Pv-270e Instruction Manual July 2015 PDF

Atlas Copco Drilling Solutions
Instruction Manual Original Instructions

MODEL: PV-270 Electric Series RCS4
July 2015
This page is intentionally blank
PV-270D RCS4 Instruction Manual
Manual Revisions
Table 1: Latest Revision PV-270E RCS4 Series Manual
DATE REVISION
January 2013 New Release
May 2013 Added Special Options to Section 5, hydraulic bit basket.
Added another lubricant name for cleaning wire rope and
cables in Section 6.
June 2014 Reformatted layout and added outstanding TDCRs
October 2014 Removed duplicated information and incorporated
outstanding TDCRs.
July 2015 Updated book incorporated outstanding TDCRs.
Customer Acknowledgment
• Use only Atlas Copco original parts. Damage or breakdown caused by non-original
spare parts will not be covered by the warranty or product liability.
• Atlas Copco will not be held responsible for any damage caused by unauthorized
modification of the drill and its associated equipment.
• Overloading the drill could result in damage to the machinery which is not noticed
during normal usage. Such damage is not covered by warranty.
• The manufacturer is not liable for damage caused by inappropriate use.
• Damage that occurs as a result of substandard repairs, as well as injury to personnel
or damage to equipment that is attributable to older un-repaired damage, is not
covered by the customer warranty policy.
• Always refer to the customer warranty policy.
• 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 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 is constantly striving for product improvements and enhancements.
Accordingly, Atlas Copco 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.
DRILLING SOLUTIONS
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-270E RCS4
TITLE PAGE
Manual Revisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Customer Acknowledgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SECTION 1 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Manual Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Receiving the Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Identification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Drill Information Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Designated Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Non-Designated Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Drill Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Identification of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Rotary Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Drill Rod Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Drill Rod Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Carousel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Cooling Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Water Injection System Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Dust Decking Misting System Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Undercarriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Leveling Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Propelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Night Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
SECTION 2 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Warnings and Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Propel Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Before Starting the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electric Motor Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
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TABLE OF CONTENTS
PV-270E RCS4
TITLE PAGE
Electric Motor Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Equipment Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SECTION 3 - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drill Information Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Environment Rate Factor Ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Application Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operational Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Ambient Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Maximum Allowable Slope Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Operating Conditions For Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Noise Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sound Pressure Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Vibration Risk Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Vibration Exposure Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
PV-271E Stability and Gradeability Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
PV-271E Pitch and Roll Inclinometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
PV-275E Stability and Gradeability Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
PV-275E Pitch and Roll Inclinometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Visibility Limitation Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Standard Tools and Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
PV-270E Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
SECTION 4 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Rig Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
GUI Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
System Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Drill Work Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Park Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Drill Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Propel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
RCS Control Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Operator Input Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
RCS Left Control Panel Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Left Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
RCS Right Control Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
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TABLE OF CONTENTS
PV-270E RCS4
TITLE PAGE
Right Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
RCS Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Jack Auto Level Override Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
RCS Operator Dash Switches and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
RCS Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
USB Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Radio Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Fault Finding Using the RCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Active Faults and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Emergency Stop Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Remote Hoist Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Optional Fire Suppression Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
SECTION 5 - OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Walk Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Compressor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
General Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Operator Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Pre-Operational Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Smart Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Rig Control System (RCS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Operator Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Operator Menus on RCS4 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
F1 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
F2 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
F3 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
F4 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
RCS4 Screen Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
System Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Logging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Drilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Control Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Starting The Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Activating the RCS Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Operating Modes or States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
RCS Drill Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Propel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Leveling Procedure (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Auto Level Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
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TABLE OF CONTENTS
PV-270E RCS4
TITLE PAGE
Tower Raising and Pinning (Vertical Drill) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Lower Tower/Unpinning (Vertical Drill) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Tower Lower/Raise and Pinning (Angle Drill Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Dust Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Hoist Load/Speed Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
Drill Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
RCS Drill Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Air Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
RCS Rotary Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Rotary Drill String Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Starter Rod / Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Tricone Bit Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
RCS Rotary Drilling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Changing Rotary Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
RCS Rod Changing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
RCS Drill Leveling Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Drill Rod Loading on a PV-271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Equipment Needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Loading Drill Rod From the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Removing Worn or Damaged Drill Rod on a PV-271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
Drill Rod Loading on a PV-275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
Equipment Needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
Loading Drill Rod From the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
Removing Worn or Damaged Drill Rod From a PV-275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
RCS Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
Shutdown the Electric Drill During Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
Shutdown Electric Drill During Emergency Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
Special Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Cold Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Hot Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Water and Muddy Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
High Altitude Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Inclement Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Preservation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Rod Support Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
Towing the Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
Remote Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
Drill Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
Carousel Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-125
Overpressure Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-125
Overpressure System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126
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TABLE OF CONTENTS
PV-270E RCS4
TITLE PAGE
SECTION 6 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Lockout and Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Service Condition Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Electric Motor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Maintenance Schedule Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Refill Capacities/Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Atlas Copco Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
