should be about 140-145 psi. Next, turn the ON-OFF Switch to the ON position.
This action cuts off the flow to the Power Chamber. Now all the pressure is passing through
DRILLING SOLUTIONS
7-139
the 100 psi check valve and into the Metering Chamber.
Adjusting Pressure
When the pressure pushing on the Metering diaphragm overcomes the spring pressure in the
Pressure Chamber, the metering pin will be pulled out of its seat and allow air pressure into
the Power Chamber. Pressure will increase in the Power Chamber until pressure against that
diaphragm overcomes the control spring and pushes the control arm back which closes the
inlet butterfly valve.
Drill pressure is adjusted by increasing or decreasing the pressure on the regulator on the
console. To increase pressure, simply turn the T handle clockwise while watching the
pressure gauge on the panel. Once it has reached the proper pressure, release the handle.
To reduce pressure on the system, refer to the procedure at the end of this section. Do
not simply unscrew the handle.
Drilling
When the operator is ready to start a DHD (Down Hole Drill), slowly open the air throttle. This
will allow the pressure in the receiver tank to escape down the hole without damaging the
separator element. Sudden release of pressure will shorten the life of the element.
When the hole is completed or the operator wants to add another drill pipe, he simply closes
the Drill Air Throttle. Pressure increases in the receiver and control lines until the inlet butterfly
valve is closed by pressure in the Power Chamber. The operator does not have to turn the
ON-OFF switch to the OFF position unless air is not going to be needed for a time. Pressure
will stay at the setting of the regulator until the Drill Air Throttle is opened again.
7-140
DRILLING SOLUTIONS
Shutting Down
Before stopping the engine, the operator must release high pressure air from the receiver
tank.
1. Turn the ON-OFF Switch to OFF.
2. Open the Drill Air Throttle slowly, and allow as much pressure as possible to
escape from the receiver tank.
3. The tank pressure should read no higher than140-150 psi.
4. When the pressure gauge shows 140-150 psi, stop the engine.
5. The automatic blowdown valve should open and exhaust all the air pressure
from the tank.
6. If the blowdown stops blowing before all the air is out of the tank, physically
check to see if the inlet butterfly valve is open. If it is not, manually open the
valve.
If the drill is shut down under high pressure, the anti-rumble valve will still be open because
there is pressure in the Power Chamber to pilot it open. The line from the UL88 inlet valve is
still seeing pressure because the 100 psi check valve is open. This pressure causes the inlet
butterfly valve to stay closed. The discharge check valve is also closed from tank pressure so
the air end becomes a pressure vessel. Now, pressure on both sides of the inlet butterfly valve
are trying to push it up evenly and it cannot open.
If the blowdown valve does not start to blow down, it will very quickly be piloted closed from
pressure in the air end. Now oil and air are being forced into the air end and will continue to
do so until tank pressure bleeds down low enough to allow the 100 psi check valve to close,
cutting off flow to the UL88.
When the inlet butterfly valve finally opens, the air and oil mixture will escape with high velocity
through the inlet and up through the inlet tubes to the air cleaners. Enough oil will be present
to saturate the primary cleaner and render it useless.
This is why the compressor should never be shut down intentionally under high
pressure. If there is a shutdown switch triggered by low oil or engine problems, there is
nothing one can do but clean up the mess and replace the air cleaner element.
Air Pressure Regulator

Theory of Operation
The Air Pressure Regulator used on all high pressure drills is a pressure reducing valve that
can handle inlet pressures up to 300 psi (20.7 bars) and reduce the output pressure to a range
of 10 psi to 250 psi (.7 to 17.2 bars). It will operate within a temperature range of 0F(-17.8C)
to 175F (79.4C).
When the drill is first started, there is no air pressure in the regulator or the pressure chamber
of the UL88. Air pressure builds up in the metering chamber as the compressor develops air
pressure.
DRILLING SOLUTIONS
7-141
At the same time, pressure is allowed into the power chamber and when receiver pressure
overcomes the 100 psi check valve and the control spring on the UL88, the inlet valve closes.
This condition is static until the compressor ON-OFF switch is turned ON.
Once the compressor is loaded by turning the ON-OFF switch to ON, pressure builds in the
metering chamber until it overcomes the spring setting in the pressure chamber. Then the
metering pin pulls away from the seat and lets pressure escape into the power chamber.
Increasing Pressure
To increase the discharge pressure down the hole, the air regulator pressure must be
increased. This is done by screwing the T handle clockwise. Each full turn increases the
discharge pressure by about 60 psi. As the T handle is screwed in, the cone in the diaphragm
forces the small pin against the inlet valve assembly and opens the valve. Inlet pressure is
allowed to flow through the valve and into the pressure chamber of the UL88. At the same time,
pressure is ported to the base of the diaphragm. As air pressure in the system increases, the
force working on the area of the diaphragm increases until it overcomes the spring setting on
top of the diaphragm. This action relieves pressure on the inlet valve spring assembly and cuts
off flow to the UL88. When the correct discharge pressure is obtained, the handle is set by
tightening the lock nut on the handle.
As air pressure varies down the hole, the metering chamber pressure varies with it. When
receiver pressure builds up enough to overcome the spring and regulator pressure in the
pressure chamber, the metering pin comes off the seat and air flows into the power chamber,
closing the inlet valve.
7-142
DRILLING SOLUTIONS
Increasing discharge pressure causes no problem for the air pressure regulator or the UL88.
However, reducing pressure by using the improper procedure can damage both the regulator
diaphragm and the metering chamber diaphragm.
The air pressure on the downstream side of the air regulator and in the pressure chamber of
the UL88 is trapped by the pressure on the inlet side of the air regulator. If the spring pressure
on top of the diaphragm is released by unscrewing the T handle without lowering the inlet
pressure, air pressure acting on the bottom of the diaphragm will rupture it after several
improper uses.
Decreasing Pressure
The proper procedure is to turn OFF the Compressor On-Off Switch, BLOW the receiver
pressure down to minimum using the DRILL AIR VALVE and then UNSCREW the T handle
to minimum. This action relieves the high pressure on the valve assembly and lets the higher
pressure in the downstream side open the valve assembly, thus pulling the valve pin away
from the diaphragm cone. The air trapped in the diaphragm will exhaust through the center
port of the diaphragm and relieve all pressure in the UL88 and under the diaphragm. There is
a port on the side of the air regulator cap that allows air pressure out of the system.
Damage to the metering chamber diaphragm can be caused by relieving spring pressure in
the air regulator while under high pressure in the system. This will leave high pressure in the
metering chamber and no pressure in the pressure chamber. The uneven pressure will rupture
the diaphragm prematurely.
Relieving the high pressure in the system while there is still pressure in the pressure chamber
will not cause the same problem to the metering chamber diaphragm since the metering pin
prevents the diaphragm from collapsing excessively. As soon as the pressure is relieved in the
system, the T handle can be unscrewed and the pressure will relieve in the regulator system.
DRILLING SOLUTIONS
7-143
Compressor Related Problems

local Drilling Solutions service office.
7-144
DRILLING SOLUTIONS
7-5.2 HIGH PRESSURE COMPRESSOR WITH EARS
WARNING

drill.
General Information
overturning.
crushing risk.
DRILLING SOLUTIONS
7-145

High Pressure compressors have discharge pressures of 350 psi.
Electronic Air Regulation System (EARS)

1.1 Introduction
The following information is general for all Atlas Copco Drilling Solutions drills using Electronic
Air Regulation. Due to differences in drill models, there will be differences in electronic air
regulation components used. As an example, a TH60 model drill utilizes a single truck engine
and therefore would use a shaft speed sensor and an engagement sensor not used on other
drill models. Also, an engine oil pressure switch is required for some installations that do not
have J1939 equipped engines.
This information contains instructions for several Electronic Air Regulator systems used on
Atlas Copco Drilling Solutions drills. Therefore, you must refer to the parts book specific to your
7-146
DRILLING SOLUTIONS
drill for parts and schematics specific to your drill.
The Electronic Air Regulation System consists of fourteen general components. Some of the
components are only required on some of the applications.
1.2 Components
1. Flow sensor
2. Proportional Butterfly Valve and Actuator on the compressor inlet
3. Pressure Sensor on the receiver tank
4. Proportional Vent Valve and Actuator on the receiver tank
5. Electronic Controller
6. Flow Control Knob
7. Maximum Pressure control Knob
8. Compressor ON/OFF Switch
9. Diagnostic Light
10. Hardware Interface Board
a. Power Control Relay
b. Diagnostics Port
c. Fuse
d. Sensor Power Conditioning Circuits
e. Electrical Noise Suppression Circuits
11. Interconnect System
12. Oil Pressure Switch (Required on some installations)
13. Shaft Speed Sensor (Required on some installations)
14. Engagement Sensor (Required on some installations)
DRILLING SOLUTIONS
7-147
1.2.1 Flow Sensor
The Flow Sensor detects the volume of air the compressor is producing and sends this
information to the electronic controller. This sensor is actually a vacuum sensor.
1.2.2 Proportional Butterfly Valve and Actuator
The Proportional Butterfly Valve and Actuator are controlled by the electronic controller and
regulates the air flow into the compressor from fully closed (no air enters the compressor) to
fully open. It includes a visual position indicator. The indicator will be horizontal when the valve
is closed and vertical when the valve is full open.
7-148
DRILLING SOLUTIONS
1.2.3 Pressure Sensor
The Pressure Sensor detects the pressure in the receiver tank and sends this information to
the electronic controller.
1.2.4 Proportional Vent Valve and Actuator
The Proportional Vent Valve and Actuator are controlled by the electronic controller and can
release air from the receiver tank. The air is vented to atmosphere through an air silencer. The
proportional vent valve w a s previously called the blowdown valve. The indicator will be
horizontal when the valve is closed and vertical when the valve is full open.
DRILLING SOLUTIONS
7-149
1.2.5 Electronic Controller
The Electronic Controller monitors the flow and pressure inputs, operator inputs and engine
data. It controls the actuators so that compressor outputs the flow or pressure requested. It
also detects several fault conditions and alerts the operator by flashing an error code with the
diagnostic light. The controller is initially powered up with the key switch but then latches its
power on so that it can perform a shutdown sequence after the key switch is shut off.
1.2.6 Controls Located on Console

Flow Control Knob
The Flow Control Knob is a variable electronic input into the electronic controller. When the
compressor On/Off switch is on it adjusts the flow into the compressor between the minimum
flow (required to prevent damage to the compressor) and maximum flow (full open on the
butterfly valve).
Maximum Pressure Control Knob
The Maximum Pressure Control Knob is a variable electronic input into the electronic
controller. When the compressor On/Off switch is on it adjusts the maximum pressure in the
receiver tank between the minimum holding tank pressure and the maximum working pressure
of the compressor system.
7-150
DRILLING SOLUTIONS
Compressor On/Off Switch

The Compressor On/Off Switch is used to select the source of the flow and maximum pressure
commands. When the switch is On, the Flow Control Knob and Maximum Pressure Control
Knob are active and control the compressor. When the switch is Off, the Flow Control is set to
the minimum flow required to prevent damage to the compressor and the Maximum Pressure
Control pressure is set to the minimum holding tank pressure (setting the switch to Off has the
same effect as setting the flow and pressure knobs to the minimum positions).
Diagnostic Light
The Diagnostic Light (RED) is normally off but will blink out an error code if the controller
detects an error (See Error Code Indications and Priorities section). If this light is blinking, turn
off the engine.
DRILLING SOLUTIONS
7-151
1.2.7 Hardware Interface Board
The hardware interface board is a DIN rail mounted circuit board with terminal strips down
each side. It is not intended for exposure to wash down. This board contains circuits to perform
the following functions.
1. The Power Control Relay allows the electronic controller to latch on the supply
voltage to the EAR system. This allows the system to complete the receiver
tank bleed down after the key switch has been turned off.
2. The Diagnostic Port allows a lap top computer equipped with the correct
software to monitor the system via a USB port.
3. The Fuse protects the system in the event of a wiring short.
4. Sensor Power Conditioning Circuits provide correctly regulated power to the
sensors and operator inputs.
5. Electrical Noise Suppression Circuits prevent electrical noise from being
generated by the electric motors in the valve actuators.
7-152
DRILLING SOLUTIONS
1.2.8 Interconnect System
The Interconnect System includes harness split out boxes and cables sets that connect the
various components. Several variations of the Interconnect system are required to
accommodate the wide range of drills the system can be installed on.
1.2.9 Oil Pressure Switch

An Engine Oil Pressure Switch is required for some installations that do not have J1939
equipped engines. This switch should close when a hot engine is turning 75% of the idle
speed.
1.2.10 Shaft Speed Sensor

A Shaft Speed Sensor is required for some installations. It is used to determine the speed of
a shaft associated with compressor rotation. It can be used to determine the speed of the
compressor or to check for correct transmission gear selection.
1.2.11 Engagement Sensor

Engagement Sensors are used on some installations to detect if various compressor drive line
components are engaged.
DRILLING SOLUTIONS
7-153
1.3 Operation
1.3.1 Startup Operation
engine speed reaches the minimum RPM there is a factory set delay time to allow the engine
to stabilize after which the controller regulates the compressor.
1.3.2 Shut Down Operation

When the controller detects the key has turned off and the engine is stopping, it closes the
butterfly valve and bleeds down the pressure in the receiver tank through the vent valve.
Because the system is ramping down the pressure in the receiver normal system air leaks will
usually allow the pressure to drop fast enough during the early stages of the blow down without
the controller needing to open the vent valve. This results in what appears to be a delay in
venting the tank. However, the pressure is dropping at the correct rate during this time.
1.3.3 Flow Regulation

The controller is always regulating the flow into the compressor. If more flow is called for than
the compressor can make under the conditions, the butterfly valve is opened all the way. There
are three sources for the amount of flow that is called for:
1. The flow control knob (direct control).
2. The compressor On/Off switch (calls for minimum flow).
3. The controllers maximum pressure regulation system. When the maximum
pressure commanded by the maximum pressure knob is reached, the
controller overrides the flow knob command and reduces the commanded flow
to lower the pressure in the receiver.
1.3.4 Maximum Pressure Regulation

The Controller has two methods to control the maximum pressure in the receiver:
1. Override the Flow Knob and lower the commanded flow into the compressor.
2. Open the vent valve to let air out of the receiver tank.
Method 1: When the maximum pressure commanded by the maximum pressure knob is
reached, the controller enters the pressure control mode, overrides the flow knob command
and reduces the commanded flow to lower the pressure in the receiver. The controller then
regulates the flow up and down to maintain the maximum pressure but will not command more
flow than is called for by the flow control knob. If the pressure drops to a level where the
commanded flow would be more than commanded by the flow knob, the controller exits the
pressure control mode and returns control to the flow knob.
Method 2: The controller is constantly attempting to regulate the receiver tank pressure using
7-154
DRILLING SOLUTIONS
a command that is 20 PSI (1.38 bar) above the maximum pressure knob command. If the
pressure is below the command, the vent valve is moved in the close direction. If the pressure
is above the command, the vent valve is moved in the open (vent) direction. For most
conditions, the pressure is below the command and results in the vent being closed. It is the
vent valve regulation system that controls the pressure when the compressor On/Off switch is
in the Off position.
1.3.5 Emergency Venting

If the maximum system pressure is exceeded, the controller commands the butterfly valve
closed and opens the vent valve. This allows quick system reaction to over pressure spikes.
1.3.6 Compressor Turning

In order to control the compressor correctly, the system needs to know if the compressor is
actually turning and more importantly if it is in the process of shutting down. On directly
coupled drills, this is accomplished by monitoring the key switch and the J1939 engine bus.
For other non direct configurations and for drills without a J1939 bus, the system can be
configured to use two additional inputs to make the determination. The first additional input is
a frequency reading input designed to receive a shaft speed from a magnetic or other type
pickup. The second is an On/Off type input that can be configured to function as an engine
speed at minimum indicator, or an indication a compressor drive chain component is engaged.
1.3.7 Gear Selection Error Detection

On drill configurations that utilize a single truck engine, the system is capable of monitoring
the engine speed and the transmission tail shaft speed to determine if the operator has
selected the correct gear for PTO operation.
1.3.8 Temperature Regulation

The temperature regulation is set up to monitor various system temperatures and adjust the
cooling fan speed to prevent any of the four temperatures from exceeding their individual set
points. The four temperatures being monitored are as follows:
1. Engine Coolant
2. Hydraulic Oil Cooler
3. Compressor Oil Cooler
4. Charge Air Manifold
SECTION-2 Flow Chart

EAR-EFR Diagnostics
This quick find diagnostic procedure is primarily designed as a guide for diagnosing Electronic
Air and Fan regulation system problems on a machine that was working and has failed in the
DRILLING SOLUTIONS
7-155
field. It could lead to an incorrect diagnosis if the machine is incorrectly wired or assembled.
The procedure is structured as a set of questions that lead the tester through a path that will
find the problem in the minimum number of steps.
The questions are designed to be answered in sequence. Skipping a question will always lead
to an incorrect diagnoses.
These questions are designed to avoid rotating the compressor and engine where possible.
Things to remember:
Having two people a tester and a helper is strongly advised.
The following test can be preformed using a volt/ohm meter on the interface board terminal
strips, and observing the system behavior.
These tests are not intended to replace additional trouble shooting measures once the
problem is narrowed to a component or simple circuit.
The corrosion resistant coating on the interface board terminal strips can become oxidized and
interfere with meter readings. Make sure to use sharp tips and apply enough pressure and or
scraping action to get a good connection.
Note 1: The diagnostic lamp blinks 1 to 11 times with a pause at the end of the blink cycle.
The number of blinks is the error code
Note 2: The system outputs a two second blink immediately after it is powered up. This can
be checked by turning the key off for 6 seconds then back on.
Note 3: T Terminal.
7-156
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-157
7-158
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-159
7-160
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-161
7-162
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-163
7-164
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-165
7-166
DRILLING SOLUTIONS
3.1 Standard Test Conditions
EAR/EFR system is fully assembled with all connectors, actuators, and sensors
connected and tight. The system has a limited number of parts that can easily be
given a quick examination. This can save a lot of time.
The engine is not running
The engine ignition (Key Switch) is ON
Machines with the capability to select a drill mode should be pre-set to that mode
Machines that have an transfer case should have the box disengaged.
Receiver tank discharged
Compressor on/off switch set to off position
Flow or volume knob set to minimum (fully counter clockwise)
Maximum pressure knob set to minimum (fully counter clockwise)
The throttle valve should be open. (if equipped)
3.2 Error Code Meaning and Diagnostic Information

Table 2: Diagnostic Error Codes with Possible Faults
cause the error
Code
1
Error Description
The vacuum sensor input has been below 1.05 Volts DC (2 PSIA )
and above 0.5 Volts DC (0 PSIA) for more than 30 seconds.
Possible non-rotating compressor causes include
Low vacuum sensor supply voltage
Partial short in vacuum sensor output signal wiring
Damage controller
The butterfly valve is not opening and the vacuum has remained
low for too long.
DRILLING SOLUTIONS
7-167
cause the error
1

machine.)
2
The vacuum sensor input has been below 0.25 Volts DC Possible causes
include
Disconnected or damaged vacuum sensor wiring
Low Vacuum sensor wiring
Shorted Vacuum sensor wiring
Damaged controller

machine.)
3
The pressure sensor input has been below 0.25 Volts DC or Greater than
4.75 Volts
DC Possible causes include
Damaged pressure sensor
Disconnected or damaged pressure sensor wiring
Low pressure sensor supply voltage
Shorted Pressure sensor wiring
Damaged controller
Interface board terminals for pressure sensor
7-168
49 Pressure Sensor Supply (20-30 Volts DC)
50 Pressure Sensor Ground
51 Pressure Sensor Signal (0.48-0.51 Volts DC)
DRILLING SOLUTIONS
cause the error
3
The flow potentiometer input is below 0.25 Volts DC or Greater than 5.75
Volts DC
Damaged flow potentiometer
Disconnected or damaged flow potentiometer wiring
Low flow potentiometer supply voltage
Shorted flow potentiometer wiring
Damaged controller
Interface board terminals for flow potentiometer
40 Flow Potentiometer Supply (4.6 Volts DC)
41 Flow Potentiometer Return (0.4 Volts DC)
42 Flow Potentiometer Signal (counter clockwise 0.4 Volts DC

The maximum-pressure potentiometer input is below 0.25 Volts DC or

Greater than 5.75 Volts DC Possible causes include
Damaged maximum-pressure potentiometer
Disconnected or damaged maximum-pressure potentiometer

wiring
Low maximum-pressure potentiometer supply voltage
Shorted maximum-pressure potentiometer wiring
Damaged controller
Interface board terminals for Max Pressure potentiometer
DRILLING SOLUTIONS
43 Max Pressure Pot Supply (4.6 Volts DC)
44 Max Pressure Pot Ground (0.4 Volts DC)
7-169
cause the error
5
45 Max Pressure Pot Signal (counter clockwise 0.4 Volts DC

The controller is not receiving the data from the engine. (J1939) Possible
causes include
Wiring problem in J1939 circuit
Damaged Power-view disrupting communications
Damaged Engine ECM
Damaged controller
Interface board terminals for J1939 Data from machine
34 Data Low (2-3 Volts DC)
35 Data High (2-3 Volts DC)
The regulated 5 volt supply the controller provides to the interface board is
below 4.8 Volts DC or above 5.2 Volts DC.
Short on interface board or wiring between controller and interface

board
Damaged controller
Interface board terminals for the plus 5 volt supply and ground.
7 Plus supply from controller (5 Volts DC)
The Engine speed as reported by the J1939 data link and the Shaft speed
sensor do not agree when the drill mode is selected. Possible non-rotating
compressor causes include
7-170
Damaged controller
DRILLING SOLUTIONS
cause the error
8
Wiring shorted to Fan drive PWM output or some other device that
outputs a modulated voltage.
The tail shaft is not turning at the correct speed for the reported
engine speed. Possible causes include
1. A transmission or other drive line component is in the
wrong gear.
2. A drive line disengagement component such as a clutch
is not engaged.
Damaged Speed Sensor
Disconnected or damaged speed sensor wiring
Damaged controller
Interface board terminals for Shaft Speed Sensor
72 Shaft Speed Sensor Output signal

a.
Zero Volts DC on a non running machine.
b.
Approximately 5-6 VAC running at idle.
38 Shaft Speed Sensor Ground
The speed sensor is a conventional two wire magnetic pickup. The

resistance of the coil is approximately 2.5 k ohms.
9
The COC temperature sensor input is below 0.25 Volts DC or Greater than
4.75 Volts DC Possible causes include
Damaged COC temperature sensor
Disconnected or damaged COC temperature sensor wiring
Low COC temperature sensor supply voltage
Shorted COC temperature sensor wiring
Damaged controller
Interface board terminals COC temperature sensor
DRILLING SOLUTIONS
71 COC Temp Sensor Supply (20-30 Volts DC)
75 COC Temp Sensor Ground
7-171
cause the error
9
74 COC Temp Sensor Signal (Section 3.7.4 can be used to look up

the approximate voltage to expect if the temperature of the
10
The hydraulic temperature sensor input is below 0.25 Volts DC or Greater

than 4.75 Volts DC Possible causes include
Damaged hydraulic temperature sensor
Disconnected or damaged hydraulic temperature sensor wiring
Low hydraulic temperature sensor supply voltage
Shorted hydraulic temperature sensor wiring
Damaged controller
Interface board terminals for Hydraulic temperature sensor
69 Hydraulic Temp Sensor Supply (20-30 Volts DC)
73 Hydraulic Temp Sensor Ground
70 Hydraulic Temp Sensor Signal (Section3.7.4 can be used to

look up the approximate voltage to expect if the temperature of the
11
One of the four temperatures monitored by the Electronic Fan Regulation

systems has exceeded its maximum temperature.
7-172
One of the temperatures is too hot.
Damaged hydraulic temperature sensor.
Damaged COC temperature sensor.
Damaged coolant sensor on the ECM system.
Damaged air intake sensor on the ECM system.
DRILLING SOLUTIONS
3.3 Blown Fuse Check List

1 Turn off the KEY input and verify the power to the controller is off.
Terminal 32 = Zero V
Terminal 78 = Ground
2 Use multi-meter to measure resistance between Terminal 32 and terminal 78 the resistance
should not be less that 20 Ohms.
3 If the resistance is less than 20 ohms there is a short in the system. Check the resistance of
every terminal to ground (Terminal 78) and eliminate the short.
Terminals 8 ,17, 33, N, 38, 47, 50, 53, 58, 64, 73 & 75
Are also ground and will always read zero ohms
3.4 Actuator Diagnostics Table

The actuator is composed of the following components
24 volt DC motor.
Intergrated gear box with life time lubrication.
Two cam operated limit switches.
Thermostat and heater.
Clockwise rotation always closes the valve

Counterclockwise rotation always opens the valve.
The actuator has 6 wires.
1. Clock Wise Supply
2. Counter Clock Wise Ground
3. Clock Wise Ground
4. Counter Clock Wise Supply
5. Heater Ground
6. Heater Supply
DRILLING SOLUTIONS
7-173
3.5 Actuator test using an actuator test box
Instructions
1. Make sure the white line on the actuator indicator knob is lined up with the scribed mark on
the actuator. (This requires removing the indicator knob).
2. Install the actuator test box in series with the actuator to be tested.
3. Set the speed switch to fast.
actuator response.
5. Set the speed switch to slow.
actuator operation at slow speed.
Results
7-174
The butterfly Valve should move in the direction commanded by the switch.
The actuator should have free travel from horizontal with the long edge of the
actuator to perpendicular to the same edge. (The actuator is stopped at the end of
travel by internal limit switches that can be heard as a faint click.) (The actuator
should not load up and stop.)
DRILLING SOLUTIONS
The actuator should stop in the horizontal position after moving clockwise and in the
perpendicular position after moving counter clockwise.
The actuator should move smoothly with a steady buzzing sound. (There should not
be any spots where the actuator loads up and slows down.)
If there appears to be a problem with the actuator.

Possible causes include.
If the actuator operates backwards of the indications on the tester there are two
possible causes.
1. The heater circuit is wired backwards. (Diagnose and repair.) (This problem
does not affect operation of the system. It should however be corrected.)
(Use the schematic and connector pin diagrams to diagnose and correct.)
2. The test box is wired incorrectly. (Use the tester schematic and connector
pin diagrams to diagnose and correct.)
If the actuator does not travel the full operating distance there are several possible
causes.
1. The limit switch or limit switch cam have come loose. (It will be necessary
Diagnose and repair. Remove the cover and correct the problem.)
2. Something inside the valve is stopping the actuator. (It will be necessary to
remove the actuator from the valve to isolate this cause, then diagnose and
repair the problem.)
3. The actuator has broken internal gears or other mechanical problems. (It
will be necessary to remove the actuator from the valve to isolate this
cause, then diagnose and repair the problem.)
If the actuator does not stop in the horizontal position after moving clockwise and in
the perpendicular position after moving counter clockwise. (the internal cams will
need to be adjusted.)
3.6 Potentiometer Testing using a multi-meter

Instructions
1. Rotate the shaft to a position approximately have way between the mechanical stops.
2. Measure the resistance between the three Wires/Terminals until the pair with the greatest
resistance is found.
The resistance should correspond with the resistance marked on the pot.
The resistance between either one of these wires and the third wire should be
approximately half resistance marked on the pot.
3. This pair of Wires/Terminals are the two ends of the resistive element.
4. The third Wire/Terminal is the wiper.
DRILLING SOLUTIONS
7-175
5. Rotate the shaft fully in one direction and measure the resistance as the shaft is rotated
slowly in the other direction.
The resistance should change from approximately the resistance of the pot to near zero
ohms. (Depending on the direction you rotated the action could be reversed)
The resistance should change smoothly with to places where the resistance changes or
appears to be unstable.
The resistance should be stable when side loading is applied to the shaft (provided the
shaft is not rotated)
Section 3.7 Tables

3.7.1 Voltage output for Vacuum Sensor
7-176
DRILLING SOLUTIONS
3.7.2 Voltage output for Pressure Sensor
3.7.3 Atmospheric Pressure to expect at various elevations and the Vacuum

sensor output for that pressure
DRILLING SOLUTIONS
7-177
3.7.4 Temperature Sensor voltage output at various temperatures
3.8 Summed On/Off Inputs Decode Table

The interface board sums (adds together) the three on/off inputs to create a single voltage that
the controller decodes to determine the status of these three inputs:
Key switch
Compressor on/off switch
Auxiliary on/off switch
This table can be used to determine if a specific input will be decoded as ON or OFF.
7-178
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-179
4.1 Schematics
7-180
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-181
7-182
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-183
7-184
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-185
7-186
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-187
7-188
DRILLING SOLUTIONS
7-6 HYDRAULIC SYSTEM

Hydraulic System Introduction
The 270MP series drills are hydraulically driven blast hole drills. Power to drive the hydraulic
systems is supplied by a diesel engine which drives a gearbox, which in turn drives three
hydraulic pumps. The three hydraulic pumps convert the mechanical rotary energy from the
engine to hydraulic energy which 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.
The hydraulic system consists of several circuits. Each circuit includes one or more pumps
which supply pressurized streams of hydraulic fluid to hydraulic cylinders and motors. The
three main hydraulic systems are the propel circuit, the feed and rotation circuit, and the
auxiliary functions circuit. Also included in this section is the cooling circuit.
DRILLING SOLUTIONS
7-189
7-7 HYDRAULIC SYMBOLS

Fluid Power Symbols
Understanding and recognizing fluid power symbols is skill used in reading schematic
drawings for trouble shooting. It will also aid in understanding the schematics used to describe
the hydraulic systems used on Drilling Solutions drills.
Symbols on schematics are pictographs (pictures of what the object does) and are used to
represent the component. The following symbols are an international fluid power language
designed by the American National Standard Institute.
You will remember fluid power symbols more easily if you learn the significance of these three
shapes:
1. Circle = Pump, Motor or Gauge
2. Square = Valve of some sort
3. Diamond = Fluid Container
Line Symbols
Hydraulic lines, tubes and hoses that carry fluid between components are drawn as a line.
1. The Working Line is an unbroken line which connects symbols in the hydraulic
diagram together.
2. The Pilot Line denotes pilot pressure.
3. The Drain Line denotes system drainage.
Connections for lines are shown below. Pay attention to the presence of a dot at the
intersection of lines. If there is no dot and the lines cross, the lines do not connect. If the
lines intersect but one line ends, then even without a dot the lines do connect.
7-190
DRILLING SOLUTIONS
Crossing Line Symbols

Lets examine the crossing line symbols. These are fluid or lines that cross but do not join.
They are independent and separate of each other.
Joining Line Symbol
The symbols for joining lines. They show us that fluid paths are connected.
Flexible Line Symbol

The symbol for a flexible line or hose is also shown above. The curve in the line illustrates the
flexible hose and the two heavy dots represent terminal points.
Arrow Symbols
The arrow symbol appears in the working line. The arrow shows the direction of flow of the
fluid.
Reservoir or Tank Symbols

Reservoirs and tanks are used to contain fluids, provide cooling, separate air and oil, and
provide pressure to the pump if the reservoir is pressurized.
The tank and reservoir symbols are shown next. They appear on hydraulic diagrams as the
vented tank or pressurized tank. It is important to note that even though these symbols may
appear in many different places on a hydraulic diagram, there is usually only one centralized
reservoir tank.
DRILLING SOLUTIONS
7-191
Reservoir symbols can also show the point of connection for suction and return lines as above.
Fluid Container Symbols

The condition of the oil is changed from one state to another. Typical conditioners are filters,
heaters and coolers which can contain drains of various sorts. Symbols for fluid conditioners
are shown below. The symbol with a dotted line drawn from top to bottom represents an oil
filter. The same symbol with arrows at the top and bottom of it represents an oil cooler.
Accumulator Symbols
Hydraulic accumulators act as shock absorbers for the system. They are installed in parallel
with the pump and do several things. They dampen out oscillations in pressure (keep pressure
constant) and provide flow when components move and activate. The are drawn as ovals with
a line in the center which represents the diaphragm or piston that separates the oil from the
spring or gas. On the left is the gas loaded type, in the center is the spring loaded type and on
the right is the weighted type.
7-192
DRILLING SOLUTIONS
Restrictor Symbols
Sometimes its necessary to slow down flow or to create a pressure drop at some point in the
system.
Restrictors are drawn to represent a pinch in the line, and can either be fixed or variable and
can be controlled by other systems as well, such as being temperature or pressure controlled.
Hydraulic Cylinders
Hydraulic cylinders convert fluid power to linear mechanical power. Fluid under pressure
pushes against the ends of the piston to move it in order to move some other mechanism.
Cylinders are drawn as rectangles with lines in the center to represent the piston, and lines
through the ends to represent the rod. Fluid ports are shown on the outer ends of the
cylinder barrel.
A single-acting cylinder has only one port so that fluid under pressure only enters one end
and pushes only in one direction. The cylinder reverses by opening a valve to let gravity or a
spring return the piston to the other end.
A double-acting cylinder has ports at each end so pressurized fluid will enter both ends and
push against the piston in both directions.
DRILLING SOLUTIONS
7-193
Activating Device Symbol

There are a variety of ways to actuate control valves. These include manually by hand with a
lever, by foot with a pedal, with an electric solenoid (coil), using external pilot pressure, using
a spring, using internal pilot pressure or using any combination of the above.
There are ten basic arrangements that will appear from time to time on hydraulic diagrams.
These symbols show how a pump, motor or valve is actuated. They are shown below.
7-194
DRILLING SOLUTIONS
Miscellaneous Symbols
Miscellaneous symbols are shown below.
Pump and Motor

It is important to note that the only difference in the pump and motor symbols is the direction
of the energy triangle. Remember that in the pump symbol the energy triangle is pointed
outward toward the working line. In the motor symbol the energy triangle is pointed in toward
the center of the circle, away from the working line.
Pump Symbols
Pumps are drawn as circles with triangles pointing outward from the center. The triangle
represents the direction that fluid flows out of the pump and should be viewed as an arrow. A
single arrow shows a one-direction (uni-directional) pump, while two arrows indicate a
DRILLING SOLUTIONS
7-195
reversible (bi-directional) pump. A diagonal arrow cutting across the pump body indicates the
pump displacement (output flow and volume) can be adjusted. A small rectangle on the side
of the pump with a small arrow inside indicates that the pump output is compensated (adjusted
or controlled) by a pressure signal from a pilot line.
Pumps are also drawn to indicate how their output can be controlled. The attachments to the
pumps look like the components they represent. The lever and pedal look like a lever and
pedal. The drive shaft is shown as a pair of lines on the side of the pump, either with or without
an arrow showing the direction of rotation. Pumps can also be drawn as stacks, which indicate
that all pumps are driven by the same driveshaft.
Hydraulic Motor symbols

Motors are drawn as circles with triangles pointing in toward the center of the circle. Hydraulic
motors are actually hydraulic pumps that work in reverse. Except for a few differences, pumps
and motors are identical. Use the same rules to interpret motor symbols as you would for pump
symbols.
7-196
DRILLING SOLUTIONS
Instrument Symbols
There are three types of instrument symbols which you should know. The pressure gauge
symbol is shown on the left side below. The temperature gauge is shown in the center and the
flow meter symbol is shown at the right.
Valves
Notice that the box symbols have lines drawn to them. These are referred to as ports. At the
left is a two port valve, commonly called a 2 way valve. In the center is a three port, or 3 way
valve. On the right is a four port or 4 way valve.
Hydraulic pressure is controlled through the use of valves that open and close at different
times to allow fluid to be bypassed from points of high pressure to points of low pressure. The
basic valve symbol is a square (box) which represents the valve body or spool. An arrow in
the center represents the path oil takes through the valve.
Pressure control valves are typically pilot operated - that is, the valve is moved automatically
by hydraulic pressure and not by a person. Pilot oil pressure is resisted by a spring, which can
often be adjusted. The higher the spring tension, the more fluid pressure required to move the
valve.
To visualize the operation of this type of valve, imagine that the entire square will move away
from the pilot line and towards the spring. If the valve is normally open, fluid flow will be cut off
by the pilot line. If the valve is normally closed, the pilot line will cause oil to start flowing.
Valves can either be ON/OFF valves with no flow in the middle, or infinitely variable, which
means flow will gradually increase or decrease as pilot pressure increases and/or decreases.
DRILLING SOLUTIONS
7-197
Three Position 4 Way Valve

Let us examine the most common of all control valves, the three position 4 way valve.
This control valve directs fluid or oil flow to a forward position, a neutral position, or a reverse
position. This illustration shows the fluid or oil flow path when the valve is in neutral position.
In neutral, oil flows from the pump into the valve and back to the tank.
Arrows
Arrows in the adjoining squares show the fluid flow path when the valve is shifted to the other
positions.
Forward Position
With the forward position activated, the fluid or oil flows from the pump through the valve and
onto the left side of the cylinder. Return oil from the cylinder is released through the valve and
back to the tank.
7-198
DRILLING SOLUTIONS
Neutral Position
With the valve in the neutral position, fluid or oil is allowed to flow from the pump through the
valve body and back to the tank.
Reverse Position
With the reverse position activated, fluid or oil flows from the pump through the valve and into
the right side of the cylinder.Return oil from the left side of the cylinder is released back through
the valve and returned to the tank.
Valve Centers
Lets look at valve centers now. There are four main center valve configuration symbols.
1. Closed Port - Closed Center
2. Closed Port - Opened Center
3. Open Port - Closed Center
4. Open Port - Open Center
DRILLING SOLUTIONS
7-199
Series Parallel Valve