AC Hydraulic 180 Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Compressor Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Rotary Head Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Pump Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Winch Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Final Drive Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Normal Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Arctic Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Water Injection Pump Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Grease System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Normal Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Arctic Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Standard Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Recommended Torques in Foot-Pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Recommended Torques in Newton-Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Maintenance As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Service As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Overpressure Control System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Overpressure Control System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Air Cleaner Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Connections and Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Empty Dust Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Air Cleaner Pre-Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Air Cleaner Rain Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Air Cleaner Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Air Cleaner Service Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Cooling System (HOC and COC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Cleaning Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Check for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Compressor Air Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Proheat (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Loose Bolted Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Dropout Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
toc - v
TABLE OF CONTENTS
PV-270E RCS4
TITLE PAGE
Suction Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Rod Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Main Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Feed Cable and Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Cable Tensioning Procedure (PV-271 and PV-275). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Replacement Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Feed Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Track Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Lubrication and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Reinstalling Compressor Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Installing Compressor Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Checking Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Changing Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Compressor Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Feed Cable and Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Cable/Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Hydraulic Tank Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Hydraulic Oil Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Hydraulic Fluid Condition Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Draining Hydraulic Reservoir With Central Drain Point System . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Filling Hydraulic Tank With Quick-Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Draining Hydraulic Reservoir Without Central Drain Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Refilling Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Pump Drive Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Oil Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Changing Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Rotary Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Checking Rotary Head Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Changing Rotary Head Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Rotary Head Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Gearbox Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Greasing Gearbox Drive Shaft Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Initial Break-In Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Final Drive Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Checking Oil Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Changing Initial Track Planetary Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Grease Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
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PV-270E RCS4
TITLE PAGE
Filling Grease Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
John Bean Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Dynaset Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Cab Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Change the Pressurizer Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Air Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Main Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Changing Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Automatic Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Tensioner Motor and Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Grease Tank Electric Pump (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Checking Electric Pump Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Changing Electric Pump Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Replace the NDE Tank Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
SECTION 7 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Compressor With EARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Electronic Air Regulation System (EARS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Proportional Butterfly Valve and Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Proportional Vent Valve and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Electronic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Air Regulation ON/OFF Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Air Flow Increase Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Air Flow Decrease Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Hardware Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Interconnect System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Flow Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Maximum Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Emergency Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Compressor Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Electronic Air/Fan Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
EAR-EFR Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Standard Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Error Code Meanings and Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Blown Fuse Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Actuator Diagnostics Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Potentiometer Testing Using a Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Voltage Output Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
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PV-270E RCS4
TITLE PAGE
Summed On/Off Inputs Decode Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Propel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Propel Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Main Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Propel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Motor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Diverter Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Drill/Propel Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Hot Oil Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Loop Filling/Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Loop Flushing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Oil Path Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Drill Feed and Rotation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Drill Feed Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Feed Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Feed Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Feed System Control Valve (Holding Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Overcenter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Jack Two-Way Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Overpressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Cylinder Extend and Retract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Loop Filling/Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Rotation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Rotation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Rotation Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Rotation Motor Displacement Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Rotation Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Motor Displacement Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Oil Path Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Loop Filling / Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Auxiliary Functions System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Triple Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
P1 and P3 Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
P2 Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Two-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
Pilot Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
Sequence Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
7-Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
11-Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Cooling Circuit/Cable Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Cooling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
toc - viii
TABLE OF CONTENTS
PV-270E RCS4
TITLE PAGE
Manifold System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Return Drain Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Supercharge Suction Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Pressure Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Diverter Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Manifold Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Feed System Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
7-Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
11-Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Cooling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Clamp and Coupling Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Dixon Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Victaulic Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
IC Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Down-Hole-Drill Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Lube Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Oil Flow into the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Adequate Electrical Power To Pump Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Pressurized Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Adequate Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Low Back Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
High Back Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Output Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Indicator Light Wiring Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Flow Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
DHD Lubricator Diagnostic Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Adequate Oil to the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Adequate Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Adequate Air Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Flow Indicator Light Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Flow Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Bean (FMC) Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Centro-Matic Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Lube Injector System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
SL-1 Injectors (Single and Manifold Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
toc - ix
TABLE OF CONTENTS
PV-270E RCS4
TITLE PAGE
SECTION 8 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Power Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Transformer and Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
WEG Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Electrical Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Technical Features of Enclosed Transformer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Safety Features of Enclosed Transformer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Preventative Maintenance of Enclosed Transformer Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Oil Immersed (Atlas Copco Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Preventative Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Oil Testing for Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Evaluation of Transformer Oil Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Dielectric Strength (ASTM D-877) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Neutralization Number (ASTM D-974) (Acidity Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Interfacial Tension (ASTM D-971) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Water Content (ASTM D-1533) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Electrical Starter Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Electrical Starter Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Starter Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Starter Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Electrical Soft Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
369 Motor Management Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
toc - x
Section 1 - Introduction
DRILLING SOLUTIONS July 2015 1-1