Now that we have seen our directional control valves at work, lets see how we bank two or
more valves together. In this diagram, one pump is supplying oil to two valves for control of
two different actuators. The valves are connected together by a parallel passage which allows
simultaneous operation of both functions.
When the bottom valve is shifted to the reverse position, oil is still available for the other spool
through the parallel passage. This is called a series parallel valve.
There are several other symbols which will often appear on a hydraulic diagram.
Manual On-Off Valve

The symbol for a manual on-off valve is shown.
Pressure Relief Valve

A pressure relief valve is a normally closed valve that senses the high pressure at its inlet. As
the pressure at the inlet increases, the pressure in the pilot line begins to push against the
valve body (spool). As the valve body moves, the ports begin to line up and fluid will begin
flowing through the relief valve. The relief valve typically dumps back into the reservoir. Most
relief valves are infinitely variable.
7-200
DRILLING SOLUTIONS
Sequence Valve
A sequence valve is a normally closed valve that opens once the inlet pressure reaches a preset point. This type of valve is designed to allow different components to act sequentially,
meaning one after the other. Once the primary actuator reaches the limit of its travel, fluid
pressure in the feed line will rise. This rising pressure opens the sequence valve which allows
fluid to flow through it to the secondary cylinder.
Pressure Reducing Valve

A pressure reducing valve is a normally open valve that senses the outlet pressure going to
an actuator. As the pressure in the outlet increases, pilot pressure increases which gradually
closes the reducing valve. As the valve closes, oil from the high pressure side of the valve is
directed back to the reservoir which dumps pressure at the outlet.
Check Valve
Another important valve symbol is the check valve. The check valve is shown with the direction
of the free flow to the left. Fluid cannot flow to the right because the ball will seat.
Pilot Operated Lock Check Valve

The pilot line symbol indicates a pilot operated lock check valve. This valve will allow reverse
flow when pilot pressure is present.
DRILLING SOLUTIONS
7-201
Bypass Valve
The check valve symbol is also used to show a bypass valve. In this application, the ball is
held seated by spring pressure and the valve opens when pressure drop across the filter
becomes too great.
Overcenter Valve
The over center valve shown below throttles return oil to prevent a runaway condition on a
heavily loaded cylinder or motor. If the cylinder should try to collapse faster than the pump is
supplying oil, the pilot pressure will drop and the over center valve will throttle the exhaust oil
leaving the cylinder.
Review
Lets review. A typical hydraulic diagram is shown below. Can you name all the components?
1.
2.
3.
4.
5.
6.
7.
8.
9.
7-202
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-203
7-8 PROPEL SYSTEM

Propel Circuit
The 270MP drill is mounted on two crawler type tracks, each powered by a fixed displacement
hydraulic motor, operating through a planetary gear set to a final drive which turns the drive
sprocket. The hydraulic motors are bent axis types, each driven by one main pump using a
closed loop circuit.
Components
The primary components of the propel circuit are the main hydraulic pumps, propel motors,
filters, valves and controls. Hydraulic pumps are used to provide oil flow to the various
cylinders and motors connected to different devices. They do not cause pressure in
themselves but react to forces on each system.
Main Hydraulic Pumps

The main pumps are closed-loop, hydrostatic transmission package, piston type pumps. The
main pump symbol is shown on the next page. The entire pump is depicted as a package.
Loop basically means the complete path of hoses, fittings, valves, motors and other
components the oil flows through on its way from and back to the pump. 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.
Hydrostatic Transmission means that the pump is designed for use in a system in which power
is transmitted by the pressure of a fluid. It is designed to work with very little slippage and
leakage. Package means that the pump unit contains not only the main pumping element but
also the controls, valves and auxiliary pumps needed for proper interface with the hydraulic
system. The displacement of these pumps can also be changed (variable displacement). The
main pump schematic is shown on the next page.
The main rotating group is depicted as a large circle with two triangles pointing towards the
work port lines. It has a displacement of 7.25 cu.in./rev. when adjusted to achieve full volume
output. A long arrow through the circle means the pump displacement is variable. The two
main work ports are the A and B ports. Either port can discharge oil depending on the
7-204
DRILLING SOLUTIONS
position of the pump displacement controls. Which ever port is not discharging oil is receiving
oil. In other words, if oil is leaving port A, practically the same amount of oil is being returned
to port B.
Two ports that are connected to ports A and B are AG and BG respectively. These ports
provide a place to attach a pressure gauge. On the 270MP drill, these ports are used to
interface with the hot oil shuttle.
An auxiliary charge pump, housed within the pump package, is driven off the main pump shaft.
This is represented schematically by a circle with one triangle pointed toward the work port.
The purpose of this small pump is to provide oil to work the pump controls and to charge the
main pump loop so that it never runs out of oil.
Oil is supplied to the charge pump through port C. Oil leaving the charge pump is directed to
the swash plate control system. Any oil that is not used for swash plate control passes over
the servo relief into the loop replenishment circuit.
Replenishment oil can flow through the check valves that correspond to the A and B ports
or it can flow over the 200 psi charge relief valve to the pump case. As long as pressure on
DRILLING SOLUTIONS
7-205
either side of the loop does not exceed 200 psi, the relief valve will not open. Any excess oil
which does dump over the relief valve mixes with leakage oil already in the pump case and
leaves the package pump through port D1 or port D2 (case drain flow).
Pump controls used with the main pump are proportional. Operator input is supplied
electrically to the pump through the electric stroker via a proportional electric controller. When
the operator moves the control handle, the electric input is converted to a hydraulic input (top
triangle). Here it is amplified (left triangle) and the resulting output (lower triangle) drives the
pump swashplate positioning system.
Pump controls used with this pump are the electric stroker, rotary servo control and the
pressure compensator. The electric stroker is represented schematically by the box with the
diagonal arrow that indicates variability . The rotary servo is represented schematically by the
box containing three triangles and a circle. The pump compensator (main relief valve) is
represented schematically by the box containing an arrow (between the servo control and the
main pump symbols).
The Pressure Compensator can override the swashplate controls whenever its pressure
setting is reached. The compensator can be remotely set by regulating the pressure at port
VA or port VB. If ports VA and VB are plugged, the compensator will limit the pressure
in either A port or B port to 4500 PSI.
If port VA is remotely relieved to a lower pressure, (i.e. pulldown relief), pump port A
pressure will be limited to the remote pressure instead of the higher internal setting. The same
principal governs the operation of the VB port (pullback).
The Main Pump Compensator adjustments should not normally change. If it becomes
necessary to replace a pump, a trained factory service representative should be called.
Propel Motors
Propel motors rotate the final drive mechanism in the undercarriage system to make the tracks
move forward or backward. The more flow provided to a motor, the faster it turns.
The Propel Motors are closed-loop, axial piston. fixed displacement hydrostatic transmission
motors. Oil is supplied to the basic motor through either the A port or the B port. Supplying
oil to the A port will cause the motor to rotate in one direction. After the oil is used to rotate
the motor it leaves through port B. Oil supplied to port B will cause the motor to rotate in the
7-206
DRILLING SOLUTIONS
opposite direction and will leave through port A.

Propel motors all have case drain lines that must be connected to prevent pressure buildup in
the motor housing. The case drain returns any oil from the housing to the tank.
Propel Motor Brake

Since there is no dynamic friction brake system on a hydraulically operated drill, the braking
ability is provided by a brake mechanism that prevents the hydraulic motor from turning. This
locks up the final drive and prevents the track from moving.
The motor brake is a spring actuated, hydraulically released, multiple disc, static brake unit. It
is a self-contained unit that fits between the propel motor and the track drive final gearbox. In
normal operation, springs load the brake discs to keep the motor shaft from turning. This
default operation ensures that the brake will apply automatically if oil is not supplied to the
brake oil port.
The brake is released by supplying pressurized oil (500 psi) to its oil port. Pressure pushes on
the springs to release the load on the brake discs. This allows the motor shaft to turn. The
brake will remain released as long as pressure is being supplied.
Diverter Valve Assembly

The diverter valve assembly is a complete unit that manages all shifting, flushing and auxiliary
replenishing functions for the closed circuits. The assembly also includes 7 test ports that can
be used for troubleshooting. The valve is represented schematically below.
DRILLING SOLUTIONS
7-207
The purpose of the diverter valves is to shift the flow of a pump from one actuator to another.
For example, the propel system is not needed while in the drilling mode, so the diverter valve
shifts the flow from the propel circuit to the rotation circuit. Thus, one pump is used for two
functions.
The diverter manifold part of the diverter valve assembly includes two high-flow check valve
cartridges for replenishing, a shuttle valve cartridge for loop flushing and a relief valve
cartridge for maintaining minimum charge pressure.
The shifting functions done by the assembly are managed with two diverter valves bolted to
the sides of the manifold. The shuttle valve cartridge and the relief cartridge within the diverter
manifold comprise the loop flushing circuit. These components acting together remove a small
portion of the total oil available in the transmission loop. This oil leaving the loop carries with
it some of the heat and contamination which may be present in the system. The circuit is
represented below schematically by the three position directional valve and relief valve.
The three position valve is normally centered by its springs. In this position, no oil flows out of
either the PA side or the PB side of the loop. The valve shifts whenever there is an unbalance
of pressures across the pump. For example, if the PA side of the loop is at a higher pressure
than the PB side, the shuttle valve shifts to the PB side oil (low pressure oil) to leave the loop.
The relief valve allows the selected oil to flow from the loop as long as the low side pressure
is at least 150 psi. If the pressure in the low side of the loop drops below 150 psi, then the relief
valve closes to block the flow path. The shuttle valve cartridge is a special assembly that has
a controlled shift feature. This feature is represented by the flow control and check valve
symbols on the shuttle shift ports. The slow shift keeps pressure spikes in the loop from
entering other hydraulic systems on the drill.
Three test ports allow monitoring of the loop flushing circuit. The test ports at GA and GB allow
access to the working pressures in the loop. The test port at GC provides a place to check the
relief setting.
The auxiliary replenishing check valve cartridges are represented by the check valve symbols
shown on the next page.
7-208
DRILLING SOLUTIONS
One valve connected to each side of the loop provides a path through which additional
supercharge oil can be injected into the loop. If charge pressure in either side of the circuit
drops below the pressure at port CH, the appropriate check valve opens and allows oil to flow
into the loop. When the pressure at port CH drops below pressure in the circuit, the check
valve closes again so that high pressure in the loop cannot escape.
The diverter valves are two-position, hydraulically shifted four-way valves and are represented
schematically
The spring on the top of the valve requires the valve to be shifted so that PB is connected to
DB and TB is blocked when no hydraulic shift signal is present. The shift operators are
represented by a triangle in a box on each end of the valve. A hydraulic pressure applied to
either operator will cause the valve spool to shift to the position corresponding to the signal. In
other words, pressure applied to the top of the spool through the X port will cause the valve to
shift to the PB to DB position. When no hydraulic pilot shift signal is present, the normal mode
is drill.
The diverter valve consists of a housing with the sliding spool and spool operators. The valve
is bolted to the diverter manifold with six socket head capscrews. The diverter manifold
provides test connections for measuring pressure in PB (pump pressure), TB (propel
pressure) and DB (drill pressure).
There is a spring installed within the valve body to actuate the spool on the X end. This is to
assist in moving the diverter valve to the drill position. In the event of a loss of hydraulic
pressure, the spring will shift the valve into the drill mode position. This position vents
hydraulic brake pressure to tank and prevents the drill from moving. Refer to the Oil Path
Selection information.
DRILLING SOLUTIONS
7-209
Propel/Drill Mode Selector

The mode of operation (drill or propel) is determined by the operator of the drill. This is done
with the use of the mode selector switch, commonly called the drill/propel switch on the
operators console. There are two positions for proper operation, DRILL and PROPEL. The
mode selector switch is a two position electric switch. The switch is energized whenever the
ignition key switch is in the ON position. When the operator moves the mode selector switch
from one position to the other, electric power is diverted from one circuit to another. The two
circuits control the mode of operation in which the drill can be used.When the drill mode is
selected, only controllers used for drilling are energized. When propel mode is selected, only
the controllers for propel are energized.
At the same time the propel mode is selected, the drill/propel switch energizes the solenoid
operated drill/propel valve. When this solenoid is energized, the valve is shifted to divert pilot
pressure to the Y ports of the main diverter valves and at the same time to release the track
brakes. The internal, normally open pilot operated check valves are piloted closed. This
effectively isolates the pump compensator, allowing it to control the maximum system
pressure. The drill/propel hydraulic valve and the schematic representation are shown on the
next page.
Drill/Propel Control Valve

The drill/propel valve is a manifold and valve assembly that contains all the components
required to: 1) control diverter valve shifting from the drill mode to propel position and vice
versa, 2) control propel brake operation, 3) limit torque of the drill rotation circuit and 4) limit
drill feed force.
The valve assembly consists of a steel manifold with 4 cartridge valves and an electrically
operated two-position four way valve. The drill operator selects the mode of operation by the
use of an electric mode selector switch on the operators panel. The drill/propel valve is located
below and between the diverter manifolds.
7-210
DRILLING SOLUTIONS
Hydraulic pilot pressure is provided by the fan circuit to the P port of the drill / propel valve.
When propel mode is selected, the electric coil on the solenoid operated valve is energized,
the valve shifts and flow is directed from the P port of the drill/propel valve through the 4-way
valve to the Y ports. At the same time, the pilot operated two way valves are piloted to the
closed position. Oil at the manifold Y port is also available to the brake pressure reducing
cartridge. Oil crossing this cartridge is reduced to 500 psi. The check valve in parallel with the
reducing valve allows rapid return of oil at the BR port to the drill/propel control valve to allow
monitoring of function pressure as well as diagnosis of problems.
Within the CP1 and CP2 ports are the normally open pilot operated check valves. These
valves allow communication between the pump compensator and the remotely operated
device for controlling pump pressure. When the operator selects propel mode, pilot pressure
closes these two pilot operated check valves, isolating the pump compensator. Therefore, in
propel mode the pump compensator determines the maximum pressure limit, not the operator.
Loop Filling/Replenishment
The oil needed to initially charge the main loop, and keep it full, is picked up by the charge
pump at port C. Port C connects to the reservoir through the suction hoses. Oil is
continuously injected into the main loop to make up for normal leakage in the pump, motor,
diverter valves, and to make up for the oil being stripped out of the loop by the hot oil shuttle
in the loop flushing circuit.
Leakage from the main pump is collected in the pump case and returned to the main hydraulic
reservoir by way of the pump D port. Motor leakage oil, combined with hot oil shuttle flow,
also returns to the system reservoir through the case drain manifold included in another circuit.
DRILLING SOLUTIONS
7-211
When the pump is in neutral, the leakage flow from the pump is supplemented by charge flow
that comes from the charge relief valve in the pump. Propel motor leakage is collected in the
motor case and it is also returned to the drain manifold.
Loop Flushing Circuit

The Loop Flushing Circuit removes a small portion of the total oil available in the transmission
loop. This oil, leaving the loop, carries with it some heat and contamination that may be
present in the system.
The valve circuit, commonly called the hot oil shuttle valve, is represented schematically by a
three position directional valve and relief valve. The three position directional valve is normally
centered by its springs. In this position, no oil flows out of either the A side or the B side of
the loop. The valve shifts whenever there is an unbalance of pressures across the circuit. For
example, if the A side of the loop is at a higher pressure than the B side, the shuttle valve
shifts to allow B side oil (low pressure oil) to leave the loop.
The relief valve guarantees that the minimum desired loop pressure will always be maintained.
In other words, the shuttle cant cause the main loop to run out of oil. The relief valve is set at
150 psi.
There is one loop flushing circuit for each main pump. The circuits work with their respective
pump whatever the mode of operation (drilling or propelling).
Circuit Operation
The primary oil path in the propel circuit are the closed hydrostatic loops indicated by the solid
lines connecting the main pumps to the propel motors on the schematic below.
7-212
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-213
7-214
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-215
There is a transmission system to drive each track. The main pump swash plate controls are
moved by an electrical input via a proportional electric controller. There is a controller for each
of the two main pumps corresponding to the left and right track drive systems.
Whenever the main pump is destroked (swash plate in neutral), oil does not flow in the loop
and the propel motor does not rotate. Moving the swash plate control out of its neutral position
in one direction causes oil to flow counter clockwise in the loop. The oil flow causes the propel
motor to rotate. Moving the swash plate control out of its neutral position in the other direction
causes oil to flow clockwise in the loop. The propel motor now turns in the opposite direction.
The speed of the motor in either direction is governed by the amount of pump swash plate
control movement.
The two transmission systems (two pumps and two motors) allow each drill track to operate
independently of each other. The tracks can turn at different speeds or even in different
directions to provide maximum drive and steering flexibility.
Oil Path Selection

The only interruptions in the main loops are the four diverter valves. The diverter valves are
shifted to connect the main pumps to the propel motors whenever the propel circuit is
energized. These valves are shifted to connect P to A and B to T whenever the propel
circuit is energized. The propel circuit uses the P and A ports on all four valves. The valves
are all shifted by supplying oil to the X or Y ports. This is done by shifting the drill/propel
valve. Oil for this purpose is supplied by the auxiliary circuit manifold through the drill/propel
control valve assembly.
In the Propel Mode, the Drill/Propel Selector Valve directs oil to the Diverter valve Y ports
and drains the X ports. At the same time, oil is also directed to release both motor brakes
and to energize the propel alarm switch. A point to remember is that with the drill off, the control
system defaults to the Drill Mode. This is why the spring in the Diverter is on the X port side.
7-216
DRILLING SOLUTIONS
7-9 FEED & ROTATION SYSTEM

Feed System
The function of the feed system is to provide force to the drill bit. The net downward force
comes from two sources:
1. The weight of the drill string (including the weight of the rotary head and the
feed cylinders).
2. The net force applied by the feed cylinders to the drill string.
The following description of operation will demonstrate how the individual parts of the feed
system respond to operator input to provide accurate force control at the bit.
Mechanical System
The mechanical components of the feed system are the drill string, the rotary head assembly
and the feed cylinder barrels. The weight of the drill string changes each time a drill rod is
added. For example, if four (4) drill rods are used to drill a hole and each drill rod weighs 2,200
lbs (997.9kg), the total force applied to the bit by the mechanical components varies from 6000
lbs. (2721.6kg) with no drill rods to 14,800 lbs. (6713.2kg) with four drill rods.
Hydraulic System
The hydraulic feed components include the cabside (CS) main pump, the feed cylinders, the
over-center valve, pressure control valves, two pilot operated check valves and the two 2-way
(OPC) valves.
DRILLING SOLUTIONS
7-217
7-218
DRILLING SOLUTIONS
Feed
The drill feed circuit uses the cab side (right side) pump and the pulldown cylinders in a closed
loop circuit. This pump is controlled by moving a proportional electric controller located on the
operators console in the operators cab. The controller operates the pump stroker to control
oil flow. When the pump is destroked (controller in center/off position), no oil flows in the
transmission loop and the feed cylinders do not move. If the pump is stroked (either forward
or reverse), the cylInder rod moves up or down correspondingly. The speed of cylinder travel
is proportional to the amount of main pump flow (amount of controller lever movement).
The main components of the feed system are the main pump, diverter valves, drill/propel
control valve and the feed cylinders. Lets start with the main pump.
Feed Pump (CS Main Pump)

The Main Pumps used for the Drill Feed and Rotation Circuits are also used for the Propel
Circuit. A description of their characteristics and schematic can be found in the Propel Circuit
Section of this manual.
DRILLING SOLUTIONS
7-219
The (CS feed) main pump is a variable displacement, closed loop, axial piston pump. It is bidirectional and able to supply oil flow from either of its two work ports. It is pressure
compensated and is able to limit work pressure at any available flow. When oil flows from the
B port of the pump, the feed cylinders pull the rotary head and drill string up. This is known
as pullback. Oil flow out of the pump A port moves the rotary head and drill string down.
This is called pulldown.
Feed Cylinders
The feed cylinders are double acting, double rod cylinders. Double Acting means that the
cylinder can be powered down or powered up (extend and retract) with the hydraulic system
oil. The cylinder, unlike most cylinders which have only one piston and one rod, has two
pistons which work independently of each other.
Oil supplied to the extend side of the feed cylinder is carried down the center of one rod to the
cavity between the two pistons. The oil pressure between the pistons causes the two rods to
move away from each other. As the rods extend, the oil on the opposite sides of the pistons is
forced out through paths which return the oil to the cylinder retract port.
When the oil flow is reversed, oil is supplied to the cavities between the cylinder barrel and the
cylinder rod. The pressure acting in this cavity causes the rods to retract. The oil between the
two pistons now returns to the extend port.
Holding Valve
The holding valve (feed system control valve) is shown below. The assembly contains an over
center or holding circuit to hold back pressure at the CR ports and another over center circuit
to control oil flow from the PB port.
The over center circuit that controls pressure at CR is shown on the left half of the schematic.
When oil flows from the PR port to the CR ports, the check valve opens and the oil goes around
the over center valve. When oil is flowing from the CR ports to the PR port, the over center
valve provides a flow resistance. The over center valve resistance is influenced by the spring
7-220
DRILLING SOLUTIONS
setting, the CR pressure and the PB pressure. The spring setting is always fixed for a
particular application, but the CR and PB pressures change due to influences outside the
valve.
The over center circuit that controls flow from the PB port is represented on the right half of
the schematic. The over center valve opening is influenced by its spring setting and by the
pressures at PR and PB. The valve is set so that pressure at PB alone is not sufficient to cause
valve opening. Pressure applied at the PR port will open the valve, however, since this
pressure acts on a larger area within the valve.
Over center Valve

The over center valve is in the hydraulic circuit to provide a resistance to downward rotary
head movement bias caused by gravity. The valve is a pressure controlled device and is
capable of restricting flow to whatever level necessary to sustain a desired back pressure. The
valve has a cylinder port, valve port (which is attached to the pump) and a pilot port. The
pilot port is normally attached to the A port side of the pump circuit.
While picking up the drill string, oil from the pump flows through the check valve with no
restriction. When the pump flow is reversed, oil leaving the cylinder cannot go through the over
center valve until the pilot pressure is great enough to open the relief.
Pressure Control Valve

The pressure control valve is an electronically controlled, proportional relief valve.
Two-Way Valve
The two-way valve has a closed position and an open position that can be activated by a
plunger. In the normal position, the valve spring holds the valve closed so that oil cannot flow
from the P port to the T port. When the plunger is pressed, however, the valve shifts and
free flow is allowed.
DRILLING SOLUTIONS
7-221
Diverter Valve Assembly

The diverter valve assemblies used for the drill feed and rotation circuits are also used for the
propel circuit. A description of their characteristics and schematic can be found in the propel
circuit section of this manual.

The Drill/Propel Control Valve used for the drill feed and rotation circuits is also used for the
propel circuit. A description of their characteristics and schematic can be found in the propel
section of this manual.
Remote Compensator Control

In the drill mode, the compensator vent connections are utilized to provide interface with
remote pressure control devices.
This allows for the main pumps to be remotely controlled by the operator and gives variability
and infinite control of actuator speeds and pressures. The -4 line shows the connection at the
pump for remote control of the compensator. The other end of this hose connects to the drill/
propel valve at the CP1 port (compensator pressure). The cab side main pump provides flow
for the feed system. A hose from the VA port connects to the CP2 port. When in drill mode,
the oil from the VB port flows through the drill/propel valve to an electrically operated,
proportional control valve.
Increasing the electrical power to the control valve coil proportionally blocks off the path from
VB to tank. The more current the higher the pressure rises. The less flow through the valve,
the higher the pump pressure potential.When the path is fully blocked, the pump can generate
full compensator pressure.
NOTE: De-energizing the coil opens the valve fully. Therefore, if the
electrical circuit is open to the FEMA valve, no feed pressure or rotation
torque pressure will develop (If torque limit is on the drill).
7-222
DRILLING SOLUTIONS
Jack Two-Way Valves

The jack two-way valves have closed positions and open positions that can be activated by
plungers. In the normal position, the valve springs hold the valves closed so that oil cannot
flow from the P port to the T ports. When the plungers are pressed, however, the valves
shift and free flow is allowed.
There are two (2) normally closed, two-way valves piped in line with the compensator controls
for pulldown. The two-way valves are used in the overpressure control system.
DRILLING SOLUTIONS
7-223
Their purpose is to vent the feed pump compensator pressure under certain conditions. The
valves are mounted under the pipe nipples on the drilling end leveling jacks. When the leveling
jacks are lowered to the ground and the drill is raised of its tracks, the pipe nipples on the jack
cylinders are moved upward. This action moves the nipple away from the plunger on the two
way valve. If, for any reason, either jack pad no longer touches the ground, the nipple on the
cylinder lowers and pushes the plunger down. This opens the two-way valve, allowing all
pressure to vent from the A port. This reduces all down pressure from the pump until the jack
pad is firmly back on the ground. This can happen if the driller does not set both leveling jacks
on secure ground when he starts the hole, or it can happen if the ground gives away under
one of the drilling end jacks.
Over Pressure Control

The connections for the over pressure controls are part of the drill/propel valve. When in the
drill mode, the drill has the capacity to apply seventy five thousand pounds of force on the bit.
The drill is designed to vent pulldown force if the ground gives way beneath the jacks or for
some other reason the drill is unsupported.
The ports labeled OP1 and OP2 are common to the feed pump VA port and are connected
by hoses to the overpressure control valves. These valves are mounted, one on each of the
front (side) drilling end leveling jacks. If for any reason the drill is unsupported by the leveling
jack, the pipe nipple will drop to gravity and mash the button as shown. This opens the path to
tank, venting the feed pump compensator VA port.
NOTE: The Over Pressure control system should be tested daily to insure
proper functionality. If the system does not function properly, the drill
should be shut down immediately. The drill must remain shut down and
not used until the Over Pressure control system is repaired.
7-224
DRILLING SOLUTIONS

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 (50.8mm) off the ground. The drill weight must
be fully supported by the leveling jacks.
Step Two:
Step Three:
Step Four:
Slowly increase pulldown pressure to maximum (3400 psi) 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, reduce 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 dust collector side jack slightly. If pressure vents
when the jack pad is lifted slightly off the ground, the system is working.
If it does not vent pulldown pressure, shut down the drill immediately and report any problems
encountered to your supervisor.
Feed Circuit Operation

In the complete schematic for the feed circuit. The main flow path, represented by the solid
lines, is the closed loop connecting the main pump to the feed cylinders.
Oil Path Selection

The feed circuit is connected to the main pump by the diverter valve assembly. The diverter
valves are shifted to connect the cab side main pump to the feed circuit whenever the drill
mode is selected with the drill/propel valve. This is done by supplying oil to the X port and
venting the Y port on the diverter manifold. Oil for this purpose is supplied by the fan circuit
through the drill/propel control valve assembly.
DRILLING SOLUTIONS
7-225
In the drill mode, the drill/propel control valve directs oil to the diverter manifold X port and
drains the Y port. At the same time, oil is drained from the propel brakes so that they will lock.
In this mode, the drill/propel control valve also connects the cab side main pump compensator
to the pulldown gauge, the pressure control valve for force control and the two-way valves for
overpressure control.
The feed pressure control valve is controlled from the drill cab by the operator. This valve holds
main pump VA pressure at the level called for by the operator. This in turn holds the main
pump A pressure, and consequently feed force down pressure whenever they are actuated
by either of the drilling end leveling jacks on the drill.
Cylinder Extend and Retract

The drill feed system uses the cab side main pump and the feed cylinders in a semi-closed
circuit. Maximum pulldown pressure is 3400 psi on all PV-270 series drills. The main pump is
actuated by a proportional electric controller in the operators cab. When the pump is at zero
stroke, the cylinder does not move. If the pump is stroked to either side of neutral, the feed
cylinders extend or retract at a speed proportional to the pump flow.
The operation of the feed system control valve allows the feed cylinders to operate in two
different speed modes while extending. In the regeneration (higher speed) mode, oil returning
to the feed system control valve at the CR ports is directed through an internal sequence
valve and check valve where it combines with extend flow going to the cylinders. In the lower
speed mode, oil returning to CR flows through an overcenter valve and is returned to the
main pump B port. The speed mode for extend is selected automatically by the feed system
control valve.
The feed system control valve also corrects the unbalance in flow within the feed circuit when
the feed cylinders are retracting. In retract, the amount of oil flow entering the valve CB ports
is nearly twice the amount the pump can accept. Half of the returning oil is taken by the pump
and the remaining oil leaves the feed system control valve T port and is returned to the return
manifold in another circuit.
Loop filling/Replenishment
The oil needed to initially charge the feed circuit is picked up by the main pump charge pump
at port C. Port C connects to the drill suction manifold. The charge pump continuously
injects oil into the main loop to make up for normal leakage in the individual components, and
to make up for oil being stripped out of the loop by the flushing circuit in the diverter manifold.
Leakage from the main pump is collected in the pump case and returned to the drain manifold
by way of the pump D port. When the pump is in neutral, the leakage flow from the pump is
supplemented by charge flow that comes from the charge relief valve in the pump.
The flushing circuit in the diverter manifold takes additional oil out of the feed circuit when the
feed cylinders are retracting. This oil returns to the drain manifold. When the cylinders are
extending, the charge pressure at the B side of the main pump drops below 150 psi and the
flushing circuit allows no flow.
7-226
DRILLING SOLUTIONS
An additional replenishment connection to the feed circuit is provided by the diverter manifold
at CH. This port is connected to the supercharge manifold which holds a pressure of about
100 psi. When the feed cylinders are extending, oil flows from the supercharge manifold to the
pump inlet to correct the flow unbalance caused by the area differences in the feed cylinders.
Rotation System
The function of the rotation system is to rotate the drill bit and drill string while drilling or coming
out of the hole. The rotation force comes from two rotation motors located on the rotary head.
The rotation circuit is a closed loop hydrostatic transmission system. The rotation speed is
variable from 0 to 150 rpm at minimum displacement (6500 ft/lb. torque). The maximum torque
output of the rotation circuit is 9000 ft/lb. gross at maximum displacement (110 rpm). This
torque value is achieved by adjusting both motor displacement settings to the maximum
displacement and adjusting the pump displacement to maximum with the engine at full rated
rpm.
Rotation is produced by oil flow from the (DCS) main pump entering into the rotation motors.
The direction of rotation is controlled by the operator. If the rotation controller is pulled forward,
the rotary head turns in the forward direction. If the rotation controller is pushed away from the
operator, the rotary head turns in reverse direction, or breakout direction.
The basic components of the rotation circuit are the (DCS) side main pump, controller, diverter
valves, hot oil shuttle valve, rotation motors, rotary head, motor control valve, flow control
valve, relief valves, manifold and piping. An explanation of the function and operation of the
hot oil shuttle valve and replenishment can be found in the propel circuit section of this manual.
The same is true for the diverter valves. In the drill mode, the diverter valves receive pilot
pressure at the X ports. This shifts the four main diverter valves to the P to B and A to
T position.
DRILLING SOLUTIONS
7-227
7-228
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-229
Main Pump
The main pumps used for the drill feed and rotation circuits are also used for the propel circuit.
A description of their characteristics and schematic can be found in the propel circuit section
of this manual.
Rotation Motors
The rotation motors are variable displacement, axial piston motors. Each motor has a total
maximum displacement of 6 cubic inches per revolution (in.3/rev). The displacement is
variable from 3.0 to 6.0 in.3/rev. per motor.
Motor adjustment procedure is shown in the following adjustment section. The DCS motor has
a bolt-on motor control valve block on top containing a shuttle valve and a reducing valve. The
pressure reducing valve is properly set to 500 psi. The 500 psi is used to supply flow to the
motors internal servo. The servo working pressure must be limited to 500 psi maximum. The
pressure reducing valve, when properly adjusted, insures that the servo is not over
pressurized.
Since the motors are piston type, they require a case drain to allow normal internal leakage to
escape. A 25 psi check valve is in the drain line, located in the hard piping near the bottom of
the tower. Its purpose is to prevent the motor cases from draining when the tower is horizontal
or the drill is not running.
Located in one of the case drain ports on one of the motors is a 140 psi atmospheric check/
relief valve. Its purpose is to provide an emergency vent of excess pressure from the case if
the drain hose becomes kinked, pinched or plugged.
The motor displacement is controlled by the swashplate servo system shown on the schematic
as a box sitting on the motor. Inside the box are three triangles and a circle which represent
the servo input summing and output functions. The servo receives oil to power its systems
from the motor H port. It also receives an input from a mechanical arrangement of springs
7-230
DRILLING SOLUTIONS
and pistons indicated by the hat and spring on top of the servo envelope. The displacement of
the motor can be set at its maximum level or its minimum level by energizing the X port or
the Y port, respectively, on the motor.
Rotation Motor Displacement Adjustment

Adjust the rotation speed with pump on full stroke to achieve best results. Each of the two
rotation motors are variable. They can be adjusted from minimum displacement of three cubic
inches per revolution, up to the maximum setting of six cubic inches per revolution.
The lower displacement screws are used to increase or decrease the rotation motors
displacement, thereby increasing or decreasing the rotation speed of the drill pipe. To adjust
the rotation speed, remove the cap nut, loosen the jam nut and turn the set screws. Turn CW
to reduce displacement (increase rotation speed) or CCW to increase displacement (reduce
rotation speed). The two motors are identical. It is best to keep the displacement of the two as
closely matched as possible. This can be done by counting the exposed threads of the
adjustment screws and matching the number of exposed threads. Then, turn the two screws
equally until the desired spindle speed is reached. The upper displacement screws are not
used. It may be necessary to back out fully on the upper screws to allow for desired adjustment
of lower screws.
The two motor input controls must be figured the same way internally. Drawing above shows
the proper placement of the controls internal parts. When replacing either or both rotation
motors, you must insure that the new motor(s) has its input controller configured the same as
the motor removed. The internal control spools are not identical and can be switched top to
bottom depending on the application. The spools have lands of different lengths. The internal
spring can also be used on either end, depending on the application. Note the positions of the
spools and spring inside the original motor control and insure the new motor is configured the
same way.
Rotation Motor Control Valve

The motor control valve is an assembly that bolts to the top of one of the rotation motors. The
assembly contains a shuttle valve, a pressure reducing valve and a manifold. The shuttle valve
receives oil from both sides of the motor into its two ends. If the pressure available at one end
DRILLING SOLUTIONS
7-231
is higher than the pressure at the other end, the shuttle ball shifts toward the low pressure and
seals off that port. The higher pressure is then free to flow to the pressure reducing valve.
The pressure reducing valve is responsible for reducing the pressure of the oil to a lower
pressure so that it can be used in the rotation motor server system (about 500 psi). The
pressure reducing valve will open, close or even take oil in reverse to keep the REG port
pressure at the value set by the spring adjustment. Any oil that the valve takes back from the
REG port flows to the valve drain port where it can be passed back to the motor case.
As with the main pumps, the rotation motors swashplate is hydraulically actuated by a
hydraulic servo within the motor. This is accomplished with the use of the motor control valve.
There is no charge pump within the motor, therefore the motor control valve is designed to
contain a shuttle valve that selects the high pressure system port. The ball shuttles back and
forth, by pressure from the main loop. The source is determined by the direction of rotation. A
portion of the systems oil flow is used for servo control.
The pressure in the rotation system pressure can reach up to 4500 psi. Therefore, a pressure
reducing valve within the motor control valve is required to reduce and control pressure to the
servo. The reducer limits the servo supply to 500 psi and directs reduced pressure oil to the
motors H or servo port. The first time the rotation system pump is stroked after each motor
displacement screw adjustment, the swashplate moves. The swashplate remains in that
displacement position until another screw adjustment is made. The motor control valve must
be replaced as a complete unit. There are no adjustments required.
Rotation Circuit Operation

On the complete schematic for the rotation circuit is the main flow path, represented by the
solid lines, is the closed loop connecting the main pump to the rotation motors.
Rotation
The (DC) side main pump (rotation) is controlled by moving a proportional electric controller
located on the operators console in the operators cab. The controller operates the pump
stroker to control oil flow.When the pump is destroked (controller in center/off position), no oil
flows in the transmission loop and the rotation motors do not turn. If the pump is stroked (either
forward or reverse), the rotation motors will rotate in one direction or the other. Rotation motor
speed is proportional to the amount of main pump flow (amount of controller movement).
7-232
DRILLING SOLUTIONS
Motor Displacement Control

Oil must be supplied to the motor H ports to drive the swashplate positioning servo system.
Oil for this purpose must be at a lower pressure than that normally found in the loop. A
pressure reducing valve (motor control valve) externally mounted on the rotation motor
provides this oil.
Oil available at the motor control valve REG port is supplied to the H ports on both rotation
motors. The oil pressure moves the motor swash plates to the position called for by the
mechanical displacement adjustments on each motor. Adjusting the motors for smaller
displacements results in higher speed and lower torque.

Shifting the drill/propel valve to drill drains oil from the propel alarm and the y ports of the
diverter valves. This action also pressurizes the X ports of the diverter valves and shifts them
into the drill mode.
Since both pumps will be operating at different pressures in drill and propel, a means of
changing the relief settings had to be found. This was done with the pilot-to-open check
valves. By allowing flow through the check valve in the drill mode, the compensator can be
adjusted with a remote relief valve for both feed and rotation. Thus, when the drill/propel valve
is shifted, pilot pressure is applied to the back side of the two check valves and they are held
open. This allows each compensator to be regulated by the pulldown relief valve or the torque
relief valve, both on the operators panel.
Oil Path Selection

The only interruptions in the main loops are the four diverter valves. The diverter valves are
shifted to connect the dust collector side (non cab side) main pump to the rotation motors
whenever drill mode is selected. This is done by supplying oil to the X ports and venting the
Y ports on the diverter manifolds. Oil for this purpose is supplied by the fan circuit manifold
through the drill/propel control valve assembly.
In the Drill Mode, the Drill/Propel Selector Valve directs oil to the Diverter manifold X ports
and drains the Y ports. At the same time, oil is drained from the propel brakes so that they
will lock. In this mode, the Drill/Propel valve also connects the main pump compensator to the
rotation gauge and, in some applications, a pressure control valve. A point to remember is that
with the drill off, the control system defaults to the Drill Mode. This is why the spring in the
Diverter is on the X port side.
Loop Filling / Replenishment

The oil needed to initially charge each main loop and keep it full is picked up by the main pump
charge pump at port C. Port C connects to the drill suction manifold. The charge pump
continuously injects oil into the main loop to make up for normal leakage in the pump, motor
and valves, and to make up for the oil being stripped out of the loop by the flushing circuit in
the diverter manifold.
Leakage from the main pump is collected in the pump case and returned to the drain manifold
by way of the pump D port. When the pump is in neutral, the leakage flow from the pump is
DRILLING SOLUTIONS
7-233
supplemented by charge flow that comes from the charge relief valve in the pump. Rotation
motor leakage is collected in the motor case and it also returns to the drain manifold. Oil
pressure in the case must exceed 30 psi to open a check valve in the drain manifold. The
purpose of the check valve is to keep the motor cases full of oil at all times.
The flushing circuit in the diverter manifold takes additional oil out of the closed circuit when
the main pump is not in neutral. This oil returns to the drain manifold. An additional
replenishment connection to the circuit is provided by the diverter manifold at port C. This
port is connected to the supercharge manifold which holds a pressure of about 100 psi. If
pressure in the rotation circuit attempts to fall below supercharge pressure, a check valve in
the diverter manifold will open to allow flow into the appropriate side of the rotation circuit.
7-234
DRILLING SOLUTIONS
7.10 - AUXILIARY FUNCTION CIRCUIT

Auxiliary Functions
The auxiliary function circuit performs all of the tasks associated with the actual drilling process
except rotation and drill feed. Some of these tasks are tower raising, hoisting, dust curtains,
leveling jacks, water injection, dust collection, rod changer, swing breakout wrench, sliding
breakout wrench, rod support, tower pinning, angle drill pinning, rod indexing, cable tension,
oil and air cooling.
The double pump supplies two valve assemblies: a seven (7) spool valve and an eleven (11)
spool valve. Each section of these valve assemblies control a specific auxiliary function. An
explanation of the auxiliary functions is divided into two sections, each corresponding to the
valve assemblies and each assembly divided into the valve sections (or spools) and the
functions each section of each valve assembly controls. The examination of these circuits will
follow a brief discussion of the components found in the Auxiliary Functions Circuit.
Components
The components of the auxiliary function circuit are the double pump, motors, cylinders,
valves, coolers and filters that are required to perform the drilling functions. A review of these
components and how they are represented schematically will help to give a clear view of the
auxiliary functions. Note that the cooling system will be explained separately.
Double Pump
The double pump is located in the bottom position of the three hole pump drive gearbox, below
the feed/rotation and propel main pumps. The double pump is a two section, fixed
displacement, vane type pump. The two pumping elements inside the housing have a common
inlet and two separate outlets as shown in the schematic below.
The circle contains one triangle, signifying one direction of flow. The first section (section 1)
on each pump is designated schematically as P1 and the second section (section 2) of each
pump is designated as P2. Pump section 1 is capable of delivering more oil than pump
section 2 for a given input shaft speed. The suction for the pump is designated as S.
DRILLING SOLUTIONS
7-235
The P1 section supplies oil flow for the fan circuit and the cable tension cylinders circuit. The
P2 section supplies oil flow to the 7-spool valve and then on to the 11-spool valve. The double
pump suction comes through the suction manifold of the hydraulic reservoir and enters the
pump through a 2 hose.
Oil supply for all of the hydraulic circuits comes from the hydraulic reservoir through a strainer,
a shut-off valve, suction pipe and supercharge suction manifold. The two sections of the
double pump pick up oil from a suction pipe. Each section of the double pump supplies a
different set of functions.
P1 Pump Circuit
The P1 section of the double pump drives the cooler package fan motor. This section also
supplies pilot oil for use in propel functions, feed and rotation circuits, and the cable tension
circuit functions.
After P1 oil has been used to drive the motors, it passes through the oil cooler and the system
filters and is then supplied to the supercharge manifold for use in other circuits.
P2 Pump Circuit
The P2 section of the double pump supplies the flow requirements for the 7 spool and 11 spool
valve functions.
All of the oil in the P2 circuit mixes with return drain manifold oil and enters the system main
return filters, where it is directed to the supercharge suction manifold for use in the drill feed,
rotation and propel circuits.
Motors
Representative Motor symbols are shown below. The circle may contain one triangle pointed
inward from one work port (uni-directional) or a triangle pointed inward from both ports (bidirectional).
Both motors shown are fixed displacement. This means that speed may only be changed by
changing the motor supply flow. Dotted lines leaving the circle show that the motor case
leakage is taken away from the motor externally.
7-236
DRILLING SOLUTIONS
Cylinders
Representative cylinder symbols are shown below. These are all double acting, single rod
cylinders. Double-Acting means that the cylinder can be powered by the hydraulic system to
extend and to retract. Single-Rod means that the cylinder only has one rod extending out of
one end of the cylinder tube.
The cylinder symbol on the right shows a different porting arrangement (through the rod
porting) and an integral valve arrangement. The valve section is a dual overcenter valve circuit
which effectively locks the cylinder ( in the feed and rotation circuit section of this manual for
the description of the operation of an overcenter valve). The valves are preset at the factory
to open at 4000 psi relief pressure. The cylinder symbol in the center includes a holding valve
and an orifice to control the retract mode.
Relief Valves
Relief valves are used in many locations in the auxiliary function circuit. A representative relief
valve symbol is shown below
The basic valve envelope (box) contains an arrow in the normally closed position. The
adjustable length spring holds the valve spool in the closed position until inlet pressure
overcomes the spring force. The valve opens and closes as required to limit the maximum
pressure at its inlet.
Check Valves
The check valve is a one-way valve of the hydraulic circuit. Flow into the spring end of the
valve forces the ball into its seat to block fluid flow (blocked flow direction). Flow into the seat
DRILLING SOLUTIONS
7-237
end of the valve pushes the ball out of its seat to permit fluid flow (free flow direction). The
check valve spring is typically preloaded at the factory to provide a preset, nonadjustable valve
opening pressure in the free flow direction.
Two Way Valve

The two way valve has a closed position and an open position that can be activated by a
plunger.
In the normal position, the valve spring holds the valve closed so that oil cannot flow from the
P to the T port. When the plunger is pressed, however, the valve shifts and free flow is
allowed.
Holding Valves
Holding valves are used throughout the auxiliary functions circuit to keep motors and cylinders
locked and to provide smooth load movement. Holding valves are represented schematically
below.
The holding valve is a pressure control device that receives pilot signals from the actuation
pressure as well as the return pressure. When the influence of both signals is sufficient to
overcome the valve spring setting, the valve opens to allow controlled flow. The valve is also
capable of providing protection against accidentally dropping a load. The valve is usually set
for an opening pressure higher than that which can be generated by the load alone so that, if
actuation pressure is lost, the valve closes.
7-238
DRILLING SOLUTIONS
Pilot Check Valves

The pilot check valve is shown schematically below. The pilot check valve is another type of
holding valve used for locking hydraulic components in place.
The valve works like a check valve in one flow direction and locks in the reverse flow direction.
In the reverse flow direction, the valve can be piloted open to allow reverse flow. Once the
valve has been piloted opened, oil flows with very little restriction.
Sequence Valves
Two types of sequence valves are used in the auxiliary functions circuit. The sequence valve
shown is used with the cable tensioning cylinders.
The valve symbol consists of a box with an arrow positioned to represent a blocked flow path.
An adjustable length spring holds the valve closed until inlet pressure, acting on the opposite
end of the valve spool, overcomes the spring force. When this happens oil is free to flow
through the valve. It is important to note that there will be a constant pressure drop across the
sequence valve equal to the valve spring setting.
The sequence valve shown below is used with the rod support cylinders. The valve is similar
to a relief valve but the sequence valve spring chamber is not drained downstream.
DRILLING SOLUTIONS
7-239
When oil enters the sequence valve through the VB port, it flows through the valve to the
C2B port. When the flow from port C2B stops (the cylinder reaches the end of its stroke)
the pressure rises to the level required to open the left sequence valve and oil flows to port
C1B. Oil that is returning to ports C2A and C1A is allowed to flow freely to the sequence
valve VA port.
When oil is supplied to the sequence valve VA port, the other element in the valve works in
a similar manner. Test ports in the sequence valve assembly provide a place to monitor
pressure while setting the individual valve cartridges.
7-240
DRILLING SOLUTIONS
Seven (7) Spool Valve
DRILLING SOLUTIONS
7-241
The 7-spool valve is an assembly made up of seven individual 4-way valves with a common
inlet and outlet. The 4-way valves are electrically operated, closed centered proportional
valves with load sensing capabilities and pressure compensation. Three of the sections have
individual port relief valves. The inlet section for the valve assembly contains an unloading
valve, a relief valve, a reducing valve and a filter for supplying pilot oil to the 4-way valve
sections. The 7-spool valve assembly is shown schematically below.
Oil enters the inlet section at the P port. Oil can exit the section through the parallel
passageway at the top right corner of the section schematic or through the unloader to the
section T port. When the parallel passageway is blocked, all of the oil flow must exit through
the unloader. The total oil flow can also be proportioned by the unloader so that some flow
goes in each direction.
The inlet section unloader receives signals from the parallel passageway and from a load
sense signal from the 4-way valves. The pressure in the parallel passageway must be 200
psi higher than the load sense pressure in order to open the unloader. With no load sense
pressure, the unloader closes and routes oil to the parallel passageway where it can be used
by the 4-way valve sections. When a load sense signal is received back from the valve
sections, the unloader will throttle the oil flow between the two exits to keep the parallel
passageway pressure 200 psi higher than the pressure being called for by the valve sections.
7-242
DRILLING SOLUTIONS
The inlet relief provides a way to control the maximum allowed load sense signal and
therefore the maximum valve working pressure. When the load sense signal rises to the relief
setting, the relief opens to keep the signal from going any higher. The unloader will allow the
parallel passageway pressure to exceed this setting by 200 psi.
The pilot filter and reducing valve in the inlet section provide a reduced working pressure for
the proportional electric controls on the individual 4-way valve sections. The operating
pressure provided by the reducing valve is 200-220 psi.
The four (4) way valve sections of the 7-spool valve are all similar and are represented
schematically.
The components of the 4-way valve are the pressure compensator (represented by the box
symbol at the top left corner), the directional valve (represented as a 3-position closed-center
4-way valve), the individual port relief valves, and the load sense shuttle valve.
The pressure compensator is the device that determines how much oil the directional valve
will get. The compensator receives one pressure signal from the oil that it discharges. This
signal attempts to keep the compensator open so that oil can flow freely. When the directional
valve is shifted, the compensator receives a second signal from whichever work port is
receiving the flow.
This signal indicates the working pressure needed to move the working load and this pressure
(and a spring) try to close the compensator. The compensator will throttle the oil flow in
response to the two pressure signals to supply precisely the amount of oil the directional valve
needs to operate. If the pressure in the parallel passageway happens to be higher than what
the load requires, the compensator will maintain whatever pressure drop is required to keep
the directional valve at the proper operating pressure.
The directional valve is normally held in its center (closed) position by springs. It is shifted by
applying electric current signals to proportional electro-hydraulic pressure controls on the ends
of the valve. The pressure controls receive pilot oil from the inlet section. When the pressure
control receives an electric signal, it proportions pilot pressure to a level proportional to the
electric signal. The resulting pressure pushes the valve spool against its centering springs.
The amount of movement, and therefore the amount of flow, is proportional to the positioning
pressure.
DRILLING SOLUTIONS
7-243
The maximum flow available from a particular directional valve section is indicated by a
number near the pressure compensator symbol. Each spool is intended for a particular
function and maximum flow needed is selected accordingly. Each spool is also equipped with
flow limiters which are used only on the dust collector section. The port relief valves are
responsible for limiting work port operating pressure at design levels. When work port pressure
reaches the valve setting, the valve opens and oil flows to the valve section return
passageway.
A load sense shuttle is in each of the valve sections. The shuttle determines whether or not
the highest pressure from downstream is higher than the pressure within its section. It passes
its selection to the next section upstream. Ultimately the highest working pressure (the load
sense pressure) reaches the 7-spool valve inlet where it can be used by the inlet unloader.
Oil that is returned from the individual valve sections leaves the 7-spool valve through the T
port and returns to the return manifold.
7-Spool Valve Sections
1. First Valve Section
The first valve section controls the hoist motor.
2. Second Valve Section
The second valve section controls the tower raising cylinders.
3. Third Valve Section
The third valve section controls the dust curtain cylinders.
4. Fourth Valve Section
The fourth valve section controls the leveling jack cylinder on the cab side of
the drill.
5. Fifth Valve Section
The fifth valve section controls the rear leveling jack cylinder on the non-drilling
end of the drill.
6. Sixth Valve Section
7-244
DRILLING SOLUTIONS
The sixth valve section controls the leveling jack on the dust collector side of
the drill.
7. Seventh Valve Section
The seventh valve section controls the dust collector motor and the water
injection motor. These circuits are plumbed differently in that the return oil from
both motors does not return to the valve T port. This allows one motor to be
controlled by feeding oil to the A port and the other motor to be controlled by
feeding oil to the B port. Return oil from both motors is routed back to the
Return Manifold.
DRILLING SOLUTIONS
7-245
Eleven (11) Spool Valve
7-246
DRILLING SOLUTIONS
The 11-spool valve circuit schematic is shown above. The 11-spool valve schematic is shown
below. The 11-spool valve operates like the 7-spool, but it does not have an inlet unloader or
and inlet relief valve. The highest load sense signal within the assembly is used by the 7-spool
valve unloader which keeps operating pressure within both assemblies below 3000 psi.
DRILLING SOLUTIONS
7-247
Another difference is that the pressure limiting components in the 11-spool valve sections are
not port reliefs. The common pressure limiters in some of the 11-spool valve sections
regulate the section load sense pressure and a single device controls both work ports within
a section. Like the 7-spool valve, the 11-spool valve inlet has a pilot filter and reducing valve
to supply its electro-hydraulic controls.
11-Spool Valve Sections
1. First valve section:
The first valve section controls the rod changer cylinders.
2. Second valve section:
The second valve section controls the breakout wrench swing cylinder.
3. Third valve section:
The breakout wrench clamp cylinder and rotate cylinder are supplied by the
third valve section.
4. Fourth valve section:
The fourth valve section controls the sliding breakout cylinder.
5. Fifth valve section:
The rod support swing cylinder and clamp cylinder are supplied by the fifth
valve section.
6. Sixth valve section:
The sixth valve section controls the tower pinning cylinders.
7. Seventh valve section:
The seventh valve section controls the tower angle drill cylinders.
8. Eighth valve section:
The eighth valve section controls the rod indexing cylinder.
9. Ninth valve section:
7-248
DRILLING SOLUTIONS
The ninth valve section controls a cable tensioning motor.

10. Tenth valve section:
The tenth valve section controls the other cable tensioning motor.
11. 11.Eleventh valve section (high pressure option):
The eleventh valve section controls the optional air cylinder that controls the
drill air throttle valve which allows air flow thru the drill string and down the hole
to operate the DHD and clean the hole.
P2 Pump Circuit
The P2 section of the double pump supplies the flow requirements for the rest of the drill
systems. Oil flow from the pump is fed into the seven-spool valve. P2 circuit oil, when not used
by the seven-spool valve, is supplied to the eleven-spool valve through the seven-spool valve.
All of the oil in the P2 circuit mixes with the return manifold oil and enters the system main
filters, where it is directed to the supercharge circuit for use in the drill feed, rotation and propel
circuits.
Circuit Operation
The oil supplied to the 7-spool and 11-spool valves is used by the valve circuits to do cylinder
and motor operation functions.
The spool valves are pressure compensated, load-sense components. They operate
differently from conventional spool valves in that the working pressure for the pumps is not
determined by the lowest load. In a conventional system, oil flow to a highly loaded motor or
cylinder can be interrupted by operating another spool that has a lower flow resistance. The
load sense valves, on the other hand, will attempt to satisfy the requirements of both heavy
loads and light loads at the same time. It does this by restricting flow to the light load, with a
spool pressure compensator, to make up the difference in working pressures. The only time
the valve assembly fails to satisfy all loads is when the total flow being demanded by all
actuated spools exceeds the available pump flow.
Oil is used in the valves and returned to the return manifold. The individual valve spools are
actuated by proportional or on/off electric controls controlled by the operator. The proportional
controls allow precise positioning of the valve spools and they also allow the maximum flow
from the individual spools to be limited with a maximum current adjustment.
DRILLING SOLUTIONS
7-249
Cooling Circuit/Cable Tensioners
7-250
DRILLING SOLUTIONS
The purpose of the cooling circuit is to remove heat from the hydraulic coolant circuits on the
drill. The cooling circuit accomplishes this with a set of fin and tube heat exchangers. Heat is
transferred from the liquids in the tube side to the fins, and on to the atmosphere. The P1
section of the double pump supplies oil flow for the fan circuit and the cable tension cylinders
circuit.
DRILLING SOLUTIONS
7-251
Cooling Control Valve

The cooling control valve contains the three parts necessary for controlling fan motor speed,
coast-down and controlling cooler bypass. Oil enters the cooling control valve at the P port.
From here, the oil can flow to the fan motor. The cooling control valve is shown schematically
below
When the main pump stops turning (engine off), the oil exiting the fan motors regenerates
through the 3 psi check valve from the B ports to the A ports and allows the motor to coast
to a stop. A sequence valve within the cooling control valve allows oil to bypass the cooler core
when pressure drop across the core exceeds 75 psi. This provides a way for the hydraulic
system to warm up and it protects the cooler from damage when the oil is cold. Test ports at
G1 and G2 on the cooling control valve allow pressure checks at these locations.
Fan Motor
The fan motor is shown schematically above. The hydraulic fan motor is represented by a
circle containing one triangle pointed inward from one work port indicating the motor is unidirectional. This is a fixed displacement motor, which mean the speed may only be changed
by changing the motor supply flow. The dotted lines leaving the circle indicate that the motor
case leakage is taken away from the motor externally. The arrow on the outside of the circle
reveals the direction of shaft rotation.
Circuit Operation
The P1 section of the double pump drives the fan motor for hydraulic, compressor and engine
cooling. The oil provided from the double pump P1 section flows to the cooling control valve
where it is distributed to the fan motor. The motor speed is adjusted with the relief valve setting.
The oil used by the fan motor or by the relief valve leaves the cooling control valve through the
C or T ports and is returned to the drills return manifold.
Manifold System
The manifold system is represented below. The manifold systems provide connection points
for all hoses that return oil from other systems. The manifolds contain cartridge valves that
7-252
DRILLING SOLUTIONS
regulate supercharge and drain pressures, route oil through system filters and to the hydraulic
tank, and provide connections for filtered tank filling.
DRILLING SOLUTIONS
7-253
7-254
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-255
Return Drain Manifold

As shown below, the return drain manifold is a complete assembly consisting of two manifold
sections that work at different pressures. The assembly contains two relief valves and one
check valve.
The return section of the manifold provides oil return connection for the appropriate
components in the other circuits. Once the return oil reaches the manifold, it has two possible
paths through which to exit.
The first path out of the return manifold is through the filter connections on the manifold. The
second exit path is through the two 200 psi relief valves installed in the barrier between the
return section and the drain section of the return/drain manifold assembly.
The drain section of the manifold provides a collection point for drain oil from other circuits.
There are twenty connections in the main part of the manifold and one connection in the cap
on the end of the manifold. A 30 psi check valve is installed in the end cap to provide a backpressure to the oil returning to the end cap port.
Test ports in both sections of the manifold provide access to measure working pressures.
Supercharge Suction Manifold

The supercharge/suction manifold is also a two section assembly as shown schematically
below.
7-256
DRILLING SOLUTIONS
The two sections are separated by a barrier that contains two cartridge relief valves set at 125
psi.
The supercharge section of the manifold has two ports through which filtered oil can enter. The
remaining ports are exit ports for providing clean, supercharged oil to the other drill circuits. Oil
that does not leave the supercharge manifold through the supercharge ports flows through the
relief valves to the suction section of the assembly.
The suction part of the assembly provides all of the suction connections needed by the other
circuits on the drill. Oil in the suction manifold comes either from the hydraulic tank or through
the supercharge relief valves in the manifold barrier.
Test ports on both sections of the manifold provide access to manifold working pressures.
Filter Assembly
The filter assembly is shown schematically below.
This unit contains a filter element and a check valve arrangement for bypassing oil if the
element gets clogged. The check valve is designed to open at about 30 psi pressure drop
across the filter element.
DRILLING SOLUTIONS
7-257
Hydraulic Reservoir
The hydraulic reservoir shown schematically below is a 150 gallon (567.8L) capacity tank
containing the system fluid.
The tank has two return ports, one suction port that accepts a shut off valve, a drain port, one
port in the top for an electric level sensing switch, and two tank top ports for breather elements.
The reservoir has no provisions for filling except through the filter system on the drill (there is
no hole in the tank top for pouring in oil). The hydraulic reservoir has an internal baffle for
separating return oil from suction oil.
Circuit Operation
Oil from the other circuits returns to the manifold system through either the return manifold or
the drain manifold. The return system allows back pressure of up to 200 psi on the system
components that connect to it. Components that cannot accept this back pressure return to
the drain manifold which provides a back pressure of only 30 psi maximum. Oil that enters the
return section of the return/drain manifold normally leaves the manifold and flows through the
filter assembly and enters the supercharge section of the supercharge/suction manifold.
An additional path out of the return manifold is provided through the 200 psi relief valves in the
barrier between the return manifold and the drain manifold. It is possible for oil to flow through
this path if the oil is cold and large cylinders in other circuits are retracting. When this is
happening, the 200 psi relief valves will try to hold manifold pressure to a maximum 200 psi.Oil
that enters the drain manifold in this manner is filtered and returned to the hydraulic reservoir.
The drain manifold provides a low pressure system return for all its ports except one. The port
in the end cap of the manifold accepts a check valve which provides a 30 psi back pressure
to this oil. After the oil flows across the check valve, it combines with the other drain oil and
flows through the filter assembly to the hydraulic reservoir.
The drain manifold also accepts hydraulic reservoir fill oil. One port on the top of the manifold
is used to connect an industry standard hydraulic quick fill system. The other connection is
used by the standard machine hydraulic reservoir fill. Fill oil is pumped into the manifold
through one of the fill systems. The oil is filtered by the drain filter assembly before entering
the hydraulic reservoir.
7-258
DRILLING SOLUTIONS
Service Notes
Pressure Test Ports
Hydraulic pressure test ports have been placed at key locations throughout the hydraulic
system. These test ports provide the pressure readings that are the basis for all hydraulic
system troubleshooting and diagnostics.
Connection to the individual test ports is done with a pressure test kit (the test kit can be
acquired from Drilling Solutions). Included in the test kit are two pressure transducers, two
electric cables, and a digital pressure test meter. The test meter is also capable of measuring
voltage and, with an additional flow transducer (not provided in the test kit), the meter can also
measure flow.
The pressure transducer can be connected to a test port by un-screwing the test port
protective cap and screwing on the transducer fitting. The transducer connects with no
leakage.
The pressure transducer attaches to the meter with a cable. One end of the cable snaps into
a terminal on the transducer, and other end of the cable snaps into either of two terminals on
the bottom of the meter. The meter can be attached to two transducers at the same time. A
dial on the meter face will select the first transducer pressure, the second transducer pressure,
or the difference between the two transducer pressures. Other dial positions allow voltage
measurements.
NOTICE
Hydraulic Fluid
The hydraulic fluid required is an ISO 32 grade anti-wear mineral base oil. Refer to section 6.6
(Refill Capacities/Lubricants/Fuel) in the maintenance section of this manual for more
information.
Fluid Sampling
Regular fluid sampling is required for the hydraulic system. Fluid Sampling is used to
determine the effective service life of the fluid in a particular environment in which the drill is
working. Sampling can be helpful in establishing fore casts for filter element change intervals
in a harsh environment.
Regular oil samples must be taken from the drain manifold using appropriate fluid sampling
materials such as those provided in the Drilling Solutions Sampling Kit (52298411).
DRILLING SOLUTIONS
7-259
NOTICE
or work that is performed on this component. Handle and dispose of
fluids according to local regulations and mandates.
Hydraulic Reservoir
The hydraulic reservoir has a 150 gallon (567.8 liter) oil capacity and it must be filled by
pumping an approved oil through a quick disconnect hydraulic tank fill connection. Oil entering
the hydraulic tank fill connection flows to the drain manifold on the drill and is filtered by the
drain filter assembly before it enters the reservoir.
Some drills are equipped with an optional quick fill connection at the non-drilling end of the drill.
Fluid pumped into a factory installed quick fill connection is also routed through the drain
manifold and filter assembly.
The reservoir does not have provisions for filling through the top cover. Even new fluid in unopened containers has been found to have contamination levels that are unacceptable for use
in hydraulic systems that use high-pressure piston components. Introduction of these
contaminated fluids into the hydraulic system will cause short component life.
NOTICE
Do not use the quick-fill system to drain or remove hydraulic fluid. Care
must be taken to ensure fluids are contained during any inspection or
work that is performed on this component. Handle and dispose of fluids
The hydraulic reservoir has only three connections to the hydraulic system. The suction
connection is located in the reservoir bottom. This connection is equipped with a shut off valve
that can be turned off when working on the hydraulic system. The remaining system
connections are at the return ports on the side of the reservoir. Fluid leaving the drain filters
enters the reservoir through these ports. Fluid can be siphoned out of these ports if any system
connection below the tank fluid level is broken. Siphoning can be avoided by loosening a hose
connection on a drain filter. This should be done before attempting service of hydraulic
components.
The hydraulic reservoir is also equipped with a quick disconnect coupling in the bottom of the
reservoir. A mating connector for attaching to this tank-bottom coupling is provided with the
drill. These provisions will allow removal and recovery of the fluid in the reservoir without
leakage.
7-260
DRILLING SOLUTIONS
NOTICE
or work that is performed on this component. Handle and dispose of
fluids according to local regulations and mandates.
Hydraulic Connections
All of the connections in the hydraulic system are o-ring type connections. These o-ring
connections (SAE J1926) can be found in many of the valves, cylinders, gauges, pumps,
motors, and in the hydraulic reservoir. Most of the hose connections conform to SAE J1453
(SAE fitting o-ring face seal). The remaining hose connections are SAE 4-bolt split flange
connections. The three connection types use 90 durometer o-rings of various sizes.
Diverter Manifolds
The diverter manifold assemblies control the shifting, flushing and auxiliary replenishing in the
propel and drill circuits. The manifolds consist of ductile iron manifolds into which 4 valve
cartridges are fitted. Each manifold has appropriate connection points for attaching two
diverter valves, 7 test fittings, and the appropriate piping connections.
The diverter manifolds are designed to allow quick service without removal of the assembly
from the machine. Each manifold assembly can be completely rebuilt with all new working
parts by replacing the 4 valve cartridges. The two diverter valves bolted to each manifold can
also be easily replaced. The manifolds should never be replaced as complete assemblies.
The only valve adjustment on the assembly is one for charge pressure. The adjustment can
be found on the bottom of the assembly. To adjust the pressure, first connect the pressure test
meter to the appropriate pump charge pressure port.With the drill on the leveling jacks (tracks
off the ground), engine at idle and tracks turning, adjust the charge pressure setting to 150 psi
at the test port.

The drill/propel control valve manages all of the mode selections, brake and pump
compensator enabling tasks for the machine. It is a ductile iron manifold into which 4 valve
cartridges are inserted. A 4-way valve bolted to one side of the manifold selects the drill mode
or propel mode for the machine.
The valve assembly can be completely re-built by replacing the 4 valve cartridges and the 4way valve bolted to the side of the manifold. The assembly should never be serviced as a
complete unit.
The pulldown relief pressure is set at 3400 psi.
Manifold Assemblies
The two manifold assemblies are the supercharge/suction manifold and the return/drain
DRILLING SOLUTIONS
7-261
manifold. Each assembly has two sections separated by a barrier. Valves in the barrier permit
flow from the high pressure side to the low pressure side when the valve pressure setting is
reached.
The valves in the manifold barriers are factory set by the valve manufacturer to provide the
pressure settings required by the design. No field adjustment is provided.
The manifold valves can be replaced by removing them and fitting new ones in the place. The
supercharge/suction manifold contains 2 cartridge valves and the return/drain manifold
contains 2 cartridge valves.
Feed System Control Valve

The feed system control valve is a complete assembly that controls the flow of oil leaving and
entering the feed cylinders. The valve assembly can be completely rebuilt in a few minutes
without disturbing the hydraulic piping by replacing its valve cartridges. It is not necessary to
replace the complete assembly.
7-Spool Valve
The 7 - Spool Valve assembly is an electrically operated, proportional, load sensing 4-way
valve stack.
The inlet section of the assembly contains the pilot pressure reducing valve and filter for the 7
spools. It also contains the unloader valve for setting the maximum working pressure for all
spool valve functions on the 7-spool valve and the 11-spool valve assemblies. The unloader
is adjusted to 3000 psi working pressure at the factory and should not require re-adjustment
in the field.
The inlet section pilot pressure reducing valve and filter are serviceable items. The valve can
be replaced by screwing the old one out of the inlet housing and screwing a new one in.
There are 7 work port relief valves in the 7-spool valve assembly. The first spool section has
a port relief on both C1 and C2 ports to control the hoist motor pressures. These pressures
are set at 2000 psi pressure reading at the 7-spool valve test port (with C1 and C2 ports
blocked). The second spool section has a port relief on both C1 and C2 ports to control tower
raising cylinder pressures. This valve is set for 3000 psi pressure reading at the 7-spool valve
test port (with the tower raising cylinders fully stroked). The seventh spool section has port
relieve valves at the C1 and C2 ports to control the water injection motor /dust collector motor
pressures. All of these pressures are adjusted at the factory. No adjustment should be
required in the field unless an entire assembly is being replaced.
Each spool section has two pulsar coils for shifting the spool (one for each direction. The coils
can be replaced by screwing the old part out and inserting a new one in its place. When
removing a coil, the O-ring inside the coil cavity must also be replaced. Remove the O-ring
with an O-ring pick. Insert the new O-ring into the coil cavity and be sure it is fully seated before
screwing in the new pulsar. If the O-ring has not been inserted properly, a resistance will be
felt as the pulsar is being screwed in place and the valve will not operate properly.
NOTE: Speed control of some of the valve functions is done with current
adjustments to the valve coils.
7-262
DRILLING SOLUTIONS
11-Spool Valve
The 11-spool valve assembly is an electrically operated, proportional, load sensing 4-way
valve stack.
The inlet section of the assembly contains the pilot pressure reducing valve and filter for the
11-spools. The inlet does not have an unloader. This stack sends a signal to the 7-spool valve
unloader which controls the maximum working pressure of both assemblies.
The inlet section pilot pressure reducing valve and filter are serviceable items. The valve can
be replaced by screwing the old one out of the inlet housing and screwing a new one in.
The working sections are all equipped with spool stops to limit flow. All of the flow limiters,
except one, are adjusted by the valve manufacturer to allow maximum spool flow. No
adjustments of these parts is required at the factory or in the field.
There are 2 common pressure limiters in the 11-spool valve assembly. The common
pressure limiter controls the maximum spool compensator pressure to limit working pressure
at both C1 and C2 ports. The limiter in the fourth spool section provides a means to limit
pressure in the sliding breakout wrench cylinder circuit. However, this limiter is set to allow
maximum (3000 psi) pressure in the application. The same is true for the limiter in the fifth
spool section which controls the rod support cylinders maximum pressure. The limiter in the
eleventh spool is set to allow 500 psi to limit pressure in the air control cylinder option. All of
these pressures are adjusted at the factory. No adjustment should be required in the field
unless an entire assembly is being replaced.
The maximum pressure in any cylinder circuit can be checked by extending or retracting the
cylinder all the way and reading the pressure at the test port on the 11-spool valve inlet (with
the spool actuated).
Each spool section has two pulsar coils for shifting the spool (one for each direction). The coils
removing a coil, the O-ring inside the coil cavity and must also be replaced. Remove the Oring with an O-ring pick. Insert the new O-ring into the coil cavity and be sure it is fully seated
before screwing in the new pulsar. If the O-ring has not been inserted properly, a resistance
will be felt as the pulsar is being screwed in place and the valve will not operate properly.
NOTE: Speed control of some of the valve functions is done with current
adjustments to the valve coils.
Cooling Control Valve

The cooling control valve is a modular assembly consisting of an aluminum housing into which
a relief valve cartridge is assembled. The valve controls pressure regulation and coast down
for the fan motor. It also controls the bypass function for the cooler core.
The only adjustment on the valve assembly is for cooler bypass. Fan speed is set by the pump
relief.
The valve assembly should be serviced or repaired by changing the valve cartridge, not the
complete assembly.
DRILLING SOLUTIONS
7-263
7.11 - ELECTRO HYDRAULIC SYSTEM

Overview
The primary function of the Electro-Hydraulic Controls (EHCs) is to provide a link between
operator command and valve or pump operation. The EHCs are like the manual controls used
on other machines in that they translate commands from the machine operator into movement
of the valve spools or pump swash plates. They differ from manual controls however, in that
the link is not direct. Before the operator commands reach the valve spool or pump servo, they
have been:
1. Translated into an electrical signal
2. Transmitted through a wire
3. Translated into a hydraulic pressure.
It is the hydraulic pressure acting on the valve spool or pump servo control which actually
causes the final spool or swashplate movement.
There are two basic components to each electro-hydraulic control as indicated by the name.
The electric part consists of the electronic or electrical remote controller (RC) mounted in the
control console, the associated wiring parts, and in some cases, additional relays and switches
that modify the electric signal in some way. The electrical part also includes the coil at the valve
or pump that helps to convert the electric signal back to the mechanical movement required to
develop hydraulic pressure. The second basic component of the EHC is the hydraulic part.
This part is simply an arrangement of fixed or variable orifices that oil flows through. The
adjustment of the variable orifice by the electric coil determines the amount of pressure and
the corresponding amount of valve spool movement.
From the operators point of view the EHC link will not be that much different from a direct
mechanical link. Movement of the RC in the console will still result in the corresponding
movement of the appropriate drilling function. The RC will be easier to operate and will provide
no feedback (feel) through the control handle. The operator will also find that there are some
operation sequences that the control will not allow (such as powering the rotary head into the
rod support).
From a technical point of view however, the EHC link has some distinct differences from the
direct link. The most obvious of these differences is that the EHC link is more complex. The
operators command is translated twice before reaching the end of the link. The second
primary difference is that all safety interrupts are included in the link. If the operator attempts
an illegal operation in a protected link, the electrical command that actually reaches the valve
or pump will be altered and in some cases interrupted. If however, the electrical signal actually
reaches the device coil and a pressure signal is generated, the function connected to that
device will move.
All the EHC links can be further classified as either proportional or on/off. The proportional
links provide precise movement of the valve spool that corresponds directly to movement of
the RC handle. The proportional links operate with either DC output or a Pulse Width
Modulated (PWM) current output depending on the device being controlled. The signals for
pump control for example, are 0 to 300 milliampere, DC current signal. The On/Off links
provide a DC current output which causes full travel of the valve spool whenever the RC
7-264
DRILLING SOLUTIONS
handle moves past the threshold position.
General Concepts and Terminology

The following pages provide a discussion of the general circuit concepts, as well as a detailed
description of each type of EHC and associated parts.
Current Control
The proportional RCs (remote controllers) used are current control devices. The RCs that
drive Denison coils supply a current signal in the range of 60 to 300 milliampere depending on
handle position. The rotary RCs which drive the FEMA valve coils supply a current signal from
100 to 500 milliampere range proportional to the position of the handle.
Current control devices operate differently from voltage control devices in that their output
voltage is not always useful as an indicator of valve operation or position. It is the current, not
the voltage, that is the same for a given handle or knob position. The only reliable check of the
RC output is to measure the current flowing from the device. A simple example demonstrates
this fact:
Suppose a 24 ohm coil is supplied with a 24 volt DC input. The current that will flow through
the coil is V/R = 1.00 Amp. If the voltage to the coil is reduced by half, the current will be
cut by half. If the coil fails open the current will be 0. If the coil shorts, the current will most
likely be high enough to melt the insulation from the wires.
On the other hand, suppose the same coil is supplied with a regulated current signal of 1
amp. The voltage across the coil will be 1 Amp x 24 Ohms = 24 volts. If the current is cut
by half, the voltage will be cut by half. If the coil fails open when a 1/2 Amp regulated
current is called for, the voltage goes to battery voltage, 24 volts, to try to hold up the
current signal. If the coil shorts, voltage drops to zero to try to maintain the current at 1/2
Amp.
This illustrates that the voltage on a RC output can be zero if the coil is shorted. Likewise the
voltage reading can be 24 volts if the output is open regardless of the handle position. Output
voltage is not necessarily a good indicator of circuit operation unless the circuit resistance is
known.
Pulse Width Modulation