PV-270E RCS4 Instruction Manual Section 1 - Introduction
1.1 Overview
This Instruction Manual has been developed to present the safety, operations and preventive
maintenance requirements for safe, effective operation of the Atlas Copco Pit Viper 270
Electric (PV-270E) RCS4 series blasthole drills.
This manual provides the operator and site maintenance personnel with the fundamental rules
and criteria to be followed for on-site use and maintenance of a PV-270E RCS4 series
blasthole drill rig.
Figure 1-1: PV-271E
1-2 July 2015 DRILLING SOLUTIONS

Section 1 - Introduction PV-270E RCS4 Instruction Manual
The operator and site maintenance personnel must read and fully understand this Instruction
manual before operating or servicing the drill. This manual has been organized to present the
safety precautions, operation requirements and appropriate information needed to:
• Safely operate the PV-270E series drills while achieving optimum production.
• Understand the operating principal of the PV-270E series drills.
• React effectively and safely to emergency and alarm conditions.
• 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.
Manual Organization
The information contained in this manual has been organized so the reader can easily find the
specific information needed.
This manual is divided into the following sections:
• Section 1 - General Description
• Section 2 - Safety
• Section 3 - Specifications
• Section 4 - Controls
• Section 5 - Operation
• Section 6 - Maintenance
• Section 7 - Troubleshooting
• Section 8 - Electrical
• Glossary
If any part of this manual cannot be understood, contact your supervisor or local Atlas Copco
customer center. This is essential for working safely with the drill. The correct drill operation,
use, and maintenance are also essential to provide the highest performance and safety.
NOTE: This manual is accompanied with an electric motor instruction

manual. Perform the operation and maintenance instructions as specified
in both the electric motor and drill instruction manuals.
References
The following are referenced throughout this manual.
• WEG Installation and Maintenance Manual
• Caterpillar Industrial Products Owner’s Manual (tracks)
• Lincoln Flowmaster™ 24 VDC Rotary Driven Electric Pump, Series A manual
• Lincoln Centro-Matic® Pump and Injector SL-1 Operating and Service Instructions

• FMC Technologies Operation and Maintenance Manual, A04/I04 Pump Assemblies
Manual Location
The instruction manuals are located within easy reach of the operator in the storage
compartment in the cab. Also located in the cab, is the laminated safety manual and container
attached to the outside of the storage compartment (Figure 1-2).
Figure 1-2: Manual Location
1 Safety manual and container

2 Storage compartments under
seats
Receiving the Drill

The equipment 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 receiving the drill, and before unpacking the equipment, check for damage during
transport and for missing parts.
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.
The agent will provide the information required to make a complaint.
Identification Data
An exact description of the model type and the serial number of the drill will facilitate fast and
efficient response from our parts and service support operations.
Always provide the model of the drill and the serial number when contacting the local Drilling
Solutions service or parts office.