Pulse Width Modulation (PWM) is the name given to a particular kind of electrical signal used
for some hydraulic control applications. The signal results from high speed electronic switching
of supply voltage to create a string of pulses all having the same height and varying width.
The PWM frequency for a given application is constant. That means that the amount of time
that elapses between the start of a pulse and the start of the next pulse (the period P) is
always the same. In the case of the 270MP PWM signals, that time is 1/33 HZ = .03 seconds.
The time during every period P of the wave form when the voltage is switched on is the on
time or pulse width. Likewise the time during every period when the voltage is switched off
is the off time. The variation of the pulse width, or on time vs. off time, is what gives the signal
proportionality.
DRILLING SOLUTIONS
7-265
Threshold
The threshold is the minimum output level from an RC. The current ranges for the controllers
described above start at some level other than zero. In the case of the Denison RC, for
example, the current output starts at 60 milliamps. By starting at this minimum level, current
values that are too low to cause any resulting movement of the pump servo can be tuned out.
As soon as the RC handle moves off center, the current level jumps up to the minimum level
required to cause something to happen.
Maximum Out
Maximum Out is the maximum current level delivered by an RC when the handle or knob is at
full stroke. For example, the normal maximum out for the Denison RC is 350 milliamps. The
maximum out adjustment is preset but adjusting a potentiometer on the RC circuit board can
change the level.
Controllers
Dual Range
A Dual Range RC has two maximum output levels; a low range level, and a high range level.
These controllers can be identified by the R terminal on the main terminal strip. When the R
terminal is supplied with a 24 VDC signal, the controller is in high range and the corresponding
current range will be from the threshold setting to the normal maximum out setting. The high
range value is set by the maximum out pot described above. When the voltage signal to the
R terminal is interrupted, the controller is in the low range. In this range, the current output
will be from threshold to the low range setting. The low range setting is adjustable with the low
range pot on the RC circuit board.
Single Coil Controllers

The Denison RC can be further classified as single coil controllers. In these circuits, there is 1
coil connected between the A and B terminal on the RC terminal strip. When the handle is
moved toward the A terminal, current flows out A, through the coil winding in the pump
stroker, and back to the RC B terminal. When the handle moves toward the B terminal,
current flows out B, through the coil winding and back to the RC A terminal. The pump
stroker interprets the direction of the current as well as the magnitude of the current.
Dual Coil Controllers

The Apitech and Fema valve coils interpret only the magnitude of the current signal, not the
direction of the current flow. In the case of the Apitech valves, there is one coil that moves the
spool in one direction and another coil moves the spool in the other direction. In these dual
coil circuits, the A terminal is connected to either of two wires on a valve coil. The remaining
coil wire is connected to ground. The B terminal of the RC is connected to either of the two
wires on the second coil. The remaining coil wire is connected to ground. When the handle is
moved toward the A terminal, current flows through the first coil, and then to ground. When
7-266
DRILLING SOLUTIONS
the handle is moved toward the B terminal, current flows through the second coil to ground.
Denison 500 Stroker

The Denison 500 Electro-Hydraulic Stroker provides a modulating servo position proportional
to input current. It does not require electrical displacement.
The electro-hydraulics stroker, consisting of a voice coil, jet pipe and piston, positions the
rotary servo shaft, which controls the pump rocker cam position. With zero current input, the
voice coil exerts no force, and the two springs center the jet pipe between the receivers, the
jet stream splits evenly to produce the same pressure in each receiver. These pressures are
connected to corresponding ends of the piston and being equal create no motion.
If current is applied to the voice coil, it exerts a force on the armature in proportion to the
magnitude and polarity of the current. This causes the jet pipe to deflect so that it is aimed
more directly at one receiver pipe. The pressure in that pipe rises and the pressure in the other
pipe falls, causing the pressure on the ends of the piston to change accordingly. The piston
then moves, rotating the servo shaft and either compressing or relaxing the feedback spring,
depending on the direction of motion. When the piston moves far enough that the change in
feedback spring force equals the voice coil force, the jet pipe re-centers and the piston stops
at that position.
The numbers above correspond to the numbers below. Each number below precedes a
description of the component it represents.
1. Manual Override Shaft - Used to manually stroke the pump.
2. Mechanical Null Adjustment-Used to mechanically center pump swashplate in
the neutral position.
3. Servo Supply Tube -The tube which carries pump servo pressure to the
Denison Stroker from the main body of the pump.
4. Mechanical Volume Stop Adjustment - Used to mechanically set the pump
volume.
5. Two Pin Electrical Connector - Military style connector which receives electrical
signals.
6. Electrical Null Adjustment - Used to fine tune main pump after initial mechanical
adjustment has been done.
DRILLING SOLUTIONS
7-267
Denison 500 Stroker Adjustment

There are two styles of electric input controls used on Denison pumps. One control style has
an acorn nut type mechanical null adjustment assembly. The other has an enclosed style
mechanical null adjustment assembly. Tools needed for Null adjustment are:
Acorn Type
a. 2 x 3/4 open end wrenches
b. 1 x rod to fit through a 1/8 hole in the null adjustment shaft
c. 2 x 7/16 open end wrench (for electrical null steps)
d. 2 x -4 (1/4) JIC cap nuts
e. 1 x 3/32 allen wrench
Enclosed Mechanical Type

a. 1 x 3/4 open end wrench
b. 2 x 7/16 open end wrench (for electrical null steps)
c. 1 x 3/16 allen wrench
d. 1 x 1/4 allen wrench
e. 1 x 3/32 allen wrench
Adjustment Steps
1. Track mounted drills should be in propel mode and raised up on the leveling
jacks with the tracks off the ground.
2. With the drill turned off, disconnect the electric wires from the two pin connector
on the pump input control.
3. Start the drill. If the tracks creep, the pump null is out of adjustment.
4. With the drill turned off, remove the servo supply tube and cap the two open
ports with the -4 JIC cap nuts.
5. A. For acorn nut style adjustments, remove acorn nut from the mechanical
null adjust screw using a 3/4 wrench. Hold the null adjust screw with a rod
inserted through the 1/8 hole in the side of the screw. Loosen the lock nut.
B. If the adjustment is the enclosed type, remove the plug from the end of
the 3/4 hex barrel using a 3/16 allen wrench. Insert a 1/4 allen into the end
of the barrel to hold the internal screw stem. Loosen the 3/4 hex barrel.
6. Turn the null adjust screw in one direction until the track starts creeping. Note
the position of the null adjust screw.
Note: The null adjust screw has a mechanical stop that limits its rotation in both
directions. Do not force the screw past its stops.
7-268
DRILLING SOLUTIONS
7. Turn the null adjust screw in the other direction until the track starts creeping in
the other direction. Again, note the position of the adjust screw.
8. Position the null adjust screw halfway between the two positions found in steps
6 and 7, and then lock adjustment screw in place by tightening the locknut
(acorn style control) or hex barrel (within 100 psi). This can be verified by
measuring the pressures at the pump A and B ports.
9. Replace the acorn nut (acorn nut style control) or barrel nut plug (enclosed style
control). The pump is now mechanically nulled.
10. With the drill turned off, remove the -4 JIC cap nuts from the input control and
re-install the servo supply tube. Restart the engine.
Note: When the engine is started, the tracks may creep even though the pump
has been mechanically nulled. The electric part of the adjustment will correct
the creeping.
11. The electric null adjust screw is an allen screw located under the cap nut.
Remove the cap nut from the electric null adjust screw using two 7/16 open
end wrenches. Hold the internal allen screw with a 3/32 allen wrench and
loosen the jam nut.
12. Turn the electric null adjust screw in one direction until the track starts to creep.
Note the position of the screw.
13. Turn the electric null adjust screw in the other direction until the track starts to
creep in the other direction. Again, note the position of the null adjust screw.
14. Position the electric null adjust screw half way between the two positions found
in steps 12 and 13, and then lock the adjustment screw in place by tightening
jam nut. Pump A and B side pressures should now be equal (within 100 psi).
This can be verified, if desired, by measuring the pressures at the pump A and
B ports.
15. Replace the cap nut and reconnect the electric wires to the two-pin connector.
The pump null adjustment is now complete.
Valves
The PULSAR VS Series pressure control valve is a normally closed, spring biased, solenoid
actuated, high speed, digital (on/off) valve. It consists of a removable, replaceable cartridge
assembly specifically matched with a separate orifice plate and O-ring seal. To generate a
proportional control pressure, the coil is energized 33 times per second with a pulse width
modulated (PWM) electrical signal. The resulting control pressure is directly proportional to the
duty cycle or On time per cycle of this excitation.
Apitech Pulsars
Oil exiting the cartridge is restricted by the 0.024 fixed orifice plate; the resulting back
pressure is proportional to the operator-regulated duty cycle. This pressure is then routed
within the working section to the end of the main spool to furnish the control pressure.
DRILLING SOLUTIONS
7-269
7-Spool Valve
The 7-spool valve assembly is an electrically operated, proportional, load sensing 4-way valve
stack. The individual parts and features are shown above.
The inlet section of the assembly contains the pilot pressure reducing valve and filter for the 7
spools. It also contains the unloader valve for setting the maximum working pressure for all
spool valve functions on the machine. The unloader is adjusted to 3000 psi working pressure
at the factory and should not require readjustment in the field.
The inlet section, pilot pressure reducing valve and filter are serviceable items. The valve can
be replaced by screwing the old one out of the inlet housing and screwing in a new one.
There are 5 work port relief valves in the 7-spool valve assembly. The first spool section has
7-270
DRILLING SOLUTIONS
a port relief on both C1 and C2 ports to control hoist pressures. These pressures are set for
2000 psi pressure reading at the 7-spool valve test port (with C1 and C2 ports blocked). The
second spool section has a port relief on both C1 and C2 ports to control tower raising
pressure. These pressures are set for 3000 psi pressure reading at the 7-spool valve test port
(with the tower raising cylinders fully stroked). The seventh spool section has a port relief on
the C2 port to control maximum water injection or dust collector motor pressure. This valve is
set for 1000 psi pressure reading at the 7-spool valve test port (with C2 port blocked). All of
these pressures are adjusted at the factory. No adjustment should be required in the field
unless an entire assembly is being replaced.
and the respective ports they control are shown above. The coils can be replaced by screwing
the old part out and inserting a new one in its place. When removing a coil, the o-ring inside
the coil cavity must also be replaced. Remove the o-ring with an o-ring pick. Insert the new oring into the coil cavity and be sure it is fully seated before screwing in the new pulsar. If the
o-ring has not been inserted properly, a resistance will be felt as the pulsar is being screwed
in place and the valve will not operate properly.
Note: Speed control of some of the valve functions is done with current adjustments to the
valve coils. See the electrical EHC section for more details.
10-Spool Valve
The 10-spool valve assembly is an electrically operated, proportional, load sensing 4-way
valve stack. The individual parts and features are shown below.
The inlet section of the assembly contains the pilot pressure reducing valve and filter for the
10 spools. The inlet does not have an unloader. This stack sends a signal to the 7-spool valve
unloader that controls the maximum working pressure for both assemblies.
The inlet section, pilot pressure reducing valve and filter are serviceable items. The valve can
be replaced by screwing the old one out of the inlet housing and screwing in a new one.
DRILLING SOLUTIONS
7-271
There are 2 common pressure limiters in the 10-spool valve assembly. The common
pressure limiter controls the maximum spool compensator pressure to limit working pressure
at both C1 and C2 ports. The limiter in the fourth spool section provides a means to limit
pressure in the breakout fork circuit. However, this limiter is set to allow maximum (3000 psi)
pressure in this application. The same is true for the limiter in the fifth spool section which
controls rod support maximum pressure. All of these pressures are adjusted at the factory. No
adjustment should be required in the field unless an entire assembly is being replaced.
Extending or retracting the cylinder all the way and reading the pressure at the test port on the
7-spool valve inlet (with the spool actuated) can check the maximum pressure in any cylinder
circuit. The maximum pressure in a motor circuit can be checked by plugging the valve work
ports and reading the pressure at 7-Spool Valve test port (with the spool actuated).
removing a coil, the o-ring inside the coil cavity must also be replaced. Remove the o-ring with
an o-ring pick. Insert the new o-ring into the coil cavity and be sure it is fully seated before
screwing in the new pulsar. If the o-ring has not been inserted properly, a resistance will be
felt as the pulsar is being screwed in place and the valve will not operate properly.
Note: Speed control of some of the valve functions is done with current adjustments to the
valve coils. See the electrical EHC section for more details.
Holding Valve
The FEMA pressure controller is used in the drill feed system. On low-pressure drills it is used
only in the pulldown circuit. The FEMA pressure controller is a proportional pressure controller
which consists of a coil, armature, poppet, nozzle, filter and housing. The FEMA valve is used
as part of the main pump compensator control circuit in the Drill mode of operation. It is
hydraulically isolated from the pump by a pilot operated N.O. two way valve when the machine
is in the propel mode.
7-272
DRILLING SOLUTIONS
Controllers
Pulldown Controller
As the operator turns the pulldown or holdback controller to the right, the DC electrical current
signal to the FEMA controller is increased. As current is increased to the valve coil, the internal
poppet is pushed closer to the nozzle. This poppet movement causes a restriction to oil flow
that in turn builds pressure proportionally at the valves C port. This valve adjustment is made
by the drill operator when there is a requirement for feed pressure increase or decrease.
The pulldown force rotary controller is energized (wire # 82) when the drill/propel switch is in
the drill mode. The electrical current output of the controller is a direct current proportional
signal from 0-12 VDC w/24 Ohm coil. When the operator turns the control knob to the right,
current signal is supplied to the FEMA valve coil. The farther the knob is turned the higher the
current signal output will be.
When the feed control lever is in the feed down position, the feed system hydraulic pressure
can be controlled remotely by turning the pulldown force knob. The pressure is variable from
zero to maximum (3400 psi) pulldown pressure.
Note: Maximum pulldown pressure developed while drilling is dependent on force controller
output and ground (rock) formation conditions. While drilling in soft ground formations, it may
be impossible to reach the maximum hydraulic pressure relief setting.
Water Injection Rotary Activated Controller

The water injection remote controller provides a proportional signal that is actuated by the drill
operator through a rotary control knob. The output it provides is the same 33 Hz PWM signal
as the other controllers associated with Apitech valves.
The water injection controller electrical power is provided from wire number 80 on the electrical
circuit through the three position dust control switch. The rotary controller is energized when
the switch is turned to the water injection position. As the knob is turned from its off position,
it supplies a proportional current signal to the upper coil on the seventh spool of the 7-spool
valve stack. This shifts the spool to allow oil to flow out the C2 port to the water injection
motor. The oil flow, and therefore the motor speed, is determined by the position of the rotary
remote controller knob.
DRILLING SOLUTIONS
7-273
Limit Switches
In some cases, an EHC link must receive information about the position of drill components
so that drilling operations can be sequenced or protected against movement that would cause
damage. Limit switches mounted at appropriate locations in the tower assembly provide this
information.
The limit switches all have two sets of contacts (four terminals). One set of contacts is normally
open (NO) and the other is normally closed (NC). Whenever the lever is in its normal (unactuated) position, a circuit attached to the NO contacts will be interrupted so that no current
can flow. If the switch arm is rotated either clockwise or counter-clockwise, the contacts
change state. The NO contacts will close to enable their circuit and the NC contacts will open
to interrupt their circuit.
There is only one limit switch used for this purpose. It is located at the upper end of the feed
cylinder on the dust collector side. The limit switch is mounted along the path of the traveling
sheave cage such that the lever is actuated as the sheave cage passes. This switch provides
information about rotary head position for feed deceleration and optional tram interlock
circuits.
On drills equipped with additional options such as Rod Support or No Bump Rod Changer,
there will additional switches of this type in the tower.
7-274
DRILLING SOLUTIONS
Relays
DPDT 24 VDC Relay
There are several relays that are used in various electrical circuits. The relay illustrated below
is typical of the relays used. This is a double pole, double throw, 24 VDC relay. Each relay
includes a 24 VDC coil and two sets of contacts. Each set of contacts (A and B) has a
normally open pair and a normally closed pair. When the coil of the relay is energized, the
electro-magnetic energy causes the internal contact pairs to change state. The normally open
pairs will close, and the normally closed pairs will open.
Picture below shows relays located behind the engine functions panel of the operators console
(see Section 4 Operating Controls for panel location).
Typical Coil Resistance

The resistance of a coil on an Apitech valve, Fema valve or a Denison stroker can be checked
from the cab console. Use the following procedure for the coil being checked.
Denison Stroker Coil

When checking the Denison coil, it is recommended to switch the drill propel selector switch
to the propel position. Remove the wires from the A and B terminals of the propel controller.
Measure the resistance between the two open wires. The resistance should be 27 to 30 ohms.
If checked in the drill mode, the feed circuit resistance can be greater than 30 ohms (Denison
coil resistance) due to the possibility of the deceleration resistor being in the circuit. If checked
in the drill mode, with the rotary head at the top of the tower, the resistance between the A
DRILLING SOLUTIONS
7-275
and B wires should be about 420 ohms. The additional resistance will come from a 390-ohm
resistor in the feed deceleration circuit.
Adjustments
Apitech Coils
There are two coils on each Apitech valve section. To check the coil attached to the controller
A terminal, remove the wire from the A terminal and read the resistance between the open
wire and ground. The resistance should be about 65 ohms. The B side coil resistance can
be checked the same way.
Fema Coils
The Pulldown FEMA coil resistance can be checked only if the carousel is in the stowed (open)
position. Remove the wires from the controller A and B terminals. Measure the resistance
between the two open wires. The resistance should be about 24 ohms.
Proportional Remote Control Output

OEM or remote controllers can be checked for proper output with a voltmeter. To check an RC
with a voltmeter follow the procedure below.
1. Check for 24 VDC input voltage. Read from terminal + to ground -.
2. Check for good ground. Power off, read resistance from terminal - to ground.
Resistance should be zero.
3. Check the coil resistance for the particular circuit as explained in the section
above.
4. With the resistance known and the A and B wires connected back up, the
voltage from A to - or from B to - can be measured. Voltage should be in
the following ranges:
a. Apitech Circuits: Variable 0 - 24 VDC w/65 Ohm coil
b. FEMA Circuit: Variable 0 - 12 VDC w/24 Ohm coil
c. Denison Circuits: Variable 0 - 10 VDC w/27-30 Ohm coil
Checking Relay
The easiest way to do a quick check on a relay is to listen to or feel the relay. If the relay is
being actuated by a switch signal, it will click when the connection is made. A more reliable
check requires the use of a voltmeter. Check the coil terminals. One coil terminal should be
grounded and one should receive a voltage signal when appropriate. If the relay is switching,
check the individual contact pairs next. Check the resistance across the contact pairs (both
open and closed) with the wires disconnected or the relay pulled from its socket. Open
contacts read infinite resistance. Closed contacts read zero resistance. Make sure the
7-276
DRILLING SOLUTIONS
contacts are not welded together by switching the relay with 24 volts and repeating the
resistance check.
Checking Limit Switch

The easiest way to check the function of a limit switch is to rotate the arm and listen for the
click of the switch. A more reliable check requires the use of a voltmeter. Open up the cover
and check the resistance across the contact pairs (open and closed) with the wires
disconnected. Also make sure the contact pairs change from open to closed or closed to open
when the arm is switched back and forth.
Checking Diode
To check a diode, remove it from the circuit. The diode is a uni-directional device (like a check
valve) so be sure to remember exactly what end was connected to what terminal so that it can
be put back in the same orientation. One end of the diode has a line printed around it. The line
is on the end that BLOCKS current flow. Set the voltmeter to read resistance (ohms). Connect
the red lead to the end with the line. Connect the black lead to the end away from the line. The
resistance indicated should be infinite (open circuit). Now switch the meter leads black on line
and red away from the line). Resistance should be zero (closed circuit). If either test fails, the
diode is no good.
DRILLING SOLUTIONS
7-277
7.12 - EHC OPERATION

Operation
Jack Controllers
The controllers used in conjunction with the Apitech hydraulic valves are Pulse Width
Modulated (PWM) controllers. The controllers shown below are representations of the typical
controllers used.
The jack controller (A) EHCs are only energized when the drill/propel switch is in the DRILL
mode. The EHC links that operate the 3 jack spools are pulse width modulated (PWM) links.
These links control spools number four, five and six in the seven-spool valve stack. The RCs
(remote controllers) are set up to drive dual coils as described in VALVES, Apitech Pulsars.
The jack remote controllers (RCs) have a neutral lock that must be lifted by the operator
before the lever can be taken off center. The neutral locks are intended to prevent
unintentional movement of the handle.
Whenever an RC handle is moved away from the operator, the A terminal delivers a PWM
current signal to the upper pulsar on the appropriate valve spool. (The current level coming
from the RC is proportional to the handle position). The upper pulsar converts the current
signal to the proportional pressure signal required to position the valve spool and oil flows out
the valve C1 port to retract the jack cylinder. When the RC handle is moved toward the
operator, the B terminal on the RC board delivers a proportional PWM current signal to the
wire connected to the lower pulsar. The pulsar converts the current signal to a pressure signal
that acts on the valve spool to shift in the other direction. Oil flows out port C2 to extend the
jack cylinder.
Hoist Controller
The hoist controller RC above is the same type with the same PWM output as the jacks RC.
When the control handle is moved away from the operator, the A terminal and the circuit
attached to it is powered with a proportional PWM current signal. This raises the hoist cable.
When the handle is moved in the B direction, current flows through the lower valve coil on
the hoist spool (7 spool valve) and oil flows out the C2 valve port to lower the hoist cable.
7-278
DRILLING SOLUTIONS
Tower Raising Controller

The tower raising controller RC is the same type controller as the jacks and hoist. It is a PWM
control with a neutral lock. Current from the B terminal powers the upper pulsar on the
second spool of the seven-spool valve stack. This causes oil to flow from the C2 port to
extend the tower raise cylinders and raise the tower. The A terminal is connected to the lower
pulsar that controls oil flow out the spool valves C1 port to retract the cylinders and lower the
tower.
Rod Indexer Controller

The rod indexer RC is the same type as the tower raise, hoist and jack controllers. PWM
proportional current from B causes oil to flow from port C2 to the rod changer to index
clockwise. Current from A causes the rod changer to index counter-clockwise.
Breakout Fork Wrench Controller

The breakout (sliding) fork wrench RC is the same as the tower raise, hoist, rod index and jack
controllers. A proportional current signal from B powers the upper pulsar on the fourth section
of the ten-spool valve stack. This causes oil to flow from the C1 port to retract the breakout
fork cylinder. The lower pulsar is powered by a proportional current signal from the A terminal
on the RC when the handle is moved in that direction. This causes oil to flow out port C2 that
extends the breakout fork cylinder to engage the fork.
Carousel Swing Controller

The carousel swing RC is the same as the controllers for the jacks, hoist, tower raise, rod
index, and the sliding breakout fork. When the handle is moved in the direction of the B
terminal, a proportional PWM signal is available at the B terminal. Current flows from the
terminal to the lower pulsar on the first spool in the ten spool valve bank. The pulsar positions
the spool so that oil flows out the C1 port and causes the carousel swing cylinders to extend
and swing the carousel toward the load position.
Note: Drills with No Bump rod changer protection. This complete EHC link differs because
it is protected against swinging the carousel in if the rotary head is in the way. An electrical
limit switch protects the carousel by interrupting the current to the pulsar. The switch is
normally open, held closed by the rotary head. If the rotary head is not at the top of the tower,
current to the pulsar is interrupted due to the open contacts in the limit switch.
There are no interrupts in the circuit for opening the carousel. When the operator moves the
RC handle away toward the A terminal, current is supplied to the upper pulsar on the first ten
spool section. This causes the spool to shift to flow oil out of the C2 port to retract the
carousel swing cylinders and move the carousel to the open or stowed position.
Water Injection Controller

The water injection RC is a proportional control with a rotary knob. The output it provides is
the same 33 Hz PWM signal that the above RCs use.
The water injection RC power is provided from wire number eighty (80) in the electrical circuit
DRILLING SOLUTIONS
7-279
through a three-position switch. The RC is turned on when the water injection/dust collector
switch is turned to the water injection position. As the RC knob is turned away from its off
position, it supplies a proportional PWM current signal to the upper coil of the seven-spool
valve stack. This shifts the spool to allow oil flow out the C2 port to the water injection motor.
The oil flow and therefore the motor speed is determined by the position of the RC knob.
Dust Collector
The EHC link for the dust collector is significantly less complicated than those described in the
previous discussions. This link is an on/off control that powers up the lower pulsar on the
seventh spool in the seven-spool valve stack. The 24 VDC signal comes from the dust
collector/water injection selector switch when it is shifted to the DC/PULSE position. The 24
VDC signal causes the valve spool to shift all the way to its spool stop to flow oil out the C1
port to turn the dust collector motor.
Tower Pinning
The tower pinning is controlled by a spring-centered switch. The switch supplies 24 VDC to
the pulsars on section six of the ten-spool valve stack. Pushing the switch up energizes the
pulsar corresponding to the C1 port diverting oil to extend the pinning cylinder. Pushing the
switch down energizes the pulsar corresponding to the C2 port of the valve section. This
disengages (retracts) the pinning cylinder, unpinning the tower from the pinning clevis.
Note: Do not operate the machine in DRILL mode with the tower unpinned. This can result
in excessive loading of the tower support pivot area and the tower raising cylinders. Improper
operation of the machine can cause severe damage or injury.
Tower Angle Leg Pinning (Option)

The tower angle leg pinning is controlled by a spring-centered switch. The switch supplies 24
VDC to the pulsars on section seven of the ten-spool valve stack. Pushing the switch up
energizes the pulsar corresponding to the C1 port diverting oil to extend the pinning cylinder.
Pushing the switch down energizes the pulsar corresponding to the C2 port of the valve
section. This disengages (retracts) the pinning cylinder, unpinning the tower from the pinning
clevis.
Note: Do not operate the machine in DRILL mode with the tower unpinned.
Drill Propel Valve

The drill/propel mode control valve manages all of the mode selection, brake and pump
compensator enabling tasks for the drill. It is a ductile iron manifold into which 4 valve
cartridges are inserted. A solenoid operated 4-way valve, bolted to one side of the manifold,
selects the drill mode or the propel mode for the drill. The solenoid is energized when the
propel mode is selected and de-energized when in the Drill mode.
7-280
DRILLING SOLUTIONS
The valve assembly can be completely rebuilt by replacing the 4 valve cartridges and the
solenoid operated 4-way valve bolted to the side of the manifold. The assembly should never
be serviced as a complete unit.
The only adjustment on the assembly is a pressure adjustment for the propel brakes. The
brake pressure is set at 500 psi by turning the adjustment until this pressure is indicated at the
brake pressure test port. The engine should be running (at high idle) and propel mode should
be selected when the pressure is being adjusted. The drill does not have to be propelling.
Drill Feed Circuit

With the drill/propel selector in the drill position, electrical power transfers from wire number
80 to wire number 82. This supplies power to the feed, rotation and auxiliary function
controllers. These controllers are used in conjunction with the drilling process.
To start the rotary head moving down the tower, the operator pulls the feed controller forward.
This sends a proportional electrical current from the controller to the cab side Denison main
pump stroker (See CONTROLLERS, Denison 500 Stroker). The electrical signal to the stroker
results in changing the main pump swashplate angle. The farther the lever is moved, the
farther the swashplate will come on stroke, increasing the pump displacement from zero
displacement up to the full displacement setting of the pump. Reducing the lever movement,
(reducing the current output to the stroker) reduces the swashplate angle. Therefore, rotary
head speed is affected by the amount of feed lever movement.
The drill/propel control valve and the FEMA actuator also affect the movement of the rotary
head. When the drill /propel switch is in the DRILL mode, power is supplied to the feed
controller, pulldown force controller and to the solenoid operated four way valve portion of the
drill/propel control valve. Energizing the solenoid shifts the valve, enabling communication
(hydraulically) between the main pump compensator VA port and the drain manifold through
the drill/propel control valve and the FEMA actuator.
Rotation Control
When the drill/propel switch is in the drill mode, the main pump controller on the dust collector
side is used to control the drill pipe rotation. It controls both speed and direction of rotation.
Pushing the controller away from the operator makes the drill pipe turn counterclockwise or
reverse for breakout. This direction of rotation is used to uncouple drill pipes from one another.
DRILLING SOLUTIONS
7-281
Pulling the controller forward starts the drill pipe turning clockwise. This direction of rotation is
used for normal drilling and for connecting pipes together. The rotation controller is shown
below. For torque control information, see torque limit section.
LP Drill Feed and Rotation Controller

The EHC link for feed pump control uses a proportional, single coil RC with a neutral safety
lock and dual range control switch. The RC output is a proportional DC current signal, not a
PWM current signal. The mode selector switch must be set to the DRILL MODE before the
drill feed and rotation controllers will function.
The feed and rotation controllers are identical on XL machines. The RCs each have two
terminal strips. The first strip provides access to the +, -, A, X, B, R, and N terminals
(N is spade connection on micro switch opposite side). The second strip is mounted on the
side of the RC and it provides access to terminals 7, 8, and 9. These connect to a micro switch
that is switched by a button in the end of the RC handle. Terminals 7 and 9 area (NC) normally
closed pair. Terminals 7 and 8 are a (NO) normally open contact pair.
The normal mode for the feed and rotation RCs is high range mode. The NC contacts 7 and
9 switch 24 VDC from the RC + terminal to the R terminal to shift the control into high range.
If the button on the end of the handle is pressed, the NC contacts 7 and 9 open and interrupt
the power to the R terminal. This shifts the control into low range mode.
The high range mode allows a proportional DC current signal from about 60 mA to 350 mA (no
pump stroke to full pump stroke). The low range allows a proportional DC current signal from
about 60 mA to 100 mA (no pump stroke to 1/16 stroke). In the low range, full RC handle
movement corresponds to a change of only 40 mA that gives a finer control for more precise
alignment of the drill steel flats with the breakout fork. The actual maximum low range speed
can be adjusted with the low range pot on the RC circuit board.
When the RC controller (feed or rotation) is pulled toward the operator, a proportional DC
current signal is supplied from the B terminal to the corresponding main pump stroker. This
causes the pump swashplate to position to allow flow from the pump A port.
If this controller is used for control of the rotation pump, the rotation motors will turn the drill
pipe clockwise. The amount of oil the pump supplies and therefore the forward rotation speed
is proportional to the handle position.
When the RC controller is pushed away from the operator, the proportional current signal from
the RD A terminal flows through the stroker coil in the other direction. This causes the pump
swashplate to position to allow flow from the pump B port and the drill pipe turns counterclockwise. The reverse rotation speed is proportional to handle position.
7-282
DRILLING SOLUTIONS
The EHC link for the feed pump control uses the same RC as for the rotation speed control
(low pressure drills machines only). The RC output is a proportional DC current signal, not a
PWM current signal. This RC uses the dual range selection circuit described in the discussion
above. (The low range mode is particularly useful for precise positioning of the drill pipe.) This
link is different, however, in that both control directions have protection circuits.
When the feed RC controller is pulled toward the operator, a proportional DC current signal is
supplied from the RC B terminal to the feed pump stroker coil. The other side of the stroker
coil is connected to the circuit components (limit switches) that provide feed down interrupt
control and feed up deceleration control. If the action of any of these components closes a
direct path to RC terminal A, the pump will stroke to allow oil flow from pump port A and the
rotary head will feed down. If the action of any of the components adds resistance before
closing a path to RC terminal A, the pump will stroke slightly to allow very slow feed down
speed. If the action of any of the components interrupts the path to RC A terminal, the pump
will not stroke and the rotary head will not feed down.
Feed Controller (HP)

The feed controller is different on high pressure drills than from those on low-pressure drills.
Like the LP controller, the HP feed controller also has two terminal strips. It is different,
however, in that it has an additional micro switch connected to the circuit board.
The first terminal strip provides access to the +, -, A, X, B, and R terminals. The N
and D terminals indicated on the schematic are actually micro switches located on the circuit
board side of the controller. The D micro switch makes it different from the ones in the
previous discussion. When the handle is moved toward the operator, NO contact D within
the micro switch is actuated. This energizes wire number 81. When terminal D is energized,
24 VDC current flows through wire # 81 to the coil of the holdback solenoid operated control
valve. When the solenoid operated valve coil is energized, the hydraulic holdback circuit is
functional.
The second terminal strip is mounted on the side of the RC and it provides access to terminals
7, 8, and 9. These connect to a micro switch that is switched by a button in the end of the RC
handle. Terminals 7 and 9 are a (NC) normally closed pair. Terminals 7 and 8 are a (NO)
normally open contact pair.
On high-pressure drills used for DHD drilling, the feed system requirements are different than
DRILLING SOLUTIONS
7-283
those of an LP low pressure rotary drill. The additional terminal and switches interact with the
holdback control circuit. These controls will be discussed in the holdback control section.
Drill Feed Force / No Bump Rod Changer (Option)

The EHC link for feed force control uses a rotary RC with a proportional DC output. The output
range is from 100 to 500 mA.
The RC receives 24 VDC from wire number 82. When the knob is turned from its off position,
a proportional current flows from terminal A to the normally open contacts of the rod support
limit switch. If the rod support is stowed out of the way of the rotary head, the NO switch
contacts close and allow RC output to drive the FEMA valve coil. Pressures from 400 to 3400
psi can now be commanded by the RC.
On drills that are equipped with the no bump rod changer option, the NC contacts on the
carousel limit switch are connected between the NO BUMP resistor (located in operators
console) and the FEMA valve coil. The other end of the resistor is connected to 24 VDC from
wire 82. If the carousel is loading a rod, the switch is in the normal position and current from
the resistor is supplied to the FEMA coil. The resistor can be adjusted to limit maximum feed
down pressure. This prevents the rotary head from feeding down with enough force to damage
the carousel. If the carousel is out of the way of the rotary head, the NC contacts open and the
current path through the resistor is disconnected from the FEMA coil.
Holdback Control (HP)

The EHC link for holdback force control uses a rotary RC with a proportional DC output. The
output range is from 100 to 500 mA. Also included in the holdback circuit is a solenoid
operated, two way valve. The two way valve is energized by a limit switch on the feed
controller. When the feed lever is moved in the feed down direction, the normally open limit
switch immediately closes, energizing wire #81. Wire 81 is connected to the solenoid operated
two-way valve. When energized, the valve opens and the holdback function is enabled.
The holdback rotary controller receives 24 VDC from wire number 82. When the knob is turned
from its off position, a proportional current flows from terminal A to the FEMA valve coil in the
holdback circuit. As long as the feed controller is actuated in the feed down direction (toward
the operator), the holdback rotary controller can be used to affect the feed system bit loading.
As weight is added to the drill string, the operator must increase the holdback pressure to take
weight off the bit.
7-284
DRILLING SOLUTIONS
Rotation Control
The EHC link for rotation pump controller uses a proportional, single coil RC with a neutral
safety lock and dual range control switch. The RC output is a proportional DC current signal,
not a PWM current signal. The drill/propel selector switch must be set to the DRILL MODE
before the rotation controller will function.
The rotation control RC has two terminal strips. The first strip provides access to the +, -,
A, X, B, R terminals. Terminal N is located on a micro switch located on the circuit
board side of the controller. It is used for neutral start protection and is a spade connection on
the circuit board.
The second strip is mounted on the side of the RC and it provides access to terminals 7, 8,
and 9. These connect to a micro switch that is switched by a button in the end of the RC
handle. Terminals 7 and 9 are a (NC) normally closed pair. Terminals 7 and 8 are a (NO)
normally open contact pair.
The normal mode for the rotation speed RC is the high range mode. The NC contacts 7 and 9
switch 24 VDC from the RC + terminal to the R terminal to shift the control into high range.
If the button on the end of the controller is pressed, the NC contacts 7 and 9 open and interrupt
power to the R terminal. This shifts the control into low range mode. The high range mode
allows a proportional DC current signal from about 60 milliamps to 350 milliamps (no pump
stroke to full pump stroke). The low range allows a proportional DC current signal from about
60 milliamps to about 100 milliamps (no pump stroke to about 1/16 pump stroke). In the low
range, full RC handle movement corresponds to a change of only 40 mA that gives a finer
control for more precise alignment of the drill steel flats with the breakout fork. The actual
maximum low range speed can be adjusted with the low range pot on the RC circuit board.
Torque Limit Control (Option)

The EHC link for torque limit control uses a rotary RC with a proportional DC output. The output
range is from 100 to 500 mA (same part # as pulldown and holdback).
DRILLING SOLUTIONS
7-285
The RC receives 24 VDC from wire number 82. When the knob is turned from its off position,
a proportional 24 VDC signal flows from terminal A to the FEMA valve coil in the torque limit
circuit. As long as the rotation controller is actuated in the forward rotation direction (toward
the operator), the torque limit rotary controller can be used to affect (raise or lower) the rotation
system torque force. Turning the knob to the right increases the torque force available in the
rotation circuit.
7-286
DRILLING SOLUTIONS
7.13 - EHC ADJUSTMENTS

EHC Adjustments
Feed and Rotation Controllers
Drills with (low-pressure) LP compressors used for rotary drilling use the same type controller
for both the feed and rotation functions. The feed and rotation controllers are only energized
when the machine is in the DRILL mode. The feed and rotation controller is shown below.
These controllers are located on the drill functions panel of the operators console (see section
4 Operating Controls for panel location) and are used to control the main pumps during the
drilling operations.
On HP (high-pressure) drills, the feed controller has an additional micro-switch for holdback
functions, and it works in conjunction with the holdback regulator.
These controllers are electrical devices that send an output current of 60-350 milliamps to the
Denison 500 stroker. The electrical output current is proportional to the degree of movement
of the control lever. The farther the lever is pushed in either direction, the higher the current
signal to the pump stroker. The result is a machine that operates smoothly while providing the
operator with proportional actuation of the hydraulic functions used for drilling.
The Feed and Rotation controllers must be adjusted at installation. Tools required:
a. 1 Phillips screwdriver for opening control panel
b. 1 Slotted screwdriver for removal of wires from terminal strip
c. 1 Ammeter with milliamps readings
d. 1 Trim Pot screwdriver
Two identical controllers are used for controlling the track functions while in the tramming
mode. The controller used is shown below.
The instructions for adjustment of the feed and rotation controllers are as follows:
DRILLING SOLUTIONS
7-287
1. Start procedure with the engine OFF, key switch ON, and the Drill/Propel
selector in the DRILL position.
2. Remove the B wire from the controller terminal strip and splice an ammeter
between the controller and the B wire (red lead to B and black lead to open
wire).
3. Pull remote controller handle slightly on stroke (until a faint click is heard). Set
Threshold pot to 60 milliamps. Friction hold should keep the controller on
stroke.
4. Pull remote controller handle fully on stroke and set the Hi Range pot to 350
milliamps.
5. With the remote controller handle still fully on stroke, push and hold the low
range actuator button. Set the low range pot to 100 milliamps.
6. Remove the meter and reconnect the wire to the B terminal.
Propel Controller Adjustment

Adjustment of the propel controllers is described in the following steps:
1. Start with the engine OFF, key switch in the ON position and the drill/propel
selector in the PROPEL mode.
2. Remove the B wire from the controller terminal strip and splice an ammeter
between the controller and the B wire (red lead to B terminal and black lead
to the open wire).
3. Pull remote controller handle slightly on stroke (until a faint click is heard). Set
Threshold pot to 60 milliamps. The controller will have to be held on stroke
because the controller is spring returned to center.
4. Pull remote control handle fully on stroke, hold and set max pot to 350 Milliamps.
5. Remove the ammeter and reconnect the wire to the B terminal.
Note: These controllers are mounted very near to one another.When installing, care should
7-288
DRILLING SOLUTIONS
be taken to ensure that the two controllers cannot make contact with each other. If they contact
each other they will not function, or may be sporadically inoperative.
Auxiliary Function Controllers

There are up to fifteen auxiliary functions that are powered by the Apitech electro-hydraulic
control valve. The Apitech valve is actuated by the drill operator through the use of electrical
controllers. The Apitech Pulsar is not designed for use with a constant 24 VDC current signal.
Therefore, the controllers used are either Pulse Width Modulated (PWM) current signal, or
spring returned to neutral ON/OFF controllers. The controller shown below is a PWM signal
controller. It also is spring returned to neutral and has a locking detent to prevent unintentional
actuation.
The controllers must be adjusted at installation. This adjustment is accomplished by setting

the Threshold and Max voltage pots. Adjust the pots as follows:
1. Slightly pull the lever on stroke in either direction, until a faint click is heard and
hold.
2. Adjust the Threshold pot until the function being actuated just begins to move
(i.e. chain wrench cylinder just starts to move). LED on the card should be just
flickering. This is an indicator of the ON Time and OFF Time of the PWM
signal.
3. Pull handle to full stroke. Adjust the Max pot until the LED is constantly ON.
The controller voltage output should now be proportional to the controller movement, from the
Threshold to Max. The speed and some characteristics of each function can be adjusted in
this manner to suit the preferences of the operator.
Picture below shows one rotary controller (water injection) on the console that controls an
Apitech valve section. While it looks virtually the same, this controller is electronically different
from the rotary type controllers that control the feed system.
DRILLING SOLUTIONS
7-289
The water injection controller above uses a PWM signal to proportionally control the water
injection pump. This gives the drill operator the ability to control the speed and flow volume of
the water injection pump. This RC is adjusted in the same manner as the lever operated RCs
only it is operated with a rotary knob rather than a lever. Turn the RC on till a faint click is heard
and set the Threshold to approximately 60mA. Then turn the knob to Full ON position and
adjust the Max pot to the point where the LED is constant and bright. This provides the
proportional control desired.Minimum output can be adjusted to suit the operator or drilling
condition.
The feed system rotary type controllers (pulldown and holdback) are 24 VDC proportional
controllers. The feed system controllers, can be visually differentiated from the water injection
controller by the presence of a red and black wire that runs from the circuit board to the mount
(knob) end of the controller. The water injection RC has no wire.
Pulldown Force Rotary Controller

Drills used for rotary drilling have one rotary type controller in the feed system. It is used by
the operator, in conjunction with the feed lever, to adjust the pulldown force or weight on the
bit while drilling. Turning the knob to the right increases feed force. When replacement is
required, the controller current output will require adjustment.
Tools needed for adjustments:
a. One 24 VDC Voltmeter (can be used if desired)
b. One phillips screwdriver to open console
c. One slotted screwdriver to remove wires from terminal (for controller
replacement)
7-290
DRILLING SOLUTIONS
d. One trim pot screwdriver

Adjustment of the Pulldown Force rotary controller is done as follows:
1. Start adjustment with the engine running at high idle, machine in the Drill
Mode, and the rotary head against the lower feed stops.
2. With the pulldown rotary controller in the OFF position, pull the feed system
main pump controller downward.
3. Turn the pulldown force rotary controller to the ON position until a faint click
is heard.
4. Turn Threshold trim pot until the pulldown gauge reads 400 psi maximum. If
the minimum pulldown pressure is higher than 400 psi, back out on the
Threshold trim pot until it reads 400 psi.
5. Turn rotary controller knob to its maximum position. If Max prescribed pulldown
pressure is not reached, adjust the Max pot clockwise until proper maximum
pressure is reached.
6. If the pulldown pressure control is proportional to knob movement, the
adjustment is complete.
Drills equipped with (HP) high-pressure compressors for DTH (down the hole) drilling will have
two rotary type controllers in the feed system. One is the pulldown controller, as described
above, and the other is a holdback rotary controller.
Holdback Rotary Controller

DTH (down the hole) operations require operating the drill with a limited and specific amount
of weight on the bit. Holdback control allows the drill operator to control the amount of weight
on the bit as more pipe is added to the drill string. When a drill pipe is added, the operator can
off set the weight of the new pipe by increasing the holdback setting. The holdback rotary
controllers should be checked for proper operation at installation. To verify holdback function:
1. Turn the pulldown rotary controller OFF.
2. Turn the holdback controller ON.
3. Start the engine.
4. Pull the feed lever to the down direction.
5. The rotary head may begin to move downward due to main pump charge
pressure. (About 250 psi.)
6. Turn the holdback regulator to the right to increase the setting until the head
stops moving downward.
7. Refer to the holdback gauge to see if holdback pressure rises as the knob is
turned to the right, and as the head slows to a stop. Pressure seen on the
holdback gauge will show the weight of the rotary head, drill pipe, subs and bit.
Once the rotary head stops, turning the regulator more will not increase the
pressure. Reducing the holdback setting allows the operator to apply more
weight on the bit while drilling.
DRILLING SOLUTIONS
7-291
7.14 - TROUBLESHOOTING (DUST COLLECTOR)

Dust Collector
If, upon inspection of your dust control system, it is obvious that the unit is not operating
properly, the following discussion should help you to troubleshoot the problem.
All problems with the dust collector system can be isolated through the use of a water
manometer. Measurements should be made separately on the upper and lower vacuum taps
located on the dust collector housing. Depending on whether your readings are higher or lower
than the normal values, the following explanations will apply.
7-292
DRILLING SOLUTIONS
Upper Tap HIGH - Lower Tap LOW

This situation indicates that the blower assembly is being choked off, causing the vacuum in
the clean air section to go up. The fact that the area around the filter elements (lower tap) is
low indicates that air is not moving through the filters (i.e. plugged filter elements). The main
reason that this occurs is failure of the back-pulsing system of pulsed air. Three probable
causes are:
1. The incoming air pressure is too low. This pressure should be maintained at
about 40 psi. Insert a gauge at the point where air enters the dust collector to
make your measurement.
2. The pneumatic or electric timer could be malfunctioning. Check the timer to see
that each station is being fired at a timer interval of about 2-3 seconds between
stations.
3. Impulse valves over the filter elements may themselves be faulty. If one of the
diaphragms of the impulse valves develops a hole or a rock becomes lodged
in the valve causing the diaphragm to seat improperly, the compressed air may
never be allowed to build up to the required 40 psi pressure and/or the valve
may not fire properly. Also, for electric systems, the electric-air solenoid valve
operating the impulse valve may be faulty.
Upper Tap HIGH - Lower Tap HIGH

This situation indicates that the system is being choked off prior to the filter elements. This
generally results from a plugged suction hose due to the build-up of dirt and mud or obstruction
by a foreign obstacle such as a shot-sack.
Upper Tap LOW - Lower Tap LOW

This condition points to a loss in suction capacity. The primary concern here is fan speed. The
fan may be turning below the suggested 3000 rpm because of a problem in hydraulic oil supply
(or the air supply in the case of an air motor). Another situation often occurs when the motor
is changed out or repaired. The motor may be reconnected incorrectly to cause the blower
wheel to turn in a reverse direction.When this happens, a vacuum will be produced and some
air flow will occur. The best way to verify proper rotation of the wheel is to observe it visually
upon startup or shut down. The blower wheel should turn clockwise when viewed from the top
looking down at the dust collector.
As a final comment, one should note that the dust collector fan should be run as close to 3000
rpm as possible. Although the fan can easily tolerate higher speeds and the system will indeed
pull more air at higher speeds, operating the system at such speeds can cause unnecessary
wear of filter elements, dust collector housing and suction hose.
DRILLING SOLUTIONS
7-293
Dust Collector Trouble Shooting Guide
Excess Dust
7-294
DRILLING SOLUTIONS
Fan Dust
Pulse
Setting the Electric Timer

There are three (3) switches on the DET-9000 timer that control the First Out and Last Out.
A flathead screwdriver can be used to set each switch to a digital value from 0 to 9. The
procedure is as follows:
1. The OFF TIME switch controls the amount of time between pulses. A value of
0 represents On/Off time of 0.5 seconds. Each step after adds 0.5 seconds,
with step 9 representing the maximum value of five (5) seconds.
2. The FIRST OUT switch should be set to the station number of the first
solenoid that is to be activated. A value of 0 is not allowed and will cause the
yellow error lamp to blink on and off.
3. The LAST OUT switch should likewise be set to the last station number to be
activated. If there are four filter elements in the dust collector and the first
solenoid is connected to station 1, then the LAST OUT switch should be set
to 4. Once again, 0 is not allowed.
4. If power is on when any adjustments to the above switches are made, then the
reset push button must be pushed before the adjustments will take place.
DRILLING SOLUTIONS
7-295
7.15 - TROUBLESHOOTING (CENTROMATIC LUBE)

General Information
Retain this information for reference. If additional information is needed, supply model and
serial numbers stamped on the nameplate.
1. The pump should be located where there is sufficient space around and above
the unit for raising pump to change lubricant drum or to make adjustments.
2. The time controller should be located adjacent to the pump and it should be
accessible for adjustments. The length of connecting air and lubricant hoses
limits the spacing between the pump and the time controller.
3. Connect air supply line to the 3/8 NPT female inlet of the solenoid air valve.
Connect air hose from pump to the 3/8 NPT elbow at the back side of solenoid
air valve. Connect the lubricant delivery hose from pump to the 3/4 NPT female
inlet at the bottom of the junction block.
4. Install lubricant supply line to system into the 3/4 NPT female outlet of the
junction block.
5. Finally, install electric power supply to time controller.
Principle of Operation
The pump is operated by the time controller. The timer closes the electric circuit to the solenoid
air valve. The solenoid air valve opens and permits air to pass through the air hose, operating
the pump and closing the vent valve.
The pump continues to operate until the lubricant pressure in the supply lines is sufficient to
operate the injectors. After the injectors operate (discharge lubricant to bearings), the pump
continues to build up pressure in the supply lines until there is sufficient pressure to open the
pressure switch.
The opening of the pressure switch breaks the electric circuit to the solenoid air valve, which
shuts off air supply to the pump. At the same time the lubricant pressure opens the vent valve
and allows the supply line pressure to vent back into the lubricant drum. The injectors
automatically reload and the system is ready for next lubrication period.
Typical System Drawing

The drawing shown below is the actual manufacturers drawing used for descriptive purposes.
7-296
DRILLING SOLUTIONS
Fill Supply Line

Refer to drawing above for additional information.
1. Remove pipe plugs from the injector manifold at the end of each run.
2. Set time delay relay to maximum position.
3. Place timer toggle switch in A position.
4. Close line switch to start pump.
DRILLING SOLUTIONS
7-297
5. Pump in operation will charge supply line with lubricant.

6. When lubricant begins to flow from the open end of injector manifold (injector
farthest from pump), open line switch to shut off pump.
7. Replace pipe plugs in all injector manifolds.
8. Re-adjust time delay relay to desired delay interval.
Prime Feed Lines

Operate the pump by rotating program disc clockwise by hand through one clip. Repeat
several times to be sure each injector is operating.
Operation Check
1. Open shut-off valve A which should be installed in the supply line adjacent to
the pressure gauge and pump. Start pump as above. Allow the pump to operate
until the supply line pressure builds up to about 2500 PSIG (for high pressure
units) as indicated on the pressure gauge B or 850 PSIG (for low pressure
units).
2. Close the shut-off valve A and this will trap the lubricant pressure in the supply
line. Each individual injector can now be inspected for the correct discharge
position of the indicator stem.
Note:
Pressure reading on the pressure gauge should remain constant after the shut-off valve is
closed. A pressure decline on the pressure gauge indicates a leak in the supply line. After the
system has been checked, open the shut-off valve and the system is ready for the desired
lubrication cycles.
Set timer to program the lubrication cycle frequency.
Attach Air Motor to Pump Tube

1. Tightly connect air motor coupling nut to the pump plunger.
2. Attach the air motor to the pump outlet body flange with the four bolts & nuts
(hand tight) supplied with air motor.
3. Slowly cycle the pump several times by using just enough air pressure to
operate the pump without stalling.
4. Stop the pump on an up stroke and tighten the four bolts & nuts to securely
fasten the air motor to the pump tube.
7-298
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-299
Failures without Alarm Systems
Failures with Alarm Systems
7-300
DRILLING SOLUTIONS
7.16 - ENGINE HEATER

Introduction
This section is provided to present an overview of the engine block heater system currently
used.
The preheater will preheat an engine block to ensure reliable starting in cold weather. At the
same time it may be used throughout the year to reduce the wear associated with cold starts.
DRILLING SOLUTIONS
7-301
Technical Specifications
WARNING
DO NOT use gasoline

Ignition Type: --------------------------------- Electronic spark ignition
Fuel Types: ------------------------------------ Diesel #1, #2, Kerosine
Coolant Temperature: --------------------- 150 to 185F (65 to 85C) @ heater
Enclosure Dimensions: ------------------- 12.5W x 11H x 20.5L inches
(318W x 280H x 521L mm)
Weight, Heater only ------------------------ 40 lbs. (18 kg)
Weight, with Enclosure: ------------------ 55 lbs. (25 kg)
Operating Temperature Range: ------- -40 to 122F (-40 to 50C)
Heat Exchanger Capacity: ---------------- 1 quart U.S. (0.95 liter)
7-302
DRILLING SOLUTIONS
Principal of Operation
1. Fuel Pump
A gear pump driven from the same motor as the compressor pulls fuel from the
tank. The fuel is filtered at the fuel pump inlet. The gear pump will develop a
maximum pressure of 10 psi on the outlet side of the pump.
DRILLING SOLUTIONS
7-303
2. Fuel Regulator
Reduces fuel to atmospheric pressure. Siphoning action from the nozzle draws
fuel from the regulator. Without this siphoning there is no fuel flow.
3. Air Compressor
A diaphragm type compressor supplies air to the fuel nozzle.
4. Ignition Coil
An automotive type ignition coil supplies high voltage to the ignition electrode,
sparking to the combustion tube.
5. Coolant Pump
Circulates the engine coolant. An impeller style pump is used because of its low
current draw and free flow during engine operation. It is not self priming. The
pump must be flooded and the system must be purged of all air for it to operate.
(DO NOT run dry).
6. Proheat Control Module (PMC)
Utilizes a microprocessor to monitor conditions and control outputs to the
motors and sensors. It has powerful diagnostics to assist in troubleshooting.
One of the key features is the diagnostic display on the front of the PMC which
has LEDs to indicate function or component problems.
Note: The PCM is unique in that it uses ground side switching for the blower,
compressor, coolant pump and ignition coil. The positive wire to the motors and
ignition coil will show voltage even when the heater is switched OFF.
7. Nozzle
An air/fuel aspirating type spray nozzle is located inside the housing. The
compressed air flows through the nozzle at high speed creating a venturi effect.
This siphons fuel from the regulator and combines it with the air, creating an
extremely fine mist which is sprayed out of the nozzle into the combustion
chamber. The nozzle determines the air/fuel ratio.
7-304
DRILLING SOLUTIONS
8. Blower
The blower uses an impeller type fan to supply approximately 90% of the
combustion air at low pressure. It is also used to cool and purge the combustion
chamber during the 3 minute shutdown sequence.
9. Inspection Port
The inspection port allows for visual inspection of the combustion process and
is invaluable for reducing time spent on troubleshooting and servicing the
heater.
10. Heat Exchanger
The heat exchanger is a two part cast aluminum housing. Coolant will typically
rise 10 to 15F (6-8C) in temperature as it passes through the heat
exchanger, depending on the flow rate.
11. Ignition Electrode
The electrode is located near the nozzle just out of the air/fuel mixture path.
During the ignition sequence the spark jumps the gap between the electrode
and the combustion tube, igniting the air/fuel mixture. Spark duration is 60
seconds.
12. Coolant Temperature Sensor
The coolant temperature sensor measures coolant temperature at the outlet
port of the heat exchanger.
13. Overheat Breaker Sensor
The overheat breaker sensor protects the heater from damage should it be
operated without coolant. The overheat breaker monitors the surface
temperature of the heat exchanger casting. When the temperature reaches
286F (141C) the breaker trips out. This shuts off the power to the air
compressor, extinguishing the flame. The breaker can be reset by pushing
down on the red button located under the rubber cap.
14. Flame Sensor
The flame sensor photo-electronically measures the intensity of the flame. It is
the flame sensor that signals to the PCM that the air/fuel mixture is burning
properly.
15. On/Off Switch
The on/off switch is used to switch the heater on and off. It has an indicator
lamp that displays a red light when switched on. A flashing red light indicates
a heater diagnostic code and one of the LEDs on the PCM diagnostic display
will be lit. The on/off switch is not used on Drilling Solutions drills. A
timer is used on Drilling Solutions drills.
DRILLING SOLUTIONS
7-305
16. Seven (7) Day Timer

The 7 day timer is used to switch the heater on and off. This can be done
manually or by a preset time and day. It has an indicator lamp that displays a
red light when switched or timed ON. A flashing red light indicates a heater
diagnostic code and one of the LEDs on the PCM diagnostic display will be lit
(See Normal Operating Sequence for details).
NORMAL OPERATING SEQUENCE

1. Switch ON
The timer lamp (or the on/off switch if used) and the PCM ON LED will light.
The heater goes to Precheck.
2. Precheck
The PCM performs a short diagnostic cycle. This takes several seconds,
checking components for proper ranges, short circuits and open circuits. If
there are no errors indicated, the heater goes to ignition.
3. Ignition
The blower starts first, followed by the coolant pump, ignition spark, air
compressor and fuel pump. The ignition electrode sparks, 60 seconds
maximum, until the flame sensor sees a flame. Once the flame sensor sees
a flame, the heater goes to full output.
4. Full Output
The heater runs at full output until the coolant temperature reaches 185F
(85C) at the heater outlet. At this time, the heater shuts the flame off and goes
to purge.
5. Purge
The air compressor and fuel pump shut off immediately. The blower and
coolant pump continue to run. After 3 minutes, the blower stops and the heater
goes to Standby.
6. Standby
The coolant pump circulates the coolant through the system until the
7-306
DRILLING SOLUTIONS
temperature drops to 150F (66C) at the heater outlet; then it will enter
Precheck and repeat steps 2-6. The heater will continue to repeat steps 2-5
until it is turned OFF.
7. Switch OFF
If the heater is in Full Output, it will purge first and then shut OFF. If the heater
is in Standby, it will shut OFF immediately. Note: The heater will purge for
three reasons:
a. The coolant reaches 185F (85C)
b. There is a function or component problem (see Troubleshooting & Repair)
c. The heater is operating at Full Output when it is shut OFF.
Function and Component Diagnostics

The microprocessor in the PCM continually monitors all the heater systems. If the internal
diagnostics discover a problem, a diagnostic code will be displayed on the PCM function
display. The Timer red ON light will also flash the diagnostic code followed by a pause and
then repeated, the number of flashes correspond to the numbered diagnostic code; eg. 5
flashes indicate a VOLTAGE ERROR. (See Diagnostic Code Description below for a complete
list of error flash codes). If this occurs, refer to the troubleshooting section to assist in problem
diagnosis.
* The fuel pump is a gear pump driven by the compressor motor. The fuel pump is NOT being
monitored electrically. Should this component diagnostic code appear, there is a fault in the
main wire harness connector or in the PCM. All mechanical problems with the fuel pump will
be indicated as either a (1) START or a (2) FLAME OUT diagnostic code.
DRILLING SOLUTIONS
7-307
Troubleshooting & Repair

The Troubleshooting & Repair Guide is divided into four sections:
Function Errors:
Errors displayed on the PCM diagnostic panel will cause the heater to shut down. These
diagnostic codes are usually the result of a system problem.
It is possible to have two or more diagnostic codes displayed at the same time. A function
diagnostic code may be displayed in conjunction with a component diagnostic code.
Component Faults:
This section covers the individual heater components. In many cases there is a corresponding
indicator light on the PCM function display. The indicator light only indicates an electrical
problem, NOT a mechanical failure. Component problems can also cause Function diagnostic
codes.
7-308
DRILLING SOLUTIONS
Component:
This section includes the electrode gap, fuse, nozzle and fuel regulator.
Operational Problems:
These are problems that are not specifically described in the Function or Component
diagnostic sections.
Note: Always let the heater run through two cycles when troubleshooting. The heater will
attempt one restart after any function or component diagnostic code. The heater will not start
if it is in a purge cycle or if the coolant temperature is above 150F (66C).
On
A continuously flashing ON indicator indicates a problem in the PCM.
Check: Heater PCM function

a. Turn the heater switch located on the timer to OFF. Reset the PCM by
removing the power connection for 10 seconds, then reconnecting it. If
the ON light continues to flash, replace the PCM.
Function Diagnostic
(1) Start
A START diagnostic code indicates that the flame sensor did not see a flame during the 60
second ignition period.
If the START diagnostic code is displayed, turn the heater OFF and then ON to restart.
Observe the heater operation through the inspection window.
Symptom: Flame visible
The heater shuts down after 60 second ignition period.
Check: Flame Sensor
a. Inspect for open circuit in the wiring.
b. Inspect the lens for cleanliness.
DRILLING SOLUTIONS
7-309
Check: Fuel System

c. Is there restriction in the fuel system?
d. Is the nozzle plugged?
e. Is the fuel pump operating?
f.
For a defective pressure regulator.
g. Is the compressor functioning?

h. What type of fuel is being used?
Symptom: No Flame visible

The spark continues for the 60 second ignition period. The heater shuts down after
the 60 second ignition period.
Check: Fuel System
a. Is there a restriction in the fuel system?
b. Is the nozzle plugged?
c. Is the fuel pump operating?
d. For a defective pressure regulator.
e. Is the compressor functioning?
Note: A spark should be visible across the gap between the ignition electrode and the
combustion tube.
Symptom: Heater is Backfiring

Backfiring is usually caused by a severe restriction of combustion air or air in the fuel
line.
Check: Inlet Air Flow
a. Is the blower error displayed?
b. Blower Operation:
1. Is the blower turning?
2. Is the blower turning slowly?
c. For restrictions at the fan inlet port and in the exhaust system.
d. For carbon build up in the combustion chamber.
Check: Fuel System
a. Is fuel level low?
b. Air leaking into fuel system?
7-310
DRILLING SOLUTIONS
Symptom: No Flame visible

No spark
The heater shuts down after the 60 second ignition period
Check: Ignition System
a. Check for a poor electrical connection between the ignition coil and the high
tension lead.
b. Check for a poor electrical connection between the electrode and the high
tension lead.
c. Inspect the electrode gap. Check for carbon bridging from the ignition electrode
to the combustion tube.
d. Inspect the primary electrical connections to the ignition coil and coil function.
e. Is the heater chassis ground wire attached? The ground is connected to the
boss located near the fuel pump.
(2) Flame Out

A Flame Out diagnostic code occurs when the heater has started successfully but is unable to
maintain a steady flame.
If during ignition the flame sensor does not see a flame, the ignition electrode is switched on
immediately. If the flame is not reestablished within 10 seconds the heater will shut down and
the FLAMEOUT diagnostic code will be displayed. The heater will go into the Purge mode and
attempt to restart in 3 minutes, depending on the coolant temperature.
If the flame fails to re-ignite on the second attempt, a START diagnostic code will be displayed
on the function control panel. If, however, the flame sensor senses enough of a flame during
Ignition, it will enter the Full Output mode. During Full Output, if the flame sensor fails to see
a flame then the FLAME OUT diagnostic code will be displayed.
Check: Fuel System
a. Is there restriction in the fuel system?
b. Is the nozzle plugged?
c. Is the fuel pump operating?
d. For a defective pressure regulator.
e. Is the compressor functioning?
f.
What type of fuel is being used?
DRILLING SOLUTIONS
7-311
(3) Coolant Flow

A COOLANT FLOW diagnostic code is displayed when the coolant temperature reaches
185F (85C) in less than one minute after ignition. This indicates that the coolant flow is
severely restricted or blocked. This feature aids in detecting coolant flow problems that can
degrade the heater performance.
An in-line flow indicator is a valuable troubleshooting tool used to: a) Check the coolant flow
and direction, b) Check for air in the system, c) Check for restrictions caused by the drill
systems ie. Shuttle valves, manual valves, air operated valves.
Check: Coolant Flow
a. Coolant Lines: For restrictions and blockages. Are Clamps tight?
b. Shutoff Valves: Ensure that shutoff valves are open and functioning properly.
c. Fittings: Fittings must be at least 1/2 NPT or larger. Avoid using 90 fittings
where possible.
d. Coolant Flow Direction: The heater must be plumbed so the coolant pump is
pumping the coolant in the same direction as engine coolant pump. The heater
can be used when the engine is running.
e. Coolant Pump: Does the pump function properly?
f.
Coolant System Capacity: The coolant system must contain at least 3 gallons
(11 liters) of coolant. If the system contains less the coolant may reach 185F
(85C) in less than 1 minute causing a COOLANT FLOW diagnostic code.
NOTE: If the coolant system is contaminated with magnetic material, it may cause the impeller
to seize.
(4) Overheat
An OVERHEAT diagnostic code is displayed when the overheat breaker has tripped, shutting
the heater down. This occurs if the heater has been started with little or no coolant in the heat
exchanger.
Check: Coolant Flow

a. Is there coolant in the system?
7-312
DRILLING SOLUTIONS
b. Determine if there is a blockage or air in the plumbing.

The compressor motor is wired in series with the overheat breaker. The breaker contains a
normally closed thermo switch. When the thermostat reaches the preset temperature of 286F
(141C), the contacts OPEN shutting the compressor and fuel pump OFF, instantly shutting
the heater down. It cannot be restarted until the breaker is manually reset.
To reset the breaker, remove the rubber cap covering the top of the overheat breaker and
press the red reset button on top. If the breaker will not reset, allow the heater to cool.
Test Procedure:
Connect a multimeter (adjusted to measure resistance) to the overheat breaker connector.
The sensor should be normally closed. If the sensor has tripped, the circuit should be open.
CAUTION
Do not reset the Overheat breaker until the cause of the overheat
condition has been determined.
(5) Voltage
A VOLTAGE diagnostic code indicates that the supply voltage to the heater is out of the
normal range.
Voltage ranges:
12 Volt heater - 10.0 to 15.0 Volts
Check: Vehicle Voltage
DRILLING SOLUTIONS
7-313
a. Heater voltage must be within the specified range. See Heater Voltage
Measurement for procedure to measure heater voltage.
NOTE: Bad connections may show good voltage under no load conditions but not under full
load. With the heater OFF, measure the voltage. Then turn the heater ON and
measure the voltage again. If the voltage drop is more than one Volt, check the deck
engine battery connections and the power connection at the PCM.
b. If the measured voltage is higher than the specified range then check the
voltage regulator.
NOTE: If the engine batteries are marginal, starting the engine while the heater is running
may:
a. Drop the voltage enough to cause a voltage error.
b. Cause random component errors (brown out).
To reset the PCM, turn the heater OFF and then back ON at the timer. If the problem
continues, load test the batteries to confirm their condition. Each battery should be
independently tested.
Current: Checking current draw is done at the power harness connections on the batteries.
1. Check the current draw on the red POSITIVE wire with the heater NOT running.
Should read 80 to 100 mA.
2. Check current draw on the red POSITIVE wire with the heater running in full
output, ignition OFF. Should read 6.5 to 7.5 Amps.
3. Check current draw on the black NEGATIVE wire with the heater NOT running
and the red POSITIVE wire disconnected. Should read 0 mA. This test is to
confirm whether or not there is a power leakage from the drill through the
heater.
Heater Voltage Measurement
The positive terminal of the ignition coil is always hot relative to the heater chassis ground as
7-314
DRILLING SOLUTIONS
long as power is connected to the heater. This is the supply voltage to the heater.
Test Procedure:
a. Locate the rubber boot on the end of the ignition coil and peel it back to expose
the positive and negative terminals.
b. Select the DC Volts range of a multimeter and connect as follows. The positive
lead of the multimeter should be attached to the positive coil lead. The negative
lead of the multimeter should be attached to the heater chassis at the heater
ground boss.
c. Read the voltage with the heater running or trying to run.
Normal Voltage ranges:
Component Diagnostic
(6) Flame Sensor
A FLAME SENSOR diagnostic code indicates an electrical short circuit in the flame sensor
wiring or a flame sensor failure. It will not indicate an open circuit. The flame sensor is an
optical device which sees the flame. If the sensor lens is dirty or has an open circuit, it cannot
see the flame and results in either a START or a FLAME OUT diagnostic code to display.
DRILLING SOLUTIONS
7-315
Check: Flame Sensor

a. Inspect the flame sensor wiring for a short circuit.
b. Inspect the flame sensor lens for cleanliness.
c. Test the flame sensor (See Flame Sensor Test Procedure).
7-316
DRILLING SOLUTIONS
(7) Temp Sensor

A TEMP SENSOR diagnostic code indicates a short or open circuit in the temperature sensor
wiring or the coolant temperature is out of range, below -58F (-50C) or above 266F (130C).
The resistance of the temperature sensor is proportional to temperature.
DRILLING SOLUTIONS
7-317
Check: Temperature Sensor (CODE indicated)

a. Inspect wiring for short or open circuits.
b. Test the sensor.
Test Procedure:
a. Connect multimeter (adjusted to measure resistance) to temperature sensor as
shown below. Polarity of the sensor connections to the multimeter is not
important.
b. Measure the sensor resistance versus temperature under following conditions:
at room temperature
in a freezer
in boiling water
c. Compare the measured values against the Coolant Temperature Sensor

Graph. If values do not approximately match, then the sensor is defective and
must be replaced.
7-318
DRILLING SOLUTIONS
(8) Fuel Pump

The fuel gear pump is driven by the same motor as the compressor. Therefore, there is NO
fuel pump electrical diagnostic code. A FUEL PUMP diagnostic code would indicate a fault in
the PCM only.
A short or open circuit fault in the motor that drives the fuel pump will be indicated by a
COMPRESSOR diagnostic code.
A mechanical fault within the fuel pump such as stripped drive couplings, jammed gears or a
faulty pressure relief valve, would be indicated by:
DRILLING SOLUTIONS
7-319
START diagnostic code
FLAME OUT diagnostic code
Blown fuse in the PCM. Indicates that the pump is seized.
Check: Fuel Pump

a. Fuel pump as per procedure (See Fuel System).
b. Relief valve for contamination
c. Filter for contamination
d. Drive couplings
(9) Compressor
A COMPRESSOR diagnostic code indicates an open circuit in the wire harness, a short in the
wire harness between the positive and negative leads or an internal short in the motor. This
component is ground side switched in the PCM.
7-320
DRILLING SOLUTIONS
Symptom: Air Compressor not running (code indicated)

Check: Air Compressor wiring & function
a. That compressor is connected to harness correctly.
b. The connector pins for damage or corrosion.
c. Harness for pinched or abraded wires.
d. Test compressor. If it tests OK replace PCM.
Test Procedure:
a. Connect air compressor directly to a power source of the rated voltage (12/24
Volts) and see if the motor runs. If not, replace the compressor.
b. Measure air compressor motor resistance by using a multimeter and measure
resistance across compressor connector pins. If resistance shows an open or
short circuit, replace the compressor assembly.
c. Measure air compressor current. Use a test lead as described in the Service
Bulletin in Appendix.
Symptom: Air Compressor running (NO CODE indicated) No or low air flow
Check: Air flow using pressure gauge. Ensure gauge is accurate (0-15 psi)
Procedure: Install the pressure gauge as shown below. The Pressure Reading for X45:
6.5 psi @ 12/24 Volts.
DRILLING SOLUTIONS
7-321
High pressure reading indicates:

a. Blocked Nozzle. Air passage only ).
b. Compressor is out of adjustment. Re-adjust the compressor using
the adjustment screw as indicated below.
Low pressure reading indicates:
a. Pinched or leaking air line from the compressor outlet fitting to the fan
end inlet.
b. Plugged compressor inlet filter. Retest with the filter removed.
Normal reading but a rich or lean flame:
a. Check for contaminated nozzle, fuel passage (See Nozzle).
b. Check the blower.
c. Check the fuel regulator.
d. Check fuel system.
Pressure Adjustment:
a. Locate adjusting screw on the compressor head.
b. Adjust as necessary. Ensure that voltage is nominally 12 or 24 Volts.
Symptom: Air Compressor running (NO CODE indicated) Fuse blown in PCM
Check: Air Compressor operation
a. Harness for pinched or abraded wires. The positive wire must not short to
ground.
b. Motor for internal short.
c. Check for seized motor or fuel pump.
7-322
DRILLING SOLUTIONS
WARNING
Disconnect the PCM electrical power prior to trying to turn the

compressor counterweight by hand.
(10) Ignition Coil

An IGNITION COIL diagnostic code indicates an open circuit in the wire harness, a short in
the wire harness between the positive and negative leads or an internal short in the coil. The
fuse will blow if there is a short to ground in the positive lead or the coil. The ignition coil is the
easiest place to measure the voltage on the heater. This component is ground side switched
in the PCM.
WARNING
The heater chassis is grounded from the PCM. Ensure the ground is
securely connected. Failure to ensure a proper ground may result in
electric shock.
Symptom: No spark at the electrode (code indicated)
Check: Coil wiring
a. Inspect the wiring harness to ensure the ring terminals are secured to the coil.
DRILLING SOLUTIONS
7-323
Make sure the polarity is correct.

b. Inspect for broken or abraded wires in the wire harness.
c. Test coil.
d. If an IGNITION COIL diagnostic code occurs and no fault is found in the coil
and wiring, then the PCM must be checked.
Symptom: No spark at the electrode (code indicated)
Check: High tension wires and electrode
a. Inspect the high tension lead between the coil and the electrode.
b. Inspect the ground lead between the second electrode and the heater chassis.
c. Is the electrode gap adjusted correctly? (See Electrode Gap Detail).
Test Procedure:
a. Measure the ignition coil resistance. Use a multimeter to measure the
resistance across the positive and negative terminals. The resistance should
be less than 1 ohm. If the resistance is open circuit or 0 ohms (short circuit)
then replace the ignition coil.
NOTE: Remove positive and negative wires from the coil when testing.
(11) Coolant Pump

A COOLANT PUMP diagnostic code indicates an open circuit in the wire harness, a short in
the wire harness between the positive and negative leads or an internal short in the motor. This
7-324
DRILLING SOLUTIONS
The coolant pump is not self priming. Ensure that the coolant system has been purged of air
by running the deck engine for at least ten minutes following installation or service (DO NOT
run dry).
Symptom: Coolant Pump not running (code indicated)
Check: Coolant Pump wiring & function
a. That the coolant pump is connected to harness correctly. (See Heater Wiring
Diagram).
d. Test pump. If it tests OK replace PCM (See Test Procedure).
Symptom: Coolant Pump not running (no code indicated) Fuse blown in PCM
Check: Coolant Pump function
a. a) Harness for pinched or abraded wires. Positive lead must not short to
ground.
b. Check motor for internal short.
Symptom: Coolant Pump not pumping (no code indicated)
Check: Coolant Pump function
a. If the impeller is turning freely. If not, replace pump.
Symptom: Coolant Pump leaking
Check: Leak location
a. Hose clamps. Tighten if necessary.
b. Pump housing seal. Replace pump if required.
Test Procedure:
a. Connect coolant pump directly to the rated voltage (12/24 Volts) and see if it
runs. If not, replace the pump.
b. Measure coolant pump motor resistance. With a multimeter, measure the
resistance across the coolant pump connector pins. If resistance shows an
open circuit or an internal short circuit, replace the coolant pump.
c. Measure the coolant pump current. Use a test lead as described in the Service
Bulletin in Appendix.
DRILLING SOLUTIONS
7-325
(12) Blower
A BLOWER diagnostic code indicates an open circuit in the wire harness, a short in the wire
harness between the positive and negative leads or an internal short in the motor. This
NOTE: An RPM check was added to the PCM. This feature measures the blower RPM and
will give an error should it fall below the necessary RPM to maintain sufficient combustion air.
CAUTION
When a blower fails, the combustion chamber must be checked for

carbon buildup and cleaned as necessary.
7-326
DRILLING SOLUTIONS
Symptom: Blower not running (code indicated)

Check: Blower wiring & function
a. That blower is connected to harness correctly (See Wiring Diagram).
d. Test blower. If it tests OK replace PCM (Test Procedure).
Blower not running (no code indicated) Fuse blown in PCM
Check: Blower function
a. Harness for pinched or abraded wires. Positive lead must not short to ground.
b. Check motor for internal short (See Test Procedure).
Symptom: Blower turning slowly (no code indicated)
Check: Blower function
a. For fan blade rubbing on housing.
b. For fan blade slipping on motor shaft.
Test Procedure:
a. Connect the blower to a power supply of the rated voltage. Does the blower
turn? If not, replace the blower.
b. Measure the blower motor resistance. Using a multimeter, measure the
resistance across the blower connector pins. If resistance shows an open
circuit or an internal short circuit, replace the blower assembly.
c. Measure blower current. Use a test lead as described on the Service Bulletin
in Appendix.
DRILLING SOLUTIONS
7-327
7-328
DRILLING SOLUTIONS
Components
Electrode Gap
The electrode gap is factory set and should not require adjustment.
NOTE: Ensure that the electrode is not bent during servicing. To readjust the electrode, bend
it to the correct setting.
Fuse
If, when the heater is turned ON, the heater does not run and the ON light does not light,
check the fuse in the PCM. The fuse will blow if there is a short to ground in a positive lead or
internally for the following components: ON/OFF Switch, Air Compressor, Ignition Coil,
Coolant Pump and Blower.
Reversing polarity at the battery will also cause the fuse to blow. This will not harm the PCM.
CAUTION
Repeated replacement of the fuse or using incorrectly rated fuses without

correcting the problem can damage the PCM.
DRILLING SOLUTIONS
7-329
Check: Heater wiring

a. Check polarity of battery connections
b. Test the internal wire harness for short circuits.
The following page describes the test procedure for a blown fuse with power connected and
the heater switched off.
7-330
DRILLING SOLUTIONS
Nozzle
The nozzle (and the compressor) regulate the fuel air mixture. A set orifice size allows a certain
amount of fuel and air to flow through the distributor. Problems in the nozzle can cause poor
burning. This will be indicated by a START or FLAME OUT diagnostic code on the PCM
function display.
Check: Nozzle
a. Inspect the nozzle for blockage.
b. Clean or replace nozzle as necessary.
DRILLING SOLUTIONS
7-331
c. Check and clean fuel passage in the fan end.
Nozzle Cleaning Procedure:

a. Remove nozzle from fan end.
b. Disassemble nozzle as shown above.
c. Use a cleaner/degreaser to thoroughly wash the separate parts.
d. Dislodging contaminants in the distributor counterbore can be done by lightly
hand spinning a drill bit (0.060 dia.) and then washing. Do not use a tip cleaner
in the fuel orifice.
e. Reassemble nozzle and torque to 30 inch pounds (3.39 Nm).
f.
Use compressed air for cleaning only in the direction indicated by the arrow.
g. Lubricate the O-ring with diesel fuel and reinstall nozzle in fan end.
NOTE: See Step 6 of Fuel System Troubleshooting section to confirm that nozzle is
functioning correctly. All of the nozzles parts are matched parts. Do not interchange.
Fuel Regulator
The fuel regulator reduces the fuel pressure supplied by the fuel pump from 5 psi (0.34 Bar)
down to atmospheric pressure. Compressed air flowing through the nozzle creates a venturi
effect which siphons fuel from the regulator. If the compressed air flow through the nozzle
stops, the regulator closes, shutting off the fuel flow.
Check: Fuel Regulator
a. Ensure that the vent hole in the regulator is not plugged.
b. Ensure that all fuel line connections are tight. Check the clamps.
Test Procedure:
a. Disconnect the fuel line at the nozzle fuel inlet fitting and place it in a container.
b. Start the heater. Insert a small blunt pin in the regulator vent hole and gently
depress the diaphragm.
7-332
DRILLING SOLUTIONS
c. Fuel should flow out of the fuel line. If there is no fuel flow, the regulator is
plugged.
NOTE: Should a fuel regulator fail, the combustion chamber must be checked for carbon build
up and cleaned as necessary.
Fuel System
DRILLING SOLUTIONS
7-333
Step 1.... Is there fuel in the tank?

Step 2.... Start the heater. The heater will try to start twice.Wait until it has gone through two
cycles (approximately 10 minutes). The heater diagnostic system will tell you what
it thinks is wrong. While it is running, observe for:
Is there flame?
yes, means there is ignition and fuel. Refer to Is the ignition spark turning OFF?
No, go to step 3.
b.) Is the ignition spark turning OFF?
yes, then the Flame Sensor sees a flame.
No, then the flame is either too weak or the Flame Sensor and/or circuit is faulty. See
Flame Sensor.
Step 3... Does the Fuel Pump work?
This component must be tested before proceeding with troubleshooting.
a. Disconnect the fuel line at the inlet to the regulator. Start the heater. Check
fuel flow, approximately 1 pint (1/2 liter) in 60 seconds.
b. Run the fuel pump by connecting remote power to the compressor motor and
checking for fuel flow.
Step 4... Does the Regulator work?
a. Disconnect the fuel line at the fuel inlet fitting. Hold the line at the same level
as the inlet. Start the heater. There should be no fuel flow. This indicates that
the regulator is holding the fuel pressure.
b. Lightly push on the regulator diaphragm (use a blunt tool). Fuel should flow
from the line.
NOTE: A regulator that is stuck open will produce a rich flame, and blockage in the regulator
needle valve seat will produce a lean flame.
Step 5... Does the Compressor work?
a. Check the pressure output.
Step 6... Isolate the Nozzle and Compressor
a. Split the fuel system by drawing fuel from a remote source. Disconnect the
fuel line at the outlet of the fuel regulator. Put this end into a small container
of fuel that is about the same level as the center of the regulator. This will
eliminate the fuel pump and regulator from the system. Start the heater. If
there is still a fuel problem, it must be in the Compressor or Nozzle.
7-334
DRILLING SOLUTIONS
Step 7... Is the Fuel Nozzle contaminated?

a. Clean the nozzle with a cleaner/degreaser, which will wash contamination
out the back end of the nozzle.
Operational Problems
Heater Operational Problems that are not specifically described in the function or component
diagnostic section are shown below.
Smoking exhaust and smelly exhaust fumes

These symptoms are usually an indication of an extremely rich air/fuel mixture.
Check:
a. Is the heater connected to the correct voltage?
b. Is the blower functioning? Is the air inlet restricted?
c. Is the compressor functioning?.
d. Is the exhaust restricted?
e. Is it a new heater? New heaters may smoke for 15 minutes as oil is burned off
the exhaust pipe. This is normal.
Low heat output

If the heater appears to be functioning properly but the driver complains of low heat, this is
often indicative of a coolant flow restriction.
Engine temperature gauge reads low

Depending on its location, the engine temperature sensor may not be directly in the path of
coolant flow from the heater. In these cases the gauge may read significantly lower than actual
DRILLING SOLUTIONS
7-335
coolant temperature.
Backfiring
Backfiring occurs when there is air in the fuel supply lines.
Check:
a. Fuel level in tank. Is the pickup submerged?
b. Air leaks. Are all the fuel line clamps tight?
c. For severely restricted combustion air blockage at the blower inlet, combustion
chamber, or in the exhaust system.
Maintenance
Weekly Maintenance
Run the heater a minimum once a week to keep new fuel in the heaters critical components.
Annual Maintenance
Check the system annually before each heating season. There are several maintenance
procedures you can perform to keep your heater in service. Read this maintenance section
carefully.
Always return to your authorized Drilling Solutions dealer or distributor for major maintenance.
Clean Heater Enclosure

Remove the heater enclosure cover and blow out the compartment with compressed air.
Clean any accumulated debris or dust from the components.Make sure the opening around
the exhaust pipe is clear. Visually inspect all the components for wear or damage.
7-336
DRILLING SOLUTIONS
Heat Exchanger
To maintain optimum heat output, clean any combustion deposits that may have accumulated
on the heat exchanger fins.
a. Remove ignition lead from ignition electrode.
b. Remove blower connector
c. Remove the 3 bolts securing the fan end assembly.
d. Remove the fan end assembly and combustion tube to access the inside of the
heat exchanger. Use a wire brush to loosen the deposits and an air hose to
blow them out.
HEAT EXCHANGER FINS ACCESS
Exhaust System
Check the exhaust system carefully. Make sure the exhaust pipe is vented safely away from
the vehicle cab. Check the pipe for dents, restrictions or severely corroded areas. Replace the
exhaust pipe and clamps if necessary. Ensure the exhaust pipe clamp is tight.
Electrical System
Check the internal and the external wire harnesses for damage. Replace if required.
DRILLING SOLUTIONS
7-337
Clean Air Intake

Check the combustion air inlet screen for restrictions. Clean as required.
7-338
DRILLING SOLUTIONS
Fuel System
Check the fuel system for damaged fuel lines or leakage. Make sure the clamps on the fuel
lines are secure.
Engine Batteries
Check the condition of the batteries and the power connections. The heater will not function
properly with weak batteries or corroded connections. If you are unsure of their condition, load
test each battery separately and replace as required. Clean terminals to remove all corrosion.
DRILLING SOLUTIONS
7-339
Operation Test
Run the system for at least 15 minutes or until the heater cycles OFF and then ON again.
7-340
DRILLING SOLUTIONS
Heater Wiring Diagram
DRILLING SOLUTIONS
7-341
Heater Wiring Diagram (continued)
7-342
DRILLING SOLUTIONS
Timer
General Description
The 7 day timer can be preset for a single start time, one day at a time or programmed start
times per day constantly activated for multiple days of the week. The clock can be preset for
12 or 24 hour time display. The heater run time duration can be preset for 1 or 3 hours. The
manual button can be used to override the program and run the heater indefinitely until it is
switched off.
NOTE: The time must be set for the drill system voltage.
If power to the timer is interrupted, the display will flash 12:00 am MON. in 12 hour
format or 00:00 MON. on 24 hour format. Stored programmed times will remain set in
memory.
DRILLING SOLUTIONS
7-343
Wiring & Switch Settings
Heater Connection
CAUTION
Power to the controller must be disconnected before connecting the

timer.
Connect the heater switch harness wires to the timer as follows:
a. Black to Black
b. Green to Green
c. White to White
d. Red to Red
7-344
DRILLING SOLUTIONS
CAUTION
Mis-wiring the timer connections may result in timer damage.
To Set Clock - Time & Day
Step 1
Press and hold Clock.
Step 2
Press < or > to set time.
Step 3
Press Day to set day
Step 4
Release Clock.
NOTE:
The 12 or 24 hour option is set using Dip Switch No. 1 on back of timer.
ON = 12 hour mode
OFF = 24 hour mode
(factory preset: 12 hour mode)
DRILLING SOLUTIONS
7-345
To Set Single Timer Mode
Step 1
Press and hold Timer. (Green light will go on and T1 will flash.)
Step 2
Press < or > to set ON time.
Step 3
Press Day to set day
Step 4
Release Timer. (Green light and T1 will remain lit to indicate active Timer.)
Timer set in the single timer mode only will allow you to set one ON time.With the T1 time
activated, the Timer will go ON at the preset time and will be deactivated at the end of its
duration time. To reactivate the Timer, press Timer.
NOTE:
When set time is reached, the heater switches on. Red and green lights are on.
The 1 or 3 hour duration option is set using Dip Switch No. 2 on back of timer.
ON = 3 hour duration
OFF = 1 hour duration
(factory preset: 3 hour duration)
To Set Dual Timer Mode

In the dual timer mode setting you can program your timer to come ON daily, Monday thru
Friday, Monday thru Saturday or Monday thru Sunday. It also has a built in repeat function so
that you do not have to reactivate the timer after every duration time.
7-346
DRILLING SOLUTIONS
NOTE:
In dual timer mode you can set T1, T2 or both T1 & T2. Timer mode option is set using Dip
Switch No. 3 on back of timer.
ON = single timer (T1 only)
OFF = dual timer (T1 and T2)
(factory preset: T1 only)
Step 1
Press and hold Timer. (Green light will go on and T1 will flash.)
Step 2
Step 3
Press Day to set day(s).
Step 4
Release Timer. (Green light and T1 will remain lit to indicate active T1 program.)
T1 program is now activated. Follow steps 5 thru 8 for T2 program.
DRILLING SOLUTIONS
7-347
Step 5
Press and hold Timer. (Green light will remain on and T2 will flash.)
Step 6
Step 7
Press Day to set day(s).
Step 8
Release Timer. (Green light and T2 will remain lit to indicate active T2 program.)
Step 9
Press Timer once more to activate both T1 and T2. (T1 and T2 will remain lit to
indicate active T1 and T2 program.)
NOTE:
Timer will repeat each set day until switched off.
Example:
Drill timer set T1 at 6:00 a.m. Monday thru Friday. Set T2 at 2:00 p.m. Monday thru Friday.
Timer will repeat each cycle each week until it is switched off.
Manual & Timed Heater Operation

The Manual button is used to turn the heater on and off when desired.
Step 1
Press Manual to activate the heater. (Red light will go on and the heater will operate
indefinitely.)
Step 2
Press Manual again to deactivate the heater. (Red light will go out and the heater will
turn off.)
7-348
DRILLING SOLUTIONS
NOTE:
Manual and Timer cannot be active at the same time. If Manual is active and Timer
is pressed, the heater will turn off and the red light goes out.
If Timer is active and Manual is pressed, Timer is deactivated and the green light goes
out.
When the heater has been turned on by the T1 Timer in a single timer mode, the heater
can be turned off by pressing either Manual or Timer. Both red and green lights will go
out.
If the heater has been turned on by the T1 or T2 Timer in dual mode, pressing Manual
will turn the heater off but leaves the timer(s) activated. Pressing Timer will turn off the
heater and deactivate the timer(s).
Diagnostics
When the timer is installed on a heater, the timers red Heater Activated Light will be lit
constantly while the heater is running normally. In the case of a heater error, the timers red
light will flash an error code followed by a pause.
Example:
Repeatedly flashing five pulses separated by a pause indicates a heater voltage error.
The heater error codes are as follows:
1 Flash-------- Start Error
2 Flashes -----Flame Out
3 Flashed ----Coolant Flow
4 Flashes ----Overheat
5 Flashes ----Voltage
6 Flashes ----Flame Sensor
7 Flashes ----Temperature Sensor
8 Flashes ----Fuel Pump
DRILLING SOLUTIONS
7-349
9 Flashes -----Compressor
10 Flashes ---Ignition Coil
11 Flashes ---Coolant Pump
12 Flashes ---Blower
13 Not Used --Not Used
These errors correspond to those displayed on the Control Module diagnostic panel.
7-350
DRILLING SOLUTIONS
7-17 DIXON Boss Clamp Selection and Installation

SAFETY INFORMATION
MSHA (Mine Safety and Health Administration) Regulations
30 CFR Sections 56.13021 and 57.13021
Except where automatic shutoff valves are used, safety chains or other suitable locking
devices shall be used at connections to machines of high pressure hose line of 3/4 inch inside
diameter or larger, and between high pressure hose lines of 3/4 inch inside diameter or larger,
where a connection failure would create a hazard.
30 CFR Section 75.1730
(e) Safety chains, suitable locking devices, or automatic cut-off valves shall be used at
connections to machines of high pressure hose lines of 3/4 of an inch inside diameter or larger,
and between high pressure hose lines of 3/4 of an inch inside diameter or larger, where a
connection failure would create a hazard. For purposes of this paragraph, high pressure
means pressure of 100 PSI (6.9 bar) or more.
30 CFR Section 77.412
(d) Safety chains or suitable locking devices shall be used at connections to machines of high
pressure hose line of 1-inch inside diameter or larger, and between high pressure hose line of
1-inch inside diameter or larger, where a connection failure would create a hazard.
S.T.A.M.P.E.D.
When fabricating and specifying hose assemblies, ask the following questions:
1. Size:
What is the I.D. (Inside Diameter) of the hose? What is the O.D. (Outside
Diameter) of both ends of the hose? What is the overall length of the assembly
required?
2. Temperature:
What is the temperature range of the media (product) that is flowing through the
hose assembly? What is the temperature range of the environment that
surrounds the outside of the hose assembly?
3. Application:
How is the hose assembly actually being used? Is it a pressure application? Is
it a vacuum (suction) application? Is it a gravity flow application? Are there any
special requirements that the hose assembly is expected to perform? Is the
hose being used in a horizontal or vertical position? Are there any pulsations or
vibrations acting on the hose assembly?
4. Media:
What is the media/material that is flowing through the hose assembly? Being
specific is critical. Check for: Abrasive materials, chemical compatibility, etc.
DRILLING SOLUTIONS
7-351
5. Pressure:
What is the maximum pressure including surges (or, maximum vacuum) that
this hose assembly will be subjected to? Always rate the maximum working
pressure of your hose assembly by the lowest rated component in the system.
6. Ends:
What couplings have been requested by the user? Are they the proper fittings
for the application and hose selected.
7. Dixon:
Dixon recommends that, based on the hose, fittings and attachment method
used, all assemblies be permanently marked with the designed working
pressure and intended media. Do not use other manufacturer's fittings or
ferrules with Dixon products due to the differences in dimensions and
tolerances. We also recommend that all hose assemblies be tested frequently.
Be Safe: Any questions on application, use or assembly contact your local Atlas
Copco dealer or distributor.
1. Force is the dynamic power which is exported longitudinally through a hose,

towards the ends. To arrive at the number of pounds of force exerted, you
merely multiply the area of the I.D. times the working pressure being used.
2. Area of a circle: (PI[3.1416] times radius squared)
3. Force = Area x Pressure
7-352
DRILLING SOLUTIONS
General Preparation Instructions

The following contains general procedures that relate to all assemblies in terms of preparation.
1. Cutting the Hose - Two terms are used:
a. Cut to length means cut the hose to the length requested excluding the
length of the fitting(s).
b. Overall Length (O.A.L.) refers to the overall length of the assembly
including fittings.
Example: The hose has to be cut to a certain length so that when couplings
are installed the length of entire assembly is the required overall length. The
calculation below describes the steps to determine hose length to be cut to
obtain the required overall length.
O.A.L = requirement is 50 ft. (This is the total length of the assembly).
Fitting Length = 7 inches (This is the overall length of the fitting).
Shank Length = 4 inches (This is length of the fitting that is inserted into the
hose).
2. Cut Ends Square - Hose ends must be cut square (90 to the length of the
hose) for proper coupling insertion. Improper insertion can reduce coupling
retention.
3. Clean Hose Ends - Debris left inside the hose from the cutting process must
be removed prior to coupling insertion. This is especially important when an
abrasive wheel or chop saw is used to make a cut. Debris will reduce coupling
retention.
4. Determine number of clamps required
DRILLING SOLUTIONS
7-353
5. Mark Hose for Proper Clamp Placement - The Boss Clamps and Air King
Clamps do not require a hose marking for placement because the clamp's
gripping finger positions the clamp automatically.
6. Static Grounding - When static grounding is required it's essential that it be
done properly. Typically, it is accomplished by bending the built-in static wire or
the helical wire (or wires) into the hose I.D. (Inside Diameter) so that the wire
or the wires make contact with the metal coupling. Bend in no more wire than
necessary. One half inch is usually sufficient. Other methods of static
grounding may be required due to hose type, hose manufacturer or style of
coupling being installed. Always contact the hose manufacturer to verify
proper static grounding techniques for that particular hose. Improper static
grounding can lead to fire, explosions reduced assembly life, damage to
property and injury or death to personnel.
7. Hoses with Helical Wire - Determine which direction the helical wire is
pointing. Proper installation of pre-formed band clamps or bands and buckles
relies upon proper orientation of the clamp tail with the helical wire. Note: If
helical wire is not used for static grounding, trim the wire flush with the hose.
This will prevent operator injuries during the assembly.
8. Seal the Hose Ends - At each end of the hose, the reinforcement is exposed
to the outside elements. This exposure can lead to premature assembly failure
especially if the end of the assembly is laying in a puddle of water or puddle of
product. If assembly is to be subjected to these conditions, the hose ends must
be sealed. Typically, rubber cement or shellac can be used. Wire reinforce
hoses can corrode to the point of failure near the clamp. Textile or fabric
reinforced hoses can wick water or product to anywhere in the length of the
hose and exit the cover at the weakest spot.
9. Apply Coupling Lubricant - Lubricate the coupling shank and hose inside
diameter prior to the coupling insertion. Dixon recommends using Dixon
Coupling Lubricant (DCL10 pint, DCL80 gallon). Do not use hand soap, oil,
grease, WD40, Silicon Spray or other similar substances that may attack the
hose tube material and / or reduce coupling retention.
Dixon Diameter Tape Procedures
All Dixon clamping devises (Boss Clamps, Double Bolt Clamps, Single Bolt Clamps, T-Bolt
Clamps, Holedall Ferrules, etc.) have a minimum and maximum hose O.D. (Outside Diameter)
range. To ensure proper coupling performance, it is imperative that the clamping devise
selected be the correct size for the hose O.D. being used.
Accurate hose O.D. measurement is achieved by using a Diameter Tape. Both ends of the
hose must be measured due to the variances allowed by the hose manufacturers in their
production tolerances. In addition, the hose manufacturers change dimensional specifications
on their products without prior notification.
Procedure
1. Grasping the tape buckle, pull several inches of tape from the case.
7-354
DRILLING SOLUTIONS
2. One side of the tape is a regular ruler. The other side of the tape is marked
INCHES OF DIA. BY 64THS. (See A on Diagram 1). This is the side of the tape
used to measure hose O.D.
3. To understand how the diameter tape works, do the following:

a. Locate the numbers (1,2,3,etc.) with a line the width of the tape to the right
of it (See B in Diagram 1). These represent inches of diameter.
b. The numbers 16, 32, and 48 are reference numbers (See D in Diagram 1).
They represent 16/64ths, 32/64ths and 48/64ths of an inch respectively.
c. Each hash mark between these two numbers represents 1/64th of an inch
(See C) in Diagram 1).
These numbers, when combined as outlined below, convert the hose
circumference into inches of diameter.
4. To measure the hose O.D. with the diameter tape, do the following:
a. With the diameter side of the tape facing up, loop the tape around the end
of the hose to be measured keeping the loop two to three inches from the
hose end.
b. While the tape is being looped around the hose, keep the buckle to the
bottom of the loop.
c. Making sure that the tape is as flat on the hose as possible. Pull the tape
tight.
d. The line to the right of INCHES OF DIA. BY 64THS should line up with one
of the inches of diameter marks, reference number marks or hash marks
above it.
5. To read the hose O.D. just measured in step 4, do the following:
a. Determine the inches of diameter number. If the line from Step 4d above
lines up with one of these numbers, this is your outside diameter (See
Diagram 2). If line from Step 4d above lines up with a reference the number
to the LEFT of an inches of diameter number, see Step 5b below.
b. Locate the reference number (if needed) to the LEFT of inches of diameter
number determined by the line from Step 4d above. The outside diameter
will be the inches of diameter number from Step 5a above PLUS the 64ths
represented by the reference number (See Diagram 3). If the line from Step
4d above is to the left of a reference number, see Step 5c.
DRILLING SOLUTIONS
7-355
c. Locate the hash mark (if needed) to the LEFT of the reference number
determined by the line from Step 4d. The outside diameter will be the
inches of diameter from Step 5a PLUS the 64ths represented by reference
number from Step 5b PLUS the number of hash marks from the reference
number including the one above the line from Step 4d (See Diagram 4).
Diagram 2
Diagram 3:
7-356
DRILLING SOLUTIONS
Diagram 4:
Note: It is a good practice to measure each hose end twice to ensure an accurate
measurement.
DRILLING SOLUTIONS
7-357
Boss Clamps
7-358
DRILLING SOLUTIONS
DRILLING SOLUTIONS
7-359
Note:
1. The bolts used in the Boss interlocking clamps are not standard bolts. They
vary from standard bolts in their length, diameter, overall thread length and
material hardness. These bolts can be re-torqued, but it is not recommended
that they be reused, as they are designed for a single bend only. Dixon
recommends using only factory supplied replacement bolts.
2. Torque values for clamps are based on dry bolts. The use of lubricant on bolts
will adversely effect clamp performance.
3. Do not lubricate bolts.
4. Recommended torque rating is in ft./lbs.
Boss Clamp Selection
1. Measure the hose Free O.D. (Outside Diameter) with a diameter tape. Free
O.D. is the outside diameter before the stem is inserted.
2. Determine the hose I.D. (Inside Diameter).
3. On the Boss Clamp Chart, locate the Hose I.D. column.
4. Locate the section of clamps in that column that correspond with the hose I.D.
5. From that section of the clamps, find the clamp that has an O.D. range in the
Hose O.D. From / To column that best fits the hose O.D. just measured.
Additional Information
1. For steam hose, select the clamp that has a maximum range as close to (but
not smaller than) the measured hose O.D. This will allow the clamp to be retightened many times to adjust for Cold-Flow which speeds up with increased
temperature and /or hot and cold cycles.
2. For hard wall constructed hose (wire present) with an O.D. at or near the
clamp's maximum range, use of the next largest clamp may be required. See
Criteria For Sufficient Fit of a Boss Clamp to determine proper clamp fit.
3. For soft wall constructed hose (no wire present) having an O.D. at or near
clamp's minimum range, use of the next smallest clam may be required. See
Criteria For Sufficient Fit of a Boss Clamp to determine proper clamp fit.
7-360
DRILLING SOLUTIONS
Notes:
1. Use of an incorrectly sized Boss clamp can result in damage to property and
serious injury to personnel.
2. Refer to the DIXON DIAMETER TAPE PROCEDURE for instructions on how
to read a diameter tape.
3. Refer to INSTALLATION OF BOSS 2 BOLT CLAMP for assembly techniques
when using a two bolt Boss clamp.
when using a four bolt Boss clamp.
when using a six bolt Boss clamp.
Criteria For Sufficient Fit of a Boss Clamp
Notes:
1. Sufficient fit criteria provides inspection guidelines when the clamp has been
assembled in accordance with prescribed procedures and all of the bolts are
tightened to 150 FT/LBS. FOR 3 INCH CLAMP, 60 FT/LBS FOR THE 2-1/2
AND 2 INCH CLAMPS.
2. The failure to adhere to these guidelines could produce poor clamp
performance, leaking assemblies or even separation of hose and coupling that
may cause property damage and /or serious injury to personnel.
Minimum Range
1. 1/32 clearance between clamp halves (both sides) for clamps that are
designed to fit 1/4 I.D. through 2" I.D. hose.
2. 1/16 clearance between clamp halves (both sides for 4 bolt clamps) or all
segments (6 bolt clamps) for clamps designed to fit 2-1/2 I.D. through 6" I.D.
hose.
3. 1/32 of an inch clearance between clamp gripping fingers (all gripping fingers)
and stem groove for all sizes.
Maximum Range
1. 1/32 of an inch interlock between the clamp gripping finger and stem collar (all
gripping fingers) for clamps designed to fit 1/4 inch I.D. through 2 inch I.D.
2. 1/16 of an inch interlock between the clamp gripping finger and stem collar (all
gripping fingers) for clamps designed to fit 2-1/2 inch I.D. through 6 inch I.D.
3. 1/32 of an inch interlock between dovetail extensions (both sides) for clamps
designed to fit 1/4 inch I.D. through 2 inch I.D. hose.
4. 1/16 of an inch interlock between dovetail extensions on both sides (4 bolt
clamps) or all segments (6 bolt clamps) for clamps designed to fit 2-1/2 inch I.D.
through 6 inch I.D. hose.
DRILLING SOLUTIONS
7-361
INSTALLATION OF BOSS 2 BOLT CLAMP
Procedure
1. Prepare the hose. Refer to GENERAL PREPARATION INSTRUCTIONS.
2. Place the stem in a vise.
a. For male stems, tighten the vise on the hex.
b. For female stems (wing nut), place a spud in the vice, tighten and then
thread the wing nut onto the spud.
3. Select the proper Boss Clamp. Refer to Boss Clamp Selection.
4. Position the clamp gripping fingers behind the stem collar as illustrated above.
5. Tighten the bolts by hand until there is equal thread engagement. Note: When
hose O.D. is at or near clamp maximum range, starting of nuts on bolts may
require squeezing clamp halves in a vise.
6. Bolt tightening sequence is as follows:
a. Front bolt, 1 full turn.
b. Opposite side front bolt, 1 full turn.
c. Repeat 1" and 2" until all bolts are tightened to recommended torque value
listed on BOSS CLAMPS chart. Torque values are based upon dry bolts.
Lubricant on bolts will adversely effect clamp performance. Use a torque
wrench.
d. Remove assembly from vise.
7. Test assembly if required. Refer to TESTING.
Notes:
1. Clamp bolts are designed to bend during tightening. This bending allows the
clamp to conform to the hose circumference.
7-362
DRILLING SOLUTIONS
2. Periodic bolt re-tightening is necessary due to Cold-Flow present in all rubber

hoses.
3. Boss clamps (including the nuts and bolts) are for single use only. Do not
reuse. Once removed, discard.
4. Refer to Criteria For Sufficient Fit of a Boss Clamp to determine proper
assembly.
Notes:
hoses.
2. Boss clamps (including nuts and bolts) are for single use only! Once
removed, discard.
Process
4. Position the clamp gripping fingers behind the stem collar as illustrated above.
5. Tighten the bolts by hand until there is equal thread engagement. Note: When
hose O.D. is at or near clamp maximum range, starting of nuts on bolts may
require squeezing clamp halves.
DRILLING SOLUTIONS
7-363
6. Using a torque wrench, tighten bolts to the recommended torque of 150 ft-lbs
for the 3 inch clamp and 60 ft-lbs for the 2-12 inch and 2 inch clamps. Torque
values are based upon dry bolts. Lubricant on bolts will adversely effect clamp
performance. Bolt tightening sequence is as follows:
a. Back bolt, 1 full turn.
b. Front bolt, 1 full turn.
c. Snug by hand, nuts on opposite side of bolts just tightened.
d. Opposite side back bolt, 1 full turn.
e. Opposite side front bolt, 1 full turn.
f.
Snug by hand, nuts on opposite side of bolts just tightened.
g. Repeat steps a to f until all bolts are tightened to recommended torque.

Clamp bolts are designed to bend during tightening. This bending allows
the clamp to conform to the hose circumference.
8. Refer to Criteria For Sufficient Fit of a Boss Clamp to determine proper
assembly.
7-364
DRILLING SOLUTIONS
Procedure
4. Position the clamp gripping fingers behind the stem collar.
5. Tighten the bolts by hand until there is equal thread engagement on all six nuts.
6. Tighten nuts on bolts in the following sequence. See Boss 6 Bolt Clamp
illustration.
a. Bolt 1 - one full turn. Before tightening each bolt in sequence, snug the nut
by hand if loose.
b. Bolt 2 - one full turn.
c. Bolt 3 - one full turn.
d. Bolt 4 - one full turn.
e. Bolt 5 - one full turn.
f.
Bolt 6 - one full turn.
g. Repeat 1 to 6 until all bolts are tightened to recommended torque value

listed on BOSS CLAMPS chart. Torque values are based upon dry bolts.
Lubricant on bolts will adversely effect clamp performance. Use a torque
wrench.
h. Remove assembly from vice.
Notes:
1. Clamp bolts are designed to bend during tightening. This bending allows the
clamp to conform to the hose circumference.
hoses.
3. Boss clamps (including the nuts and bolts) are for single use only. Do not
reuse. Once removed, discard.
4. Refer to the Criteria For Sufficient Fit of a Boss Clamp for guidelines to
determine proper assembly.
DRILLING SOLUTIONS
7-365
TESTING
The following is for general hydrostatic testing and electrical continuity testing. Other
procedures may need to be employed. Follow the RMA (Rubber Manufacturers Association)
hydrostatic test procedures IP-11-1 through IP-11-8 or ASTM D-380 (latest revision). Consult
the hose manufacturer if questions arise. If an assembly requires both hydrostatic and
electrical continuity testing, perform the electrical continuity test first.
Hydrostatic Testing
1. Determine the assembly working pressure. The assembly working pressure is
the lesser pressure rating of either the hose or the couplings.
2. Determine the test pressure. Test pressure is 1-1/2 times the assembly working
pressure.
3. Lay the assembly in a straight line.
4. Install test caps or test plugs to both ends.
5. Connect bleed-off valve to one end and test pump intermediate hose to other
end of test sample.
6. Position test pump (or test sample) to that test pump and test sample are at a
90 angle to each other.
7. Fill test sample with water. Elevate end with bleed-off valve to purge air from
sample. Make certain that all air is removed.
8. Bulwark ends of test sample to prevent damage from accidental coupling
separation.
9. Activate pump until test pressure is achieved.
10. Hold test pressure for 15 minutes.
11. Turn off pump and relieve pressure from test sample.
12. Remove test fixtures from test sample.
13. Drain water from test sample.
14. Complete test report for sample just tested.
CAUTION
No one is to stand near ends of test samples while under pressure for any
reason.
Electrical Continuity Testing
No standard exists for testing electrical continuity. Generally speaking, this type of testing is
done with either a continuity meter or a multimeter.
The continuity meter simply has a light that goes on when each coupling is simultaneously
touched with a probe. A multimeter registers electricity in ohms (W).
7-366
DRILLING SOLUTIONS
Always contact the hose manufacturer for instructions on the proper method and criteria for
electrical continuity testing.
DRILLING SOLUTIONS
7-367
7-18 HNBR Hose/Victaulic Coupling Installation

The following text contains Installation Instructions for HNBR hose using 2-bolt Victaulic rigid
couplings.
7-368
DRILLING SOLUTIONS
Coupling Installation
WARNING
1. Read and understand all instructions before attempting to install any Victaulic
piping products.
2. Depressurize and drain the piping system before attempting to install, remove
or adjust any Victaulic piping products.
3. Wear safety glasses, an approved hard hat and foot protection.
Failure to follow these instructions could result in serious personal injury, improper product
installation and/or property damage.
Preparatory Steps for Coupling Installation

1. Check Hose/Pipe Ends: The outside surface of the pipe from the end to the
groove must be smooth and free from indentations, projections (including weld
seams) and roll marks to ensure a leak tight seal for the gasket. All oil, grease,
loose paint and dirt bust be removed.
2. Check Gasket and Lubricate: Check the gasket to make sure it is suitable for
the intended service. Apply a thin coat of silicone lubricant to the gasket lips
and exterior.
DRILLING SOLUTIONS
7-369
CAUTION
Always use a compatible lubricant to prevent the gasket from pinching or

tearing during installation. Failure to follow this instruction could result
in joint leakage.
3. Position Gasket: Position the gasket over the hose end. Make sure the gasket
does not overhang the hose end.
4. Join Hose/Pipe Ends: Align and bring the hose end and pipe end together.
Slide the gasket into position and make sure it is centered between the grooves
in each hose/pipe end. Make sure no portion of the gasket extends into the
groove in either pipe/hose end.
Coupling Installation
1. Assemble Housings: Insert one bolt into the housings and thread the nut
loosely onto the bolt (nut should be flush with the end of bolt) to allow for the
swing-over feature, as shown below.
7-370
DRILLING SOLUTIONS
2. Install Housings: Using the swing-over feature, install the housings over the
gasket. Make sure the housings keys engage the grooves properly on both the
hose end and the pipe end.
CAUTION
Make sure the gasket does not become rolled or pinched while installing
the housings. Failure to follow this instruction could cause damage to the
gasket, resulting in joint leakage.
3. Install Remaining Bolt/Nut: Install the remaining bolt and thread the nut
finger-tight onto the bolt. Note: Make sure the oval necks of the bolts seat
properly in the bolt holes.
DRILLING SOLUTIONS
7-371
4. Tighten Nuts: Tighten all nuts evenly by alternating sides until metal-to-metal
contact occurs at the angle bolt pads. Make sure the housings keys completely
engage the grooves. Make sure the offsets are equal at the bolt pads.This is
necessary to ensure a rigid joint (refer to the example below). Note: It is
important to tighten all nuts evenly to prevent gasket pinching.
WARNING
Victaulic rigid, angle-pad couplings must have the nuts tightened evenly
by alternating sides until metal-to-metal contact occurs at the bolt pads.
Victaulic rigid, angle-pad couplings must have equal offsets at both bolt
pads.
Failure to follow these instructions could cause joint failures resulting in
serious personal injury and/or property damage.
Impact Wrench Usage Guidelines
7-372
DRILLING SOLUTIONS
DO NOT use an impact wrench after the visual installation guidelines for
the coupling are achieved.
Nuts must be tightened evenly by alternating sides until metal-to-metal
contact occurs at the bolt pads. For angle-bolt-pad couplings, even
offsets must be present at the bolt pads to obtain pipe-joint rigidity.
Failure to follow these instructions could cause gasket pinching and
coupling damage resulting in joint failure, serious personal injury and
property damage.
Installation Inspection
WARNING
Proper Installation
Proper pipe preparation and coupling installation is essential for maximum joint performance.
The following conditions must be present to ensure proper joint assembly.
DRILLING SOLUTIONS
7-373
1. The pipe O.D. and groove dimensions must be within the tolerance of current
Victaulic grooving specifications.
2. Unless stated otherwise in specific product instructions, Victaulic grooved pipe
couplings must be properly assembled with the bolt pads in firm, metal-to-metal
contact.
3. The housings keys must be fully engaged in both grooves.
4. The gasket must be slightly compressed, which adds to the strength of the seal.
Always re-inspect joints before and after the field test to identify points of possible failure. Look
for gaps at the bolt pads and/or keys that ride up on the shoulders. If any of these conditions
exist, depressurize the system and replace any questionable joints.
7-374
DRILLING SOLUTIONS
7-19 WATER INJECTION

Cat Water Injection
CAUTION
CAT PUMPS are positive displacement pumps. Therefore, a properly

designed pressure relief or safety valve must be installed in the
discharge piping. Failure to install such a relief mechanism could result
in personal injury or damage to the pump or system.
Installation and Startup

Optimum performance of the pump is dependent upon the entire fluid system and will be
obtained only with the proper selection, installation of plumbing and operation of the pump and
accessories.
Specifications
Maximum specifications refer to individual attributes. It is not implied that all maxims can be
performed simultaneously.
Lubrication
Before starting pump, fill crankcase to dot on oil dipstick per specification with Cat Pump
Crankcase Oil, ISO-68 multi-viscosity petroleum based lubricating oil with anti-wear
and rust inhibitor additives. Approximate amounts are shown below.
Table 3:
12 gpm size (45.42 liters)
40 oz. (1182.9 ml)
25 gpm size (94.64 liters)
84 oz. (2484.2ml)
Change initial fill after 50 hours running period. Change oil every three months or at 500 hour
intervals thereafter. If the pump is used in extremely dirty or humid conditions, it is strongly
recommended pump be enclosed.
Oilers
Prior to initial operation, fill the three oilers with Cat Pump Oil. With the oiler shutoff lever in a
vertical position, screw the dome down to seat the needle valve tightly (the shutoff valve
becomes loose). Then back the needle off the valve seat slightly (approximately 1/8 turn) and
tighten the lock nut. Prior to initial operation, saturate wicks. Then run pump one to two hours
with three to four drops per hour from each oiler; thereafter, one drop per hour per oiler.
DRILLING SOLUTIONS
7-375
Flipping the shutoff lever to the horizontal position shuts off the oil flow. Additional lubrication
may be required with increased hours of operation and temperature.
Inlet Conditions
Refer to the complete Inlet Condition Check List before starting your system. DO NOT RUN
PUMP DRY.
Nozzles
A worn nozzle will result in loss of pressure. Do not adjust pressure regulating device to
compensate. Replace nozzle and reset to system pressure.
Discharge Plumbing
1. OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead
overpressure condition and severe damage to the pump or system.
2. Install a pulsation dampening device mounted directly to the discharge line.
Optimum precharge should be calibrated at 30-50% of the operating system.
3. A reliable pressure gauge should be installed near the discharge outlet of the
high pressure manifold. This is extremely important for adjusting pressure
regulating devices and also for proper sizing of the nozzle or restricting orifice.
The pump is rated for a maximum pressure; this is the pressure which would
be read at the discharge manifold of the pump, NOT AT THE GUN OR
NOZZLE end of a long hose.
4. A pressure regulator or unloader valve must be installed to prevent
overpressure in the event the discharge or downstream plumbing becomes
plugged or is turned off. Severe damage to the pump will result if this condition
occurs without a relief valve in the line. Discharge regulating devices should be
at minimum pressure setting at startup. START SYSTEM WITH ALL VALVES
OPEN OR IN THE LOW PRESSURE SETTING.
5. Note: Use PTFE liquid (sparingly) or tape when connecting plumbing. Exercise
caution not to wrap tape beyond the last thread to avoid tape from becoming
lodged in the pump or accessories. This condition will cause a malfunction of
the pump or system.
Pumped Fluids
Some fluids may require a flush between operations or before storing. For extended
storing or between use in cold climates, drain all pumped fluids from pump and flush with
antifreeze solution to prevent freezing and damage to the pump. DO NOT RUN PUMP
WITH FROZEN FLUID.
Inlet Condition Check List

Inadequate inlet conditions can cause serious malfunctions in the best designed pump.
7-376
DRILLING SOLUTIONS
Surprisingly, the simplest of things can cause the most severe problems or go unnoticed to the
unfamiliar or untrained eye. REVIEW THIS CHECK LIST BEFORE OPERATION OF ANY
SYSTEM. Remember, no two systems are alike, so there can be no one best way to set up a
system. All factors must be carefully considered.
The inlet supply should be adequate to accommodate the maximum flow being delivered by
the pump.
1. Open inlet shutoff valve and turn on water supply to avoid cavitating pump. Do
not run pump dry.
2. Avoid closed loop systems especially with high temperature, ultra-high
pressure or large volumes. Conditions vary with regulating/unloader valve.
3. Low vapor pressure fluids, such as solvents, require a booster pump and a
C.A.T. (Captive Acceleration Tube) to maintain adequate inlet supply.
4. Higher viscosity fluids require a positive head and a C.A.T. to assure
adequate inlet supply.
5. Higher temperature fluids tend to vaporize and require positive heads and
C.A.T. to assure adequate inlet supply.
6. When using an inlet supply reservoir, you must size it to provide adequate fluid
to accommodate the maximum output of the pump, generally a minimum of 10
times the GPM (however, a combination of system factors can change this
requirement); provide adequate baffling in the tank to eliminate air bubbles and
turbulence; and install diffusers on all return lines to the tank.
The inlet line size should be adequate to avoid starving the pump.
1. Line size must be a minimum of one size larger than the pump inlet fitting. Avoid
thick walled fittings, tees, 90 degree elbows or valves in the inlet line of the
pump to reduce the risk of flow restriction and cavitation.
2. The line must be a flexible hose, not a rigid pipe, and reinforced on the suction
systems to avoid collapsing.
3. The simpler the inlet plumbing, the less the potential for problems. Keep the
length to a minimum, the number of elbows and joints to a minimum (ideally no
elbows) and the inlet accessories to a minimum.
4. Use pipe sealant to assure air-tight, positive sealing pipe joints.
Inlet pressure should fall within the specifications of the pump.
1. Acceleration loss of fluids may be increased by high RPM, high temperatures,
low vapor pressures or high viscosity and may require pressurized inlet and
C.A.T. to maintain adequate inlet supply.
2. Optimum pump performance is obtained with +20 psi (1.4 bar) inlet pressure
and a C.A.T. for certain applications. With an adequate inlet plumbing, most
pumps will perform with a flooded suction. The maximum inlet pressure is 40
psi (2.8 bar). Negative suction up to -8.5 psi (-0.59 bar) can be reached with
optimum plumbing conditions.
DRILLING SOLUTIONS
7-377
Inlet accessories are designed to protect against over pressurization, control inlet flow,
contamination or temperature and provide ease of servicing.
1. A shutoff valve is recommended to facilitate maintenance.
2. Installation of a C.A.T (Captive Acceleration Tube) is essential in applications
with stressful conditions such as high temperatures, a booster pump feed or
long inlet lines. Do not use C.A.T. with negative inlet pressure.
3. A stand pipe can be used in some applications to help maintain a positive head
in the inlet line.
4. Inspect and clean inlet filters on a regular schedule.
5. A pressure gauge is recommended to monitor the inlet pressure and it should
be mounted AS CLOSE TO THE PUMP INLET as possible. Short term,
intermittent cavitation will not register on a standard gauge.
6. All accessories should be sized to avoid restricting the inlet flow.
7. All accessories should be compatible with the solution being pumped in order
to prevent premature failure or malfunction.
Bypass to inlet care should be exercised when deciding the method of bypass from control
valves.
1. It is recommended the bypass be directed to a baffled reservoir tank, with at
least one baffle between the bypass line and the inlet line to the pump.
2. Although not recommended, bypass fluid may be returned to the inlet line of the
pump if the system is properly designed to protect your pump. When using this
method, a pressure reducing valve should be installed onto the inlet line
(between the bypass connection and the inlet to the pump) to avoid excessive
pressure to the inlet of the pump. It is also recommended that a thermo valve
be used in the bypass line to monitor the temperature build-up in the bypass
loop to avoid premature seal failure.
3. A low pressure, flexible cloth braid (not metal braid) hose should be used from
the bypass connection to the inlet of the pump.
4. Caution should be taken. Do not undersize the bypass hose diameter and
length. Typical length is 24 inches (609.6 mm).
5. Check the pressure in the bypass line to avoid over pressurizing the inlet.
Diagnosis & Maintenance

Table 4:
Problem
Pulsation
7-378
Probable Cause
Solution
Faulty Pulsation Dampener
Check precharge. If the

precharge is low, recharge
it or install a new one.
DRILLING SOLUTIONS
Problem
Low Pressure
Pump runs extremely

rough, pressure very low
DRILLING SOLUTIONS
Probable Cause
Solution
Worn Nozzle
Replace nozzle of proper

size
Belt Slippage
Tighten or replace. Use

correct belt type and length
Air leak in inlet plumbing
Disassemble, reseal and

reassemble
Pressure gauge
inoperative or not
registering accurately
Check with new gauge;

replace worn or damaged
gauge.
Relief valve stuck, partially

plugged or improperly
adjusted; valve seat worn
Clean and adjust relief

valve; check for worn or
dirty valve seats. Repair
with valve kit.
Inlet suction strainer

clogged or improper size
Clean. Use adequate size.

Check more frequently.
Worn piston assembly.

Abrasives in pumped fluid
or severe cavitation.
Inadequate water supply.
Install proper filter. Suction

at inlet manifold must be
limited to lifting less than
20 feet of water or -8.5 psi
vacuum.
Fouled or dirty inlet or

discharge valves.
Clean inlet and discharge

valve assemblies
Worn inlet or discharge

valves
Replace worn valves,

valve seats
Leaky discharge hose
Replace discharge hose

and check for air tight
connections
Restricted inlet or air

entering the inlet plumbing
Proper size inlet plumbing;

check for air tight seal
Damaged cup or stuck inlet

or discharge valve
Replace worn cups or

valves; clean out foreign
material.
Worn inlet seals allowing

air into system or leaking
fluid
Install new inlet manifold

seals and possibly seals
7-379
Problem
Probable Cause
Solution
Cylinder o-ring blown next

to discharge manifold.
Pressures in excess of
rated psi or distorted
manifold from freezing
damage.
Check for plugged nozzle,

closed valves or for an
improperly adjusted
bypass valve. Replace
defective manifold or oring. Protect from freezing.
Leakage at the cylinder orings, at the discharge

manifold and black
powdery substance in the
area of the o-ring
Loose cylinders. Cylinder

motion caused by improper
shimming of the discharge
manifold.
Remove spacer shims on

manifold studs. Do not
remove too many shims or
the ears of the manifold will
be bowed when the
manifold is retightened,
causing looseness in the
center cylinder.
Water leakage from under

the inlet manifold
Worn inlet manifold seals.

Leaking sleeve o-ring.
Install new o-rings and

seals as required. Replace
scored sleeves.
Oil leak between

crankcase and pumping
section
Worn crankcase piston rod

seals
Replace crankcase piston

rod seals
Excess oil from wicks
Reduce quantity of oil per

oiling
Oil leaking in the area of

the crankshaft
Worn crankshaft seal or

improperly installed oil seal
retaining packing
Remove oil seal retainer

and replace damaged
gasket and/or seals
Bad bearing
Replace bearing.
Excessive play in the end

of the crankshaft pulley
Worn main ball bearing

from excessive tension on
drive belt
Replace bearing. Properly

tension belt. Use correct
type and length.
Water in crankcase
May be caused by humid

air condensing into water
inside the crankcase.
Change oil every 3 months

or 500 hour intervals using
Premium 10W30 Grade
non-detergent hydraulic oil
(other approved oil every
month or 200 hours)
Leakage of manifold inlet

seals and/or piston rod
sleeve o-ring
Replace seals, sleeve and

o-rings.
Worn crankshaft seals
Replace seals
Oil leaking from side of

crankcase
7-380
DRILLING SOLUTIONS
Problem
Probable Cause
Solution
Oil leaking at the rear

portion of the crankcase
Damaged or improperly
installed oil gauge or worn
crankcase rear cover oring, or drain plug o-ring
Replace oil gauge, cover

o-ring, or drain plug o-ring
as needed.
Oil leakage from drain plug
Loose drain plug or worn

drain plug o-ring
Tighten drain plug or

replace 0-ring
Loud knocking noise in

pump
Pulley loose on crankshaft
Check key and tighten set

screw
Check alignment and belt
position
Frequent or premature
failure of the inlet manifold
seals
Short cup life
Strong surging at the inlet

and low pressure on the
discharge side.
DRILLING SOLUTIONS
Broken or worn bearing
Replace bearing
Scored rods or sleeves
Replace rods and sleeves
Overpressure to inlet
manifold
Reduce inlet pressure per

instructions.
Stressful inlet conditions
Install C.A.T.
Abrasive material in the

fluid being pumped
Install proper filtration on

pump inlet plumbing.
Excessive pressure and/or

temperature of fluid being
pumped
Check discharge pressure,

fluid temperature or control
valve bypass
Running pump dry
Do not run pump without

water
Front edge of piston sharp
Replace with new piston
Chrome plating of
cylinders damaged
causing excessive wear of
cups. May be caused by
pumping acid solution.
Install new cups and

cylinders. Pump only fluid
compatible with chrome.
Short life on cups on

cylinders.
Stressful inlet conditions.

Install C.A.T.
Foreign particles in the

inlet or discharge valve or
worn inlet and/or discharge
valves.
Check for smooth mating

surfaces on inlet valves
and discharge valve seats.
Flat valves and inlet valves
may be lapped on a very
fine oil stone; Quiet Valve
parts must be replaced.
7-381
Servicing the Valve Assemblies

Disassembly:
1. Remove the fasteners securing the discharge manifold to the crankcase of the
pump.
2. Support the discharge manifold and tap from the backside with a soft mallet.
Gradually work free from cylinders.
3. Valve assemblies will remain in the manifold. Pump models with o-ring groove
on the outside of the valve seat require the assistance of a Valve Seat Removal
Tool to remove the valve seat. The valve, spring and retainer will fall out when
the manifold is inverted. Pump models without the o-ring groove on the outside
of the valve seat permit the seat, valve, spring and retainer all to fall out when
the manifold is inverted.
Reassembly:
1. Examine the retainer for wear and replace as needed. Replace the retainer in
manifold chamber with nylon tab down.
2. Examine spring for fatigue and replace as needed. Insert spring into center of
retainer.
3. Inspect the valves for wear, ridges or pitting and replace as needed. Note:
Seating side of flat valves may be lapped on flat surface using 240 grit paper.
Quiet valves, due to their shape, must be replaced. Insert valve over spring
with dimpled side up.
7-382
DRILLING SOLUTIONS
4. Examine all o-rings and backup rings on the valve seat. Replace them if they
are used or worn. Always lubricate o-rings for ease of installation and to avoid
damage. Note: First install o-ring in groove on seat towards seating surface,
then backup ring. Note: Models without outer groove on seat require the o-ring
to be placed on the lip of the retainer.
5. Examine valve seats for wear, pitting or grooves. Lap the Flat Valve seats with
240 grit paper or replace if there is evidence of excessive wear. Quiet Valve
seats must be replaced if worn. Install seats with dish side down.
6. Lubricate o-rings on exposed cylinder. Exercise caution when slipping manifold
over cylinders to avoid damaging cylinder o-rings. Completely press manifold
over cylinder.
7. Replace fasteners and torque per torque chart on following pages. Note:
Replace all original shims if used. When new manifold is used, reshim
pump. When starting the pump, check to see that there is no cylinder motion.
This will cause premature failure of the cylinder o-rings. Center cylinder motion
indicates improper shimming.
Servicing the Valve Pumping Section

Disassembly:
1. Remove the discharge manifold as previously explained.

2. Grasp cylinders by hand and with an up and down motion, pull the cylinders
from inlet manifold.
3. Remove cotterpin, nut and washer from piston rod.
4. Next remove the retainer, spacer, piston-cup assembly and inlet valve.
Reassembly:
1. Examine inlet valve surface for pitting, scale or grooves. Reverse valve and
sand inlet side of valve using 240 grit paper for clean surface or replace if
evidence of excessive wear. Slip onto rod.
2. Examine piston seating surface and lightly sand on flat surface using 240 grit
paper. If extreme pitting or sharp edges, replace piston.
3. Examine cup for wear, cracking, tearing or separation from the piston. If worn,
replace and lubricate before installing on piston. Note-cup installation: Wipe
cup inserter with oil. slip backup ring (when used) onto piston. Push cup over
inserter and square with all surfaces. Faulty cup installation causes premature
cup failure. Some models use a one piece piston assembly. The cup does not
separate from the piston. Replace entire assembly. Lubricate piston assembly
and slip piston-cup assembly onto the piston rod with lip facing discharge.
4. Next, replace the piston spacer and retainer on rod.
5. Replace washer, thread on nut and torque per torque chart shown on following
pages. Note: Always replace with new stainless steel cotterpin and turn
DRILLING SOLUTIONS
7-383
ends under.
6. Examine cylinder walls for scoring or etching which causes premature wear of
cups and replace as needed.
7. Lubricate the cylinder and replace o-rings and/or backup rings if worn or
damaged. Backup rings go to low pressure side of the o-rings. Carefully
slip cylinder over rod ends and push into inlet manifold with the backup ring to
the discharge, stroke marking on the inside of the cylinder to the
crankcase,
8. Position discharge manifold onto pumps as described. Replace fasteners and
torque per specifications chart shown on following pages.
Servicing Sleeves and Seals

Disassembly:
1. Remove discharge manifold and piston assemblies as described.

2. Remove inlet manifold containing seals.
3. Grasp sleeves and with a pulling and twisting motion remove the sleeve from
the piston rod. Note: Grasp sleeve with pliers only if replacing worn sleeves, as
the procedure will mar the sleeves.
4. Next, remove the seal retainer.
5. Remove and examine o-rings and/or backup rings on piston rod for wear and
replace as needed.
Reassembly:
1. Visually inspect that the barrier-slinger is in position.

2. Lubricate new o-rings and/or backup rings and slip onto piston rod. Install the
first o-ring (A) in the groove on the piston rod. Next, position the backup ring (B)
against the stepped shoulder. Then install the second o-ring (C). Exercise
caution as you slip the o-ring over thread end of the piston rod.
3. Examine sleeves for scoring or etching and replace. Immerse sleeves (D) in
oil and carefully twist and push sleeve onto rod with machined counter
bore end (E) first.
4. Next, install seal retainers. If wicks are used, replace wicks. Thoroughly
saturate with oil, place in seal retainer and install retainer.
5. Place inlet manifold on pair of clearance blocks with crankcase side down and
drive out old seals.
7-384
DRILLING SOLUTIONS
6. Invert inlet manifold with crankcase side up and install new seals. Lubricate
O.D. of seal and install Prrrrm-A-Lube seal with garter spring down. If using
blue dot seal, install blue dot seal facing up. Note: The 25 gpm model does not
have Prrrrm-A-Lube option. Install with spring down.
7. Slip lubricated seal inserters onto piston rod ends, position inlet manifold onto
pump and remove seal inserters. Some models secure inlet manifold to
crankcase. Replace fasteners and torque per specification chart shown on
following pages.
8. Reassemble piston assemblies and discharge manifold as described.
9. Replace original quantity of shims on each stud before replacing discharge
manifold.
Servicing Crankcase Section

1. While the inlet manifold, sleeves and seal retainers are removed, examine the
seals in the crankcase for wear.
2. Check oil for proper level and for evidence of water in oil or other contaminants.
3. Rotate crankshaft by hand to feel for smooth bearing movement.
4. Examine crankshaft oil seal externally for drying, cracking or leaking.
Torque Chart
Table 5: Piston Rod Nut
Pump Model
Thread
Tool Size
Torque
12 gpm
M7 x 1.0
10mm Hex
70-120 in/lbs (8-14 Nm)
25 gpm
M8 x 1.25
13mm Hex
90-150 in/lbs (10-17 Nm)
Table 6: Manifold Stud/Nut and Cylinder Bolts

Pump Model
Thread
Tool Size
Torque
12 gpm
M10 x 1.5
17mm Hex
250 in/lbs (28 Nm)
25 gpm
M12 x 1.75
19mm Hex
370 in/lbs (42 Nm)
DRILLING SOLUTIONS
7-385
Manifold Torque Sequence
Pulse Pump Injection Head

The pulse pump is optional for high pressure Cat pumps only.
Operation
With gun open, start drive pump. After water starts to flow out the nozzle (minimum 200 psi/
13.8 bar), open bleed valve one turn to purge air from pulse pump, thus priming the pulse
pump. After all air is purged, torque valve 100 and 120 in/lbs (11.3 and 13.56 Nm). Then set
drive pump for proper discharge pressure.
CAUTION
Pulse Pump will not operate with a pressurized inlet to the drive pump.
CAUTION
Do not operate the pulse pump dry. This could damage the diaphragm.
Performance
After the unit is operating, adjust metering valve to obtain desired water/chemical ratio. Check
chemical output by measuring chemical supply tank. Note: A metering valve not supplied
by Cat Pumps with pulse pump.
Mixing Ratio varies with output of drive pump, the model pulse pump being used and whether
a metering valve is used.
Maintenance
Before shutting system down, flush pulse pump by placing chemical supply line in water. If
volume of chemical decreases, lap the discharge valve, suction valve seat and valve with 440
grit paper. Check diaphragm for leaks.
7-386
DRILLING SOLUTIONS
Trouble Shooting
No Chemical Supply From Pulse Pump

1. Failure of diaphragm or spring
2. Air in chemical supply line
3. Foreign material in inlet or discharge valves
4. Pressurized inlet to drive pump
Limited Chemical Supply From Pulse Pump
1. Air in chemical supply line
2. Clog in manifold port fitting
3. Loose lock nut of diaphragm spring
4. Worn inlet and discharge valves
Bean Water Injection

This section is designed to help with routine maintenance and do-it-yourself service that the
John Bean pump or equipment may require.
Installation
Pump Location
1. Locate the pump as close to the source of supply as possible. It is desirable to

set the pump in a clean and dry place with sufficient lighting and adequate
space for inspection and maintenance.
Foundation
1. The pump should be mounted in a vertical position and securely fastened in

order to maintain alignment and prevent vibration.
Suction Line
General
1. When installing pipe and fittings, be sure the inside of all parts are free from dirt,
scale, burrs and other foreign material which might interfere with the pump
operation. Make sure all joints are tight and free from air leaks which cause
cavitation and loss of pump capacity.
2. Return the overflow from a relief valve or pressure regulator directly to the
supply tank. Care must be taken not to locate return where it will cause
excessive turbulence directly at the suction inlet.
DRILLING SOLUTIONS
7-387
Length and Size
1. The suction line from source to pump inlet should be as short and direct as
possible, using either piping or durable non-collapsing hosing as
circumstances warrant.
2. The suction pipe size should be at least the same as the pump inlet connection,
or preferably larger to avoid limiting the pump capacity. The supply source
should be located above the inlet connection for smoother operation of the
pump and longer packing life. When a static lift is used, the lift should be kept
as small as possible. Elbows, nipples and unions should be kept at an absolute
minimum. To isolate mechanical and hydraulic vibrations, hose connections
are recommended at the pump for both suction and discharge.
3. Install both the suction and discharge piping so it is supported independently,
thus avoiding vibrations as well as strain on the pump.
Gate Valves
1. In order to cut off the supply of liquid during maintenance inspections, a gate
valve is recommended as close as possible to the inlet side of the pump. The
openings in the gate valve should not be smaller than the pump inlet openings.
Suction Dampener
1. Where long suction lines occur, it may be necessary to install a suction

dampener to minimize vibration.
Drain Plugs
1. Drain plugs or drain cocks are advisable for use at low points in both the suction
and discharge lines. This is especially true if temperature conditions drop to the
freezing point or lower.
Strainer
1. Install a strainer in the suction line to remove particles which might interfere
with the valves. Strainers may be of the open type at the end of the suction line
or fully enclosed, having a removable cover for inspection. It is very important
that strainers are cleaned periodically and sized properly so they do not restrict
suction flow.
Pump Connections
1. Install unions as close as possible to the inlet and outlet openings of the pump
to facilitate any future servicing, should the need arise.
Discharge Lines
Size and Length
1. Install the discharge piping as short and direct as possible, using the same size
pipe as the pump outlet connection. When the discharge hose is extra long, use
the next larger size diameter hose to minimize friction.
7-388
DRILLING SOLUTIONS
Relief Valve
1. Select a relief valve of adequate capacity and install in discharge line between
the pump and check valve (if used) or the shutoff valve. Bean relief valves
bypass excess liquids to prevent extreme pressures. They are easily adjusted
for pressure control.
Pressure Gauge
1. A pressure gauge is recommended to aid in checking or adjusting pressures

and it should be installed in the discharge line near the relief valve.
Discharge Dampener
1. Install a pulsation dampener of adequate size in the discharge line to ensure

smooth delivery by dampening pulsations and minimizing surging.
Power Source
1. If the pump is driven by an electric motor, use wire of sufficient size to carry the
load with the additional protection of fuses or thermal relays.
2. If the pump and motor are connected by a flexible coupling, be sure the two
shafts are in good alignment with each other.
Direction of Rotation
1. The pump may be operated in either direction with satisfactory results.
Servicing Instructions
Safety First!
Disconnect the power source before performing any service on the pump
General Care of the Pump
1. Drain and refill the pump crankcase with clean SAE30 API service clarification
MM or better oil after the first 100 hours of operation. Following the first 100
hours of operation, for best results change the oil every 750 hours of operation.
2. Keep all piping and mounting bolts tight.
3. Replace all worn parts promptly with OEM replacement parts.
Care in Freezing Weather
CAUTION
Important - Precautions must be taken to avoid damage to the pump from

liquid allowed to freeze in the valve chamber.
DRILLING SOLUTIONS
7-389
1. Drain all connecting piping.

2. Refer to above pump drawing. Remove capscrew (1), clamp(2), valve (3), valve
disc and spring (5) to drain the valve chamber (9) when freezing temperatures
are expected. Remove the top discharge valves or raise them to be sure that
no liquid is trapped under the inner suction valves.
Servicing the Plunger Packings
1. Release valve chamber (9) from pump case by removing the four capscrews
(10) shown above.
2. Lift the chamber free of the cylinders (12). Remove the cap screws (13), the cup
washers (14) and plunger packings (15).
3. Lift the cylinders (12) from the pump case (21).
4. Inspect the o-rings (17) and the umbrellas (18). If either of these parts are worn
or damaged, they should be replaced. A pocket knife can be used for easiest
7-390
DRILLING SOLUTIONS
removal of the umbrellas. Clean all parts thoroughly and replace the worn parts
with exact OEM replacement parts.
5. When reassembling plunger packings, inspect the bottom gasket (11) and
replace if necessary. Note: If it is necessary to replace one gasket at either top
or bottom of the cylinders, then all bottom or top cylinder gaskets should be
replaced. Torque capscrews to 8-10 ft/lbs (11-13.6 Nm). Note: For easier
installation of the umbrella, soak in hot water for approximately two to three
minutes to soften.
6. Fold the plastic umbrellas (18), as shown in below, to insert them through
openings and over ends of crosshead rods.
7. Press tops of umbrellas to place pilot washers (19) over ends of rods with
groove up.
8. Place o-rings (17) and packing holders (16) in position on ends of crosshead
rods.
9. Place cylinders (12) in position in the mounting plate recess.
10. Oil the plunger packings (15) and press them in the open end of the cylinders,
with the cup up. Use the thumb to press the packings into each cylinder firmly
and squarely on the plunger rod end.
11. Turn the pump by hand to raise each plunger rod to the top of the stroke, as
needed.
12. Place the cup washers (14), with the ribbed side against the plunger packing,
inside the cups of the packing.
13. Secure packing and washers to plunger rods with capscrews (13), tightening
them until the washers and cups seat firmly on the plunger rods. Torque to 1520 ft/lbs (20-27 Nm).
14. Inspect top cylinder gaskets (11) and replace all if any show defects, holding
them in place in the valve chamber by using heavy oil or grease if necessary.
15. Return the valve chamber to position over the cylinder, making sure that
gaskets (11) and cylinders (12) are properly positioned in the top and bottom
recesses.
16. Tighten capscrews (10) alternately and evenly until the parts are snugly seated.
Torque capscrews 20-25 ft/lbs (27-34 Nm).
DRILLING SOLUTIONS
7-391
17. Important: Clean buildup from cylinders. Submerge the cylinder in uncut
muriat acid (28% hydrochloric acid) for three (3) minutes, rinse in clear water,
wash with strong soap, submerge in acid for two (2) more minutes, rinse in
clear water and wipe off.
Servicing the Pump Valves
1. Remove the capscrew (1) and clamp bar (2) from the valve chamber (9) and lift
out valve covers (3) with o-rings (4) attached.
2. Remove the discharge valve springs and disc assemblies (6) and valve cages
(5).
3. Insert the round end of valve seat puller tool (39) through the opening at the
center of the valve seats (7). Loosen the seats from the valve chamber (9) with
a rocking motion of the tool.
4. Remove the valve seats from the recesses with the opposite end (curved end)
of the puller tool (39).
5. Repeat the four preceding steps to remove the suction valve parts which are
identical to the discharge valve parts and are located immediately under them
in the valve chamber.
6. Clean all parts and inspect them. Replace all worn parts as needed. Note:
Valve seats (7) may be used either side up, thus if one side shows wear, the
opposite side may be used to provide a new seat.
7. With the o-ring (4) in place on each valve seat (7), place a few drops of light oil
on the ring and seat and place each squarely in the bottom of the recess in the
valve chamber.
8. Place the valve cages (5) on the valve seats (7) and the spring and disc
assemblies (6) inside each cage.
9. Repeat steps (7) and (8) to install the outer discharge valve parts.
10. Place the valve covers (3), with o-rings on the bottom groove, over each valve
assembly.
11. Replace clamp bar (2) and capscrews (1), tightening capscrew (1) snugly only.
Do not overtighten capscrew (1). Overtightening can damage valve parts.
Torque to 30 ft/lbs (40.7 Nm).
7-392
DRILLING SOLUTIONS
Servicing the Crankshaft
1. Remove pipe plug (37) and drain oil from pump case.
2. Disconnect piping and remove pump from mounting.

3. Remove capscrews (36), wave washers (35) and mounting base (34) carefully
to protect the gasket (33).
4. Remove capscrews from the connecting rod assemblies (24). Use a center
punch or other suitable instrument to mark caps and rods for proper rematching
when they are reassembled.
5. Remove oil slingers (32) from the crankshafts (26) and (27).
6. Push the connecting rods and crosshead assemblies into the pump case to
clear the crankshafts (26) and (27).
7. Remove the driven sheave from the crankshaft extension.
8. Remove the snap rings (28) from groove in pump case at outside of bearings
(30 and 31).
9. Use a suitable wood block and hammer to tap against gear ends (outside) of
each crankshaft to remove oil seals and bearings at opposite side of pump
case. Crankshafts, with bearings at gear ends, may then be removed from
bottom of case.
CAUTION
Never pound directly on bearings (31) when removing or replacing them

on the crankshaft.
DRILLING SOLUTIONS
7-393
10. A block of wood with a suitable sized opening or block supports to assure
reasonable equal support around the bearing in a press is best for this
important work.
11. After inspecting and replacing all the worn parts, press new bearings (if
needed) against the shoulders on the crankshaft, then place the assembly
through openings into the pump case.
12. Important: Timing the Pump - Arrows on gears must be located exactly as
shown above to properly time the pump.
13. With the crankshaft and bearings assembly in place in the pump case, place
the oil seals (29) carefully over the ends of the crankshaft with the lip of the
seals facing the inside of the pump case. Care should be taken when passing
seals over the crankcase to avoid folding the lip of the seal under or damaging
the lip.
14. Set the snap rings (28) in the grooves in the bearing housings against the oil
seals and tap the crankcase to allow a slight end play in the crankshaft.
15. Assemble the connecting rods and crossheads, being sure to rematch the rod
and cap properly as marked when disassembled. Use 6-8 ft/lbs (8-11 Nm)
torque on capscrews.
16. Complete the assembly by reversing steps (1) through (8), being sure to
replace the drain plug (37).
17. Remove plug (21A) and fill the crankcase with clean SAE30 non detergent
motor oil to the filler plug level. Clean and replace the filler plug.
Turn the pump a few revolutions by hand to be sure all parts are running freely before using
the pump.
Servicing the Crossheads
1. Remove the valve chamber, the cylinders and the plunger packings as
described in paragraph (1) and (2) of Servicing the Plunger Packings.
2. Remove o-ring seal (17), backup washer (19) and the crosshead umbrellas
(18).
3. Remove the mounting base and the connecting rods as described in
paragraphs (1) through (4) of Servicing the Crankshaft.
7-394
DRILLING SOLUTIONS
4. Turn the crankshaft by hand to allow removal of the crossheads through the
pump case opening.
5. Reverse paragraphs (1) through (3) when reassembling the crossheads. Be
sure that all parts are reassembled in their exact former positions.
Operation
1. Check the drain plug located on the bottom of the base to ensure that it is
properly tightened.
2. Add clean SAE30 API service classification MM or better oil to the pump
crankcase. Maintain oil at the filler plug level.
3. Inspect the pump to see that all nuts and screws are tight.
4. Turn the pump sheave by hand a few times to make sure the pump operates
freely.
5. Start the pump and check its speed. After liquid transfer has been made, set
the pressure gauge to the desired reading.
6. Since the power required to drive the pump varies directly with the pressure
and the amount of fluid handled, it is recommended that the unit be operated
according to specifications.
If the speed is increased excessively, there is danger of either overheating the bearings or
causing cavitation in the fluid end of the pump.
If pressure is increased excessively, bearing life will be drastically reduced in addition to
breakage of other parts.
Exceeding pump specification limits for either pressure or speed results in overloading the
power source.
DRILLING SOLUTIONS
7-395
7-20 DHD LUBRICATOR

DHD Lubricator
The Down-Hole-Drill (DHD) lubricator (60 Gallon System CPN 5734755, 7 Gallon System
CPN 57353369) is a sub system of a rotary drill. The sub system consists of five parts; a
reservoir, a timer, an oil pump, flow switch/indicator light and discharge piping. The system
lubricates the DHD by pumping a prescribed amount of oil based on DHD hammer/air
compressor size. An operator is given three settings: 2 pints/hr (.95 liter/hr) for air compressor
capacity less than 600 cfm, 3 pints/hr (1.4 liter/hr) for air compressor capacity over 600 cfm
and up to 900 cfm, and 4 pints/hr (1.89 liter/hr) for air compressor capacity greater than 900
cfm.
Timer
The timer (CPN 57354342) cyclically delivers 12 volts to the pump coil and the indicator lamp
circuits. The unit houses the electronic components in a NEMA 4 rated housing (waterproof).
The timer uses a three pole switch allowing the operator to select the required oil bases on
DHD/air compressor size. External to the timer are the injection lube system electrical
terminals. The unit can use either a 12VDC or 24VDC input.
General Operation
One cycle consists of an ON (or energized) period, which lasts for one second, and the
remaining part of the cycle is referred to as the OFF (or de-energized) period, which has a
variable setting. The off period is either 11, 15, or 22.5 seconds depending on the switch
setting. The intervals were sized to operate the injection lube pump, CPN 57352973, over the
entire range of compressor capacities. The goal is to meet 1/3pt/hr/100cfm. The terminal strip
allows for both inputs and outputs. The timer accepts both 12VDC and 24VDC. To use the
12VDC, one must remove the protected terminal and switch with the 24 VDC terminal screw.
The protected terminal prevents against accidently hooking up 24VDC to the 12 VDC input.
Lube Injection Pump

The injector lube pump (CPN 57352973) is a positive displacement, pneumatically driven
device. The pump uses three inputs (air, oil, and electricity) to deliver oil (.375 in3/stroke) at
pressures up to 2000 psi. The pump has two distinct sections: pneumatic and hydraulic.
1. The pneumatic section uses the 12VDC input to energize a coil and shift the
plunger. Once shifted, up to 400 psi air is delivered into the piston chamber.
2. The hydraulic section moves the oil from the reservoir through the discharge
check valve/flow switch into the pressurized air line.
7-396
DRILLING SOLUTIONS
General Operation
1. The spring loaded plunger blocks the air inlet port when the coil is not charged.
This allows the piston, with help from its spring, to retract. The shifting of the
piston creates a vacuum on its hydraulic side thus drawing the cylinder full of
oil.
2. The timer charges the coil for one second with 12VDC. The charged coil
retracts the plunger, allowing air into the air piston chamber. The plunger also
covers the air discharge port opening. With the discharge port blocked, air
pressurizes the chamber.
3. As air pressurizes the piston chamber it moves the piston. This motion of the
piston forces oil back into the inlet until the piston covers the inlet. After the inlet
is blocked, the piston will force (.44 in3 of) oil out the discharge port, through
the 1 psi check valve, and into the flow switch.
4. The pump must use a 1 psi check valve downstream of the discharge port. This
allows oil to be drawn only from the reservoir during piston retract. The system
must also use a 1 psi check valve at the hard piping intake. These two check
valves keeps the discharge line primed.
Flow Switch
The flow switch (CPN 57353021) is a device that monitors the flow of rock drill oil into the
discharge line. The flow switch is connected to a light on the operators console. This enables
the operator to verify the lubrication of the DHD. The flow switch consists of a magnetic poppet
and a reed switch which monitors the poppets location.
General Operation
1. The poppet in the flow switch is normally in the closed position cutting off oil
flow from the pumps oil discharge outlet and the 1 psi check valve.
2. As oil is discharged from the pump it overcomes the check valve and spring
force on the poppet. The poppet is forced backwards and it is detected by the
reed switch which in turn closes and completes the indicator light circuit. When
the electric circuit is completed a light verifies that the poppet was displaced. If
this circuit is not completed then the operator knows the danger that can be
caused to the DHD. Additionally, when the poppet is displaced oil can then
travel out of the flow switchs discharge and into the lube line. After the pump
fully strokes the spring returns the poppet to its original starting position. This
is made possible by the cross porting holes in the housing which eliminates
vacuum behind the poppet.
DRILLING SOLUTIONS
7-397
Diagnostics
This section assumes the drill uses the latest lubrication injection system produced. The
system uses the higher output pump (CPN 57352973), timer unit with three-poled switch
(CPN57354342), flow switch (CPN57353021), indicator light (CPN57297137) and 60 or 7
gallon reservoirs. All diagnostics can be performed with:
1. Multimeter
2. 2000 psi pressure gauge
3. 400 psi relief valve (CPN 57359549)
4. Measuring cup
The sections below should be followed in a sequence, but a serviceman can start in any order
depending on the complaint.
There are three basic inputs needed to operate the injection lube system; oil, pressurized air
and electricity. This section describes each input and how to check to see if it is correct. Each
section also suggests repairs.
Oil
Oil Flow Into The Pump
1. The following chart provides recommended oil types for various temperature
ranges.
Table 7: Recommended Oil Type for Temperature Range

Less than 20F (-6.6C)
Medium grade rock drill oil, 450 SUS at 100F (37.8C)
20F to 90F (-6.6C to 32C)
Medium grade rock drill oil, 450 SUS at 100F (37.8C)
Above 90F (32C)
Heavy grade rock drill oil, 750 SUS at 100F (37.8C)
2. Check oil level in reservoir. Reservoir has a 1 inch stand on the oil outlet port.
3. Check oil flow into pump. Shut off oil flow into pump using shutoff valve.
Remove the flow switch and check valve. Open shutoff valve. Oil should flow
freely at a rate of 1 cup (8 ounces) per 15 minutes when the oil is at 50F
(10C).
4. If the oil doesnt flow:
a. Is the inlet piping plugged? (Back flush the inlet piping).
b. Is the correct viscosity oil being used? (Change out the oil).
c. Is the pump piston retracted, opening the inlet port?
7-398
DRILLING SOLUTIONS
5. The pump piston not being retracted may be a result of:

a. Broken piston return spring. (Replace the spring).
b. Grit in air piston chamber, causing piston to stick. (Clean and reseal the
pump).
c. Air valve leaking causing air pressure to displace piston. (Replace the
plunger and plunger spring).
d. Electronic timer holding system in the ON position. (Replace the timer
unit).
Adequate Electrical Power To Pump Coil

1. Is unit wired properly?
2. Are all connections secure? (Tighten or re-crimp connectors as required).
3. Is the timer properly wired? All blasthole or track mounted rigs use 24VDC,
while some truck mounted rigs use 12VDC. Verify proper voltage to timer. (Rewire as needed).
Note: 12VDC means 12 volts nominal and actual voltage is between 9VDC and
15VDC. Also 24VDC means 24 volts nominally and actual voltage may be
between 20VDC and 30VDC.
4. When the timer cycles 1 second ON, is 12VDC present at the coil? (Replace
timer if no output signal).
5. Can electrical current flow through the coil?
a. Check the coil resistance. With both wires disconnected, coil resistance
should be approximately 12 ohms. If not, replace the coil.
b. Check all connections for continuity.
Pressurized Air
Adequate Air Pressure
1. Tap into the air line and confirm that the lubrication pump line pressure is equal
to the console gauge.
2. Verify that air does not leak from the pump discharge port when unit is off or
during the off cycle when pump is operating. Air blow-by is a sign that the valve
plunger has failed and is needing to be replaced.
DRILLING SOLUTIONS
7-399
Output
With all the inputs verified and correct, the pump discharge can now be tested. Do this in steps;
at low back pressure and at full back pressure. Low back pressure just pumps oil across the
1 psi discharge check valve. High back pressure pumps oil across a 400 psi relief valve (CPN
5739549).
Low Back Pressure

Disconnect the discharge hose, at the flow switch, and pump oil into a measuring cup. The unit
should pump known volume in a given time. The Timer Setting - Pump Output table shown
below lists the pumped output for a given timer setting. During this test, count the number of
pump strokes. This confirms that the timer is cycling at the proper rate.
Table 8: Timer Setting - Pump Output

Timer Setting
Volume
Period
Cycles
2 pint (.95 liter)/hr
1 cup
15 minutes
38
3 pint (1.4 liter)/hr
1 cup
10 minutes
57
4 pint (1.89 liter)
1 cup
7.5 minutes
76
If the volume is low and the number of cycles is correct, the pump has leakage and should be
resealed or replaced. This is not likely, and if leakage occurs at this back pressure it should be
evident. If the volume is low and the number of cycles are low the timer has failed and should
be replaced.
High Back Pressure

Disconnect the discharge hose at the flow switch, remove the fitting from the flow switch
discharge port and install the 400 psi relief valve. While maintaining an inlet air pressure above
200 psi, measure the volume, cycles, and time. Then compare results to the Timer Setting Pump Output table.
Again, if the volume is low and the number of cycles correct, the pump has leakage. With the
high back pressure this is more likely. When the pump strokes, oil can go in three directions:
1. Out the discharge port. (This is the desired effect).
2. Out the intake port. (This occurs when the clearance between piston and barrel
increases. Change out the pump).
3. Out the breather. (This occurs when discharge seals wear. Re-seal the pump
(CPN 57307886).
If the volume is low and the number of cycles is low, change out the timer.
7-400
DRILLING SOLUTIONS
Output Detection
The DHD indicator light on the console is a light emitting diode (LED). This type of device has
a much longer life vs. incandescent type lamps. As described in the Operations Section, the
LED is wired to the flow switch, which is a device that monitors the flow of rock drill oil into the
discharge line. Fluid displaces the poppet and closes the switch, which energizes the LED.
Much like the pump, we must ensure the unit is wired correctly. And unlike the pump we must
ensure the unit is adjusted properly.
Indicator Light Wiring Circuit

1. Using the schematic, trace all wires. The indicator circuit gets its power from
the 12VDC out terminal on the timer unit.
2. Check for 12VDC at the 12 VDC out terminal on the timer unit, during ON cycle.
3. Check for voltage at the indicator light. If 12 volt is present at the LED, replace
it.
4. Check all connections.
5. Check for good ground to terminal (GND).
Flow Switch Adjustment

As discussed in the Flow Switch General Operation, the poppet/reed switch position is critical.
The poppet has a magnet embedded in itself. This magnet pulls the reed switch closed.
1. Close the inlet valve on the reservoir. Select the 2 pt./hr timer position (switch
up) and flip the ON/OFF switch to ON. With inlet closed no oil is pumped and
poppet is only slightly displaced. The console light should not illuminate. If it
does, turn the reed adjusting setscrew counter clockwise until the light stops
flashing.
DRILLING SOLUTIONS
7-401
2. Open the inlet valve. With the timer still on, oil should flow out of discharge line
and the light should start flashing during each pump cycle. If the light does not
come on, do the following:
a. Turn the reed adjusting setscrew clockwise until the light starts coming on.
b. If the light does not come on, repeat Step 1.
3. Connect a 400 psi relief valve, CPN5735949 or equal, to discharge line. Make
sure air pressure to pump is at or greater than 200 psi. Oil should flow across
relief and the light should come on during ON cycle. If the light does not come
on, do the following:
a. Turn the reed adjusting setscrew clockwise until the light starts coming on.
b. If the light does not come on, repeat Step 1.
4. As a check, block the discharge and verify the light does not illuminate.
DHD Lubricator Diagnostic Summary

Adequate Oil To The Pump
1. Correct oil/viscosity.
2. Reservoir level adequate.
3. Inlet piping clear.
4. Pump piston retracted, opening inlet port.
Adequate Electrical Power

1. Wired properly and connections secure.
2. Proper voltage to the timer unit at correct terminal.
3. 12VDC at 12VDC out terminal when timer is ON.
4. Coil resistance is 12 ohm.
Adequate Air Supply

1. Supply air is equal to console gauge.
2. Air is not leaking from pump air discharge port when timer is OFF.
Output
1. Against low back pressure, low output/proper cycles, reseal or replace pump.
2. Against low back pressure, low output/low cycles, replace timer.
7-402
DRILLING SOLUTIONS
3. Against 400 psi back pressure, low volume/proper cycles, re-seal or replace
pump.
4. Against 400 psi back pressure, low volume/low cycles, replace timer.
Flow Indicator Light Wiring

1. Wired properly and connections secure.
2. 12VDC at 12VDC out terminal of timer unit when cycled ON.
3. 12 VDC at indicator light during ON cycle.
Flow Switch Adjustment

1. Shut off oil inlet. Light should not come on. Turn setscrew CCW until light stops
flashing.
2. Open inlet valve. Light should flash with pump cycle. Turn setscrew CW until
light starts flashing.
DRILLING SOLUTIONS
7-403
7-21 Feed Cable Tension

Feed Cable Tension Adjustment
1. The upper tensioner relief valve is factory pre-set at 2300 psi. Adjustment of a
new or replacement part should not be required.
2. The sequence valve cartridge must be set at 500-psi inlet pressure while its
outlet is being directed to tank. Sequence valve is in port RSDC in the
manifold. To adjust:
A. Attach a 1000-psi gauge or transducer to the test fitting in the sequence
valve inlet.
B. Hold the upper tensioner solenoid valve open by supplying 24 VDC to the
valve coil or using the M7 maintenance screen to activate the solenoid.
C. Adjust the sequence valve until the gauge reads 500-550-psi.
D. Remove power from the valve coil and the upper tensioner cylinders will
retract and tension the upper cables.
3. Adjust the Pressure reducing valve for the upper cable-tensioning cylinder to
750-psi. To make this setting the fan speed must be set on high.
4. Cable Adjustment (machine running):
A. Fully retract the feed cylinders. Before proceeding, it is assumed the feed
cylinders have been stroked several times to purge all air from the feed
system. The next two steps can be made with the tower vertical or
horizontal.
B. Fully extend" the feed cylinders to move the power head to the bottom of
the tower until the head guides make contact with the lower stops. If the
head guides will not reach the stops, release the upper tensioning cylinders
so that contact can be made. Use the lower cable jackscrews to pull the
head guides to the stops. Reactivate the upper tensioning cylinders and
verify the head guides are not lifted up off of the stops. Move the power
head up and down the tower several times to verify the head guides will
return to contact the lower stops.
C. With the tower horizontal and the power head guides against the upper
stops, use the cab side (CS) cable tension jack screw to tension the CS
lower cable until the cable sag (measured at the midpoint of the longest
span) is 1.5 to 2.5 inches for the PV-275 or 2.0 to 3.0 inches for the PV271. Measurement is to be taken from the centerline of the front tower
tubing (i.e., chord) to the centerline of the cables.
D. Use the NCS jack screw to tension the NCS lower cable until the cable sag
measured at the lowest point of sag is the same as the CS lower cable. Both
cables must be adjusted for the identical amount of sag in order to have the
same cable preload.
7-404
DRILLING SOLUTIONS
E. With the requirement of identical sag met, the cable adjustment procedure
is complete.
Note: Pulldown cable sag: CS _____ inches: NCS ____ inches. PV-271 sag
2.0 to 3.0 inches maximum: PV-275 sag 1.5 to 2.5 inches maximum.
DRILLING SOLUTIONS
7-405
7-406
DRILLING SOLUTIONS
SECTION 8 - GLOSSARY
DRILLING SOLUTIONS
8-1
Section 8 - GLOSSARY
GLOSSARY OF TERMS
~A~
Actuator
A motor or cylinder that is being put into motion by the flow of a hydraulic pump.
Adapter-Adaptor (both spellings are accepted)
A device used to connect two different sizes or types of threads. It is used to connect
rotary head spindles to drill pipe, drill pipe to stabilizers and stabilizers to drill bits.
ANFO
Ammonium Nitrate Fuel Oil mixture: explosive most commonly used in blastholes.
Annulus
The space between the drill pipe and the outer diameter of the hole made by the bit.
Annunciator
An electrical signaling device on a switchboard.
API
American Petroleum Institute.
ASME
American Society of Mechanical Engineers.
ASTM
American Society of Testing Materials.
Auto Lube System
An air powered pump that provides grease to various components of the drill through
hoses. It can be manual or computer controlled.
Axle (Main Shaft)
The tube connecting the tracks of a Blasthole drill to the main frame.
~B~
Bank
Vertical surface of an elevation; also called face.
Beco Thread
A coarse type of thread used on drill pipe for blastholes.
Bench
Work area on top edge of an elevation. The work area for blasthole drills.
Bit, Auger
8-2
DRILLING SOLUTIONS
A type of bit used to drill soft formations. It usually has a series of flutes on the outside.
Bit, Claw
A wing-type bit that has multiple flukes. Sometimes called a Drag Bit.
Bit Breaker
A device installed in the centralizer table to hold a bit stationary while the drill pipe is
being removed from the bit by reversing the rotation. Also called Bit Basket.
Bit, DHD
A solid, one piece bit, with shaped tungsten carbide inserts in the face. Used in
percussion drilling.
Bit, Roller
Also called a Tricone bit. It usually has three conical rollers fitted with steel or tungsten
carbide teeth that rip the rock loose using down pressure.
Bits
Tools that pulverize formations so that material can be removed from the hole.
Generally 3-blade, 3-cone or percussion.
Blasthole
A drilled hole used for purposes of excavation rather than exploration, geological
information or water wells. Usually limited to 200 feet.
Blasting
The act of igniting explosives in a borehole to produce broken rock.
Blowdown
Term used when releasing compressed air from the receiver tank on a compressor
when the drill is stopped.
Blowdown Valve
The valve that opens when the drill is stopped and releases all the air pressure in the
receiver tank.
Bore
To make a hole in the ground with a drill.
Borehole
The hole made by a bit.
Box End
Fitting on the female end of a drill pipe. See Pin End.
Breakout
Refers to the act of loosening threaded pipe joints; and of unscrewing one section of
pipe from another, while coming out of the hole.
DRILLING SOLUTIONS
8-3
Breakout Wrench
A wrench, connected to a hydraulic cylinder, used to turn the upper piece of pipe while
the lower pipe is being held by the Fork Chuck or Sliding Wrench.
Bridge
An obstruction in the hole. Usually caused by a caving formation or something falling
in the hole.
Burden
Distance from the blasthole to the nearest face. Distance measured from face to a row
of holes.
Buttons
Short, rounded teeth of sintered tungsten carbide inserts which serve as teeth in drill
bits used for drilling very hard rock.
Butterfly Valve
The inlet valve of the air compressor.
Burden
Distance between a blasthole and the nearest free or open face; the material to be
displaced.
~C~
Cable
A strong, heavy steel, wire rope. Also known asWire Rope. Used for pulldown and
pullback in the derrick. Also used in hoisting. May be rotating or rotation resistant.
Cable Reel
A device that holds the electrical power cable on electric driven blasthole drills.
Carousel
A rotating device that holds extra drill pipe. It can be moved under the rotary head to
add and remove drill pipe from the string, or the rotary head moves over it.
Carbide, Tungsten
W2C. A very hard compound used in inserts in rock bits. It has a very high melting
point. It is very strong in one direction but very brittle in another.
Casing
Special pipe used to hold the overburden back in water wells. May be steel or plastic.
Casing, Drive Shoe
Coupling of forged steel to protect lower end of casing in overburden.
Cathead
Rotating drum used to spool hemp rope to pick up tools manually.
8-4
DRILLING SOLUTIONS
Catwalks
Walkways around a working area of a drill.
Cavitation
The pitting of a solid surface by the formation of low pressure bubbles formed in the
fluid. Air being allowed into the inlet of pumps.
Centralizer Bushing
A circular ring installed around the drill pipe in the drill table to keep the pipe aligned
properly with the rotary head. It usually has a replaceable insert in the center.
Chain Wrench
A special wrench, consisting of a chain section and a metal vee section, with jaws, that
grips the drill pipe and/or the DHD to tighten or loosen the connections.
Clinometer
A device for measuring the angle of the drill pipe with the ground. Also referred to as
an Inclinometer.
Collar the Hole
Opening at the top of the blasthole; the mouth where rock has been broken by blasting.
Usually the first few feet of the blasthole that are cracked and broken.
Compressor
An asymmetrical rotary screw driven device for compressing air. May be single or two
stages, depending on the discharge pressure.
Console
The panel that contains most of the drills controls. Also called the Operators Panel.
Conventional Mud
A drilling fluid containing essentially bentonite clay and water.
Conveyor
Equipment used to carry material to crushers and screens for reduction and
separation.
Cooler (HOC, COC)
Most drills have two coolers; one for the hydraulic fluid and the other for the
compressor oil. The engine radiator is sometimes referred to as an engine cooler.
Coring
The act of procuring a sample of the formation being drilled for geological information
purposes.
Coupling
A connector for drill rods, pipe or casing with identical threads, male or female, at each
end.
DRILLING SOLUTIONS
8-5
Cribbing
A set of wooden ties or metal plates used to add surface area to the jack pads to
prevent the pad from sinking into the ground. Also called blocking.
Crown Sheaves
The upper sheaves in a derrick that supports the cable that connects to the rotary
head.
Crosshead
The outer metal can surrounding the leveling jack cylinders. The crosshead slide is
the lower portion that connects to the bottom of the cylinders and the crosshead cap
is the flanged piece on top of the crosshead.
Crusher
Device used to reduce broken rock to a smaller fragment size.
Cut (verb)
Process of excavating material to lower the level of part of an elevation.
Cut (noun)
Part of an excavation of a specified depth an width.
Cuttings
Particles of formation obtained from the hole during drilling operations.
~D~
Decking
Process of alternating explosives with inert material in a blasthole to properly distribute
explosives or reduce vibrations. Also refers to the metal catwalks around the outside
of the drill.
Deephole
Rotary drills used to drill water wells, exploration holes and monitoring holes.
Delay Interval
Elapsed time between detonation of individual blastholes in a multiple hole blast.
Derrick
A tall framework over a drilled hole used to support drilling equipment. The part of the
drill that contains the feed system and the rotary head. See Tower and Mast.
DHD
Down Hole Drill. An air driven, piston powered device for drilling hard rock. It is also
called a Hammer.
DHD Bushings
The split bushings used to maintain alignment of the DHD while passing through the
8-6
DRILLING SOLUTIONS
drill table. See Split Bushings.

Differential Pressure
The difference in pressure between the inlet and outlet of a component, i.e., a cooler.
Dip
The angle between a horizontal plane and the plane of the ore vein, measured at right
angles to the Strike.
Diverter Valve
A two position, three way, valve that allows one hydraulic pump to perform two
separate functions.
Dressing a Bit
Sharpening DHD drill bits with a grinder to shape the carbides.
Drifter
An out-of-the-hole drill that rotates the drill rod and provides a percussive force, by
means of a striking bar, through the rod to the bit.
Drill
A machine for drilling rock, or unconsolidated formations. Also called a Rotary Drill.
The act of boring a hole in the ground.
Drill Collar
A heavy, thick-walled section of pipe used to add drilling weight to the bit and stabilize
the drill string.
Drill Rod
See Drill Pipe. Hollow, flush-jointed, coupled rods used on small percussion type rock
drills. Used with drifters mostly
Drill Pipe
Hollow tubing, specially welded to tool joints, used in drilling larger holes than drill rods.
Drill/Propel Valve
A switch that shifts the diverter valves to allow pump flow to go from drill functions to
propel motors.
Drill String
The string of pipe, including subs, stabilizers, collars and bit, extending from the bit to
the rotary head, that carries the air or mud down to the bit and provides rotation to the
bit.
Driller (Operator)
The employee directly in charge of a drill. Operation of the drill is their main duty.
Drill Table
The area at the bottom of the derrick that contains the centralizer bushing or master
bushing that the drill pipe travels through.
DRILLING SOLUTIONS
8-7
Dust Collector
A vacuum device with a hose attached to the dust hood that pulls cuttings away from
the hole and deposits them to the side of the drill.
~F~
Face
Vertical surface on an elevation. Also called bank.
Feed Cable
Cables, anchored on the top and the bottom of the derrick, that pass through the
traveling sheave block and connect to the top and bottom of the rotary head. They are
adjusted by tightening the threaded rods on each end.
Feed Chain
Heavy duty chain links connected to the rotary head through upper and lower
sprockets and the traveling sheave block. They are adjusted similar to cable.
Fill
Process of moving material into a depression to raise its level; often follows the cut
process.
Fish
An object accidentally lost in the hole.
Fishing
Operations on the drill for the purpose of retrieving the fish from the hole.
Fishing Magnet
Run in the hole on non-metallic line, to pick up any small pieces of metal.
Fishing Tools
Tools of various kinds run in the hole to assist in retrieving a fish from the hole.
Overshots fit over the pipe while Taps fit inside the pipe.
Flats
Machined areas on the side of drill pipe or other components where wrenches can be
installed to hold or break the joints. Some pipe has two flats, others have four flats.
Floor
Level area at the base of a bank or face.
Fork Chuck
The hand held or flop-down wrench used to hold the top of the pipe in the Drill Table
while adding or removing other pipe.
8-8
DRILLING SOLUTIONS
~G~
Grouting
To fill the hole or annulus with grout, i.e., cement and water.
~H~
Hammer
A different name for a Down Hole Drill.
Hammer Bushing
Split bushings installed in the drill table to allow the DHD to start the hole in a straight
line. It is removed once the DHD is below the table. Also called DHD Bushings.
Haul Distance
Distance material has to be moved, such as from a cut to a fill.
Hauling Equipment
Trucks and other conveyances for moving material. Also called Haul Trucks.
Hazard
Any condition of the drilling equipment or the environment that might tend to cause
accidents or fire.
Hoist
Windlass used to pick up drill pipe and other heavy objects. See Winch.
Hoist Plug
A lifting device installed in the box end of a tool. Opposite of Lifting Bail.
Hole
A bore made by rotating a bit into the ground.
Hole Openers
Large bit with pilot used to increase the diameter of a hole.
Hose, Drilling
Connects rotary head to top of hard piping to allow movement of rotary head. Also
called Standpipe Hose.
Hose, Suction
Attaches to mud pump inlet with other end submerged in mud pit.
Hydraulic Cylinders
Double acting cylinders that are extended and retracted to perform various functions
on a drill. They are powered by hydraulic fluid from a pump.
DRILLING SOLUTIONS
8-9
Hydraulic Motors
Piston or vane type motors, driven by hydraulic pumps, that rotate various devices on
a drill.
Hydraulic Pumps
Piston, vane and gear type hydraulic pumps that provide flow for the various actuators
on the drill.
Hydrostatic Head
The pressure exerted by a column of fluid, usually expressed in pounds per square
inch.
~I~
Inclinometer
An instrument for measuring the angle to the horizontal or vertical of a drill hole or vein.
I.W.R.C.
Abbreviation for Independent Wire Rope Center. This refers to type of construction of
wire rope. This wire rope center is in effect a separate wire rope in itself that provides
a core for the line and prevents it from crushing.
Interstage Pressure
The air pressure present between stages of a two-stage compressor while the
compressor is making air.
~J~
J Wrench
Specially shaped wrench to fit the backhead of a DHD. Used to hold DHD in the table
or to remove the backhead from the wear sleeve.
~K~
Kelly Bar
A fluted or square drill pipe that is turned by a rotary table using a set of pins.
~L~
Leveling Jacks
Hydraulic cylinders mounted in a crosshead that raise and lower the drill.
Also referred to as Outriggers or Stabilizers.
Lifting Bail
A threaded cap for picking up pipe, bits, DHDs and stabilizers. It screws on the pin end.
Some bails have a swivel hook while others have solid tops. See Hoist Plug.
8-10
DRILLING SOLUTIONS
Loaders
Large, front end bucket equipment used to pick up material for loading in various types
of hauling equipment.
~M~
Main Frame
The welded component of a track mounted drill. The truck frame on a wheeled drill.
Makeup
The act of tightening threaded joints. Making a connection.
Making Hole
The act of drilling.
Making Up a Joint
The act of screwing a joint of pipe into another joint or section of pipe.
Manifold
A pipe or chamber that has several openings for hose connections.
Mast
A vertical pole. See Derrick.
Micron -:- Mu
A unit of length equal to one millionth part of a meter, or one thousandth part of a
millimeter. About 4/100,000th inch.
Mid-Inlet Swivel
Device for removing cuttings from the hole while drilling with Reverse Circulation
Equipment.
Mine Plan
Plan for making cuts and creating elevations, benches for efficient removal of material.
The mine plan considers a variety of factors, including: the type and location of
material, the size and number of shovels, loaders, and hauling equipment, haul
distances, blasthole patterns, etc.
Mist Drilling
A method of rotary drilling where water is dispersed in the air as the drilling fluid.
Mud
A water or oil -base drilling fluid whose properties have been altered by solids. Mud is
a term commonly given to drilling fluids. It is used in place of air when drilling
unconsolidated formations.
Mud Drilling
Using a bentonite clay and water as the drilling fluid.
DRILLING SOLUTIONS
8-11
Mud Pit
A hole dug in the ground or a steel pit to hold the drilling mud as it is being circulated
in the hole.
Mud Pump
Pumps that are used to circulate the drilling mud.
~O~
Oscillation Yoke
The beam connecting each track of a blasthole track drill with the main frame that
allows the tracks to move independently up and down.
Open Hole
Any uncased portion of a hole.
Operator
The person who performs the drilling operation with the drill. See Driller.
Overburden
Any unconsolidated material lying on top of the bedrock or the coal seam.
~P~
Parasitic Load
The load imposed on the engine by the direct connection of the compressor and main
pump drive during starting.
Pattern
Layout and distances between blastholes, specifically including burden and spacing.
Penetration Rate
Speed at which a bit advances while drilling, measured in feet per hour.
Percussion Drill
Drill that chips and penetrates rock with repeated blows.
Pin End
Fitting on male end of drill pipe. See Box End.
Pioneer Work
Drilling in rough, broken or inclined areas. Removing the original layers of dirt and
rock.
Pipe Dope
Special lubricant used to protect the threads on pipe joints. See Thread Lube.
8-12
DRILLING SOLUTIONS
Pipe Support
A device that holds the lower section of pipe in place while connecting to the next joint
with the rotary head when angle drilling. Also called Rod Support.
Pit
An excavation in the ground for the removal of mineral deposits.
PLC
Programmable Logic Controller. A device that monitors many aspects of a drills
operation.
Potable Water
Water that is safe to drink.
Powder Factor/Specific Charge
Relationship between the weight of explosives in a blasthole and the volume of
materials to be displaced. It is measured in pounds per cubic yard or kilograms per
cubic meter.
Power Pack Base
The welded channel frame that contains the prime mover, the compressor and the
hydraulic pumps and gearbox.
Power Pack
he complete sub-assembly of base, engine, compressor, and hydraulic drive.
Presplitting
Process of drilling a line of small diameter holes spaced relatively close together,
generally before drilling a production blast and loaded with light explosive charges to
create a clean, unbroken rock face.
Production Rate
Penetration during a given reporting period. This rate includes all lost time, including
maintenance, breakdowns, long moves, inclement weather, etc.
Propel
To cause to move forward or onward. To drive or tram.
Protectors, Thread
Steel or plastic covers to cover the box and pin ends of drill pipe when they are not
being used.
Pump, Water Injection
Pump used to pump water into the drill air stream to keep the dust settled and to assist
in flushing the hole.
Pullback
The force available to remove the drill string from the hole.
DRILLING SOLUTIONS
8-13
Pulldown
Force exerted on the drill bit by the thrust of the drill rig and from the weight of the drill
string.
~R~
Raise
A mine opening, like a shaft, driven upward from the back of a level to a level above,
or to the surface.
Rate Of Penetration
The rate in which the drill proceeds in the deepening of the hole. It is usually expressed
in feet per hour.
Reamer
Bit-like tool, generally run directly above the bit to enlarge and maintain a straight hole.
Reservoir
The tank used for storing the hydraulic oil used in the hydraulic system.
Reverse Circulation Drilling
Using a double wall pipe to force air/water down the hole and removing the cuttings
between the two pipes. See Mid-Inlet Swivel.
Rod Changer
See Carousel. A device that holds extra drill rod (pipe).
Rotary Drilling
The method of drilling that depends on the rotation of a column of pipe to the bottom
of which is attached a bit. Air or fluid is circulated to remove the cuttings.
Rotary Head
A movable gearbox used to provide rotation to the drill string. It is connected to the
feed chains or cables on each end and to the drill string through the spindle.
~S~
Safety Hook
Attached to end of hoist line to secure hoist plug or lifting bail. Has a safety latch to
prevent load from slipping off hook.
Scales
Equipment used to determine the weight and value of material being transported from
a quarry.
Screens
Devices used to separate broken material into groups of similar size.
8-14
DRILLING SOLUTIONS
Shock Sub
A device used to isolate the shock of drilling from the rotary head. It is made of hard
rubber layers mounted inside of steel outer rings.
Shooting
Exploding high explosives in a hole to shatter the rock. See Blasting.
Single Pass Drill
Drill rig with a long tower that permits drilling a blasthole without stopping to add drill
pipe (rod). Uses a Kelly in place of regular pipe. Uses a rotary table to turn the Kelly
instead of a rotary head.
Stemming
Material of a specified depth added on top of a powder column to confine the blasthole
and make the explosion more efficient.
Strip Mine
A large section of land used to remove coal deposits.
Shot
A charge of high explosives deposited in a series of holes to shatter the rock
Shutdown
A term that can mean the end of the shift or workday or an unplanned stopping of the
drill due to a system failure.
Sliding Fork
A wrench that slides around the flats of the drill pipe to hold lower section. Controlled
by hydraulic cylinder(s). Used in place of Fork Chuck.
Slips
Used in the rotary table to hold and break out drill pipe. Also used to hold casing in the
table.
Spacing
Distance between blastholes measured parallel with the face.
Spear
Tools of various design that are screwed or wedged inside of bits, pipe, etc., that are
lodged in the hole. See Fishing Tools.
Spindle
The short section of pipe that rotates within the rotary head and protrudes out each
end.
Speed Switch
An electronic device that changes states when the engine reaches a certain speed.
Used to control dual oil pressure switches.
DRILLING SOLUTIONS
8-15
Split Bushings
The removable bushings that allow the DHD or Stabilizer to pass through the drill table
while drilling a straight hole. See DHD Bushings.
Stabilizer, Drill Pipe
Heavy -walled pipe having special spiral or fluted ribs extending around the diameter,
within 1/8 to 1/4 of hole size. Most stabilizers are fitted just above the bit, while in-line
stabilizers keep the hole straight.
Standpipe
Part of the circulating system. The hard and flexible piping from the main valve to the
flexible hosing leading to the rotary head. Water injection, DHD oil and foam are
injected into this line.
Static Water Level
The distance from the top of ground down to the standing water level.
Strike
The bearing of the outcrop of an inclined bed or structure on a level surface. See Dip.
Stuck In The Hole
Refers to drill pipe inadvertently becoming fastened in the hole.
Subdrilling
Bottom portion of a blasthole drilled below the floor level to permit upward
displacement of material and thereby prevent a toe at the bottom of a face.
Substitute (Sub)
A coupling with different type or diameter of threads at either end. The term pin
denotes a male thread, and box, a female thread. To connect two components with
different threads. See Adapter.
Supercharge Pressure
Inlet oil pressure to the main pump(s) that has been pressurized to prevent cavitation.
Swivel
A coupling on top of the rotary head to allow the spindle to rotate while the main hose
remains stationary.
~T~
Table Drive
Drill design that locates the drill pipe rotation mechanism on the drill deck in a
stationary position instead of using the rotary head.
Threaded and Coupled Casing (T&C)
Steel casing using a coupling between each section of pipe. Thread style is right hand,
fine thread.
8-16
DRILLING SOLUTIONS
Thread Lube
A special compound used to lubricate the threads of drill pipe. See Pipe Dope.
Tongs
A type of wrench used to make up and break out drill pipe using external forces, such
as hydraulic cylinders or cables.
Tool Joint
A drill pipe coupler consisting of a pin and box of various designs and sizes. Deephole
drills normally use API style threads, while Blasthole drills use Beco style threads.
Top Head Drill
Drill design that locates the drill pipe rotation head in the drill tower and it moves up
and down with the drill string. See Rotary Head.
Torque
A turning or twisting force. A moment caused by force acting on an arm. A one pound
force acting on a one foot arm would produce one lb-ft of torque.
Tower
A tall, slender structure used for observation, signaling or pumping. See Derrick and
Mast. Term used to indicate the derrick on a blasthole drill.
Turning To The Right
Slang term for making hole.
Tram
A cable car or a four-wheeled open box in a coal mine. See Propel.
Trammed
To move in a tram.
Tramming
Process of moving a drill with the tower up from a completed blasthole to the location
of the next. See propelling
Traveling Sheave Block
A series of sheaves, connected to the feed chains or cables, that are moved up and
down the derrick by the feed cylinders.
Twist Off
To twist a joint of pipe in two by excessive torque applied by the rotary head or rotary
table.
~U~
UL88
The unloader valve that controls pressure and volume on a high-pressure compressor
DRILLING SOLUTIONS
8-17
system.
Undercarriage
The means of moving a track type vehicle. It contains the track frame, rollers,
grousers, rock guards, drive sprocket, propel motors and planetary drive.
Uphole Velocity
The speed (in feet per minute) that the cuttings travel out of the hole.
This is dependent on the bit size, the compressor size and the pipe size.
~W~
Washpipe
Hard surfaced steel tubes inserted in swivels to allow rotation of drill string and prolong
life of packing. They are replaceable in most swivels.
Water Table
The underground level at which water is found. See Static Level.
Water Well
A hole drilled for the purpose of obtaining potable water.
Weight On Bit
In rotary drilling, a specified weight is required on the bit for maximum performance. A
gauge on the console is calibrated to correspond to the drill string weight.
Whipstock
A device inserted in the well used for deflecting or directional drilling.
Wiggins Quick Fill
A Centralized Service Station that connects to various systems on the drill to allow
remote filling of engine oil, compressor oil and hydraulic oil.
Winch
A stationary hoisting machine having a drum around which is wound a rope.
Wiper, Pipe
An annular rubber disk for wiping drill pipe clean of cuttings when it is being withdrawn
from the hole.
Wire Rope
Rope made of twisted strands of steel wire. Also called Cable.
8-18
DRILLING SOLUTIONS
8.2 - Manual Revisions

Table 1: Lastest Revision PV-270 Manual
REV.
NO.#
REVISED BY
000
DATE
REVISION
10/2008
001
James Oney
10/2009
Up-dated Complete Manual
002
James Oney
09/2010
Added Feed Cable Tension

Adjustment
DRILLING SOLUTIONS
8-19
8-20
DRILLING SOLUTIONS
SECTION 11 - ENGINE OIL

ADDENDUM
DRILLING SOLUTIONS
11-1
Instruction Manual
Section 11 Engine Oil Addendum
ENGINE OIL UPDATE
NOTICE
Lube oil information shown in the Instruction Manual may be out of date.
Refer to the Engine OEM Operation and Maintenance Manual for current
Engine Lubricating Oil Specifications, or See:
CATERPILLAR ENGINE
Refer to Special Publication SEBU6251, Caterpillar Commercial Diesel Engine Fluids
Recommendations For Additional Information that relates to Lubrications.
CUMMINS ENGINE
For further details and an explanation of Engine Lubricating Oils for Cummins Engines, Refer
to Cummins Engine oil Recommendations, Bulletin 3810340.
11-2
DRILLING SOLUTIONS
We are committed to your

superior productivity through
interaction and innovation.
Atlas Copco Drilling Solutions, LLC

A Company Within the Atlas Copco Group
P.O. Box 462288, 2100 North First Street
Garland, Texas 75040 USA
www.atlascopco.com/drillingsolutions

PV270-D Series OP M English 9-28-10

Uploaded by

Copyright:

Available Formats

PV270-D Series OP M English 9-28-10

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PV270-D Series OP M English 9-28-10

Uploaded by

Copyright:

Available Formats

ATLAS COPCO

Atlas Copco Drilling Solutions, LLC

Read the instruction manual before operating this equipment.

SECTION 1 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION 2 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 - SAFETY PRECAUTIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3 - SAFETY DECALS & NAMEPLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.4 - HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2.5 - SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

SECTION 3 - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

SECTION 4 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

SECTION 5 - OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SECTION 6 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-3 REFILL CAPACITIES/LUBRICANTS/FUEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-4 MAINTENANCE AS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

6-5 MAINTENANCE (8-10 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

6-6 MAINTENANCE (50 Hours or Weekly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

6-7 MAINTENANCE (100 - 150 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94

6-8 MAINTENANCE (250 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100

6-9 MAINTENANCE (500 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121

6-10 MAINTENANCE (1000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138

6-11 MAINTENANCE (1500-2000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149

6-12 - MAINTENANCE (3000 HOURS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-156

6-13 - MAINTENANCE (6000 HOURS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-158

6-14 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-163

SECTION 7 - TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-3 TROUBLESHOOTING (OPERATOR OBSERVED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

7-4.1 LOW PRESSURE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

7-4.2 LOW PRESSURE COMPRESSOR WITH EARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71

7-5.1 HIGH PRESSURE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115

7-5.2 HIGH PRESSURE COMPRESSOR WITH EARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145

7-6 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-189

7-7 HYDRAULIC SYMBOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-190

7-8 PROPEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-204

7-9 FEED & ROTATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-217

7.10 - AUXILIARY FUNCTION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-235

7.11 - ELECTRO HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-264

7.12 - EHC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-278

7.13 - EHC ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-287

7.14 - TROUBLESHOOTING (DUST COLLECTOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-292

7.15 - TROUBLESHOOTING (CENTROMATIC LUBE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-296

7.16 - ENGINE HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-301

7-17 DIXON Boss Clamp Selection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-351

7-19 WATER INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-375

7-20 DHD LUBRICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-396

7-21 Feed Cable Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-404

SECTION 8 - GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

SECTION 11 - ENGINE OIL ADDENDUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Rev 002 Last Revision 09/2010

PV-270 Series Instruction Manual

Rev 002 Last Revision 09/2010

PV-270 Series Instruction Manual

How this manual is organized

Where to find information

Rev 002 Last Revision 09/2010

PV-270 Series Instruction Manual

DANGER is used to indicate the presence of a hazard which will cause