Figure 1-3: Drill Identification
1 Standard drill identification plate

2 European Community (CE) identification plate
Figure 1-4: Electric Motor Identification
1 WEG electric motor

2 Motor data plate
The electric motor data plate, as shown above, provides the model identification and other
important information. Have the following information available when contacting an authorized
repair location. The following information is required when sourcing service parts:
• Drill Serial Number and Model Type
• Motor Manufacturer
• Motor Serial Number (MSN)
• Volts

• Hertz
• Horse Power
Drill Information Record

Please enter the drill data on this drill information sheet for future reference.
Model:____________________________________________________________________
Drill Serial Number:__________________________________________________________
Year of Manufacture:_________________________________________________________
Electric Motor (Mfg./Type):____________________________________________________
Electric Motor Serial Number:__________________________________________________
Drill Gross Weight (lb or kg)____________________________________________________
Max. Pulldown Force (lbf or kn) _________________________________________________
Max. Pullback Force (lbf or kn) _________________________________________________
Max. Bit Rotation (rpm) _______________________________________________________
Max. Bit Diameter (inch or mm) _________________________________________________
Main Hoist Load (lb or kg) _____________________________________________________
Aux Hoist Load (lb or kg) ______________________________________________________
Max. Operating Air Pressure (psi or kPa) _________________________________________
General Information
All safety rules must be obeyed.
If further information is required concerning recommended blasthole drilling applications,
contact the local Atlas Copco customer center.
Atlas Copco 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.

Designated Applications
! WARNING
Set up the drill on a level and firm 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.
The PV-270E is built in accordance with recognized safety standards. Misuse may constitute
a safety risk to the user or third parties, and may cause damage to the drill or other material
property.
The equipment must be used in accordance with its designated. The equipment must only be
operated by safety conscious persons who are fully trained to operate the drill. Any functional
disorders, especially those affecting the safety of the drill, must be corrected immediately.
Non-Designated Applications
The equipment is not designed for pioneering or earth moving applications. The equipment is
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.
Drill Description
The PV-270E series includes the PV-271E and the PV-275E blasthole drills. These are
crawler mounted, hydraulic rotary head drive rigs designed specifically for blasthole drilling.
They are intended to by used in mining applications on prepared benches that are flat and firm.
Both drills are available with and angle drill option.
Both the PV-271E and PV-275E drills include the following features:
• They are designed for heavy duty drilling, providing a pulldown force of up to 70,000
pounds (311 kN).
• They have a 181 hp two-stage spur gear rotary head which provides a maximum
8,700 foot-pounds (11,796 Nm) of torque. The use of variable displacement pump
and motors allows the operator a selection of rotation speeds between 0 and 150 rpm
at variable torque values.
• They use 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.

• They use an electric motor connected directly to a three-hole hydraulic pump drive
gearbox on one end and the air compressor directly connected to the other end. The
pump drive gearbox, electric motor, 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.
• Drilling functions are hydraulically powered. Compressed air is used to clean the
hole. The systems that support the drilling and propelling functions of the drill are
controlled by the Rig Control System (RCS).
• They can be equipped for either rotary or down-the-hole (DTH) drilling. Both drills are
designed to handle 6-1/4 inch (159 mm) up to 8-5/8 inch (219 mm) drill rods and drill
hole sizes from 6-3/4 to 10-5/8 inch (171 to 270 mm) diameter.
• They 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.
• They incorporate three leveling jacks as a standard feature to keep the drill level and
stable while drilling. A four jack option is also available.
• Drill rod changing is done by moving the drill rod in and out of the carousel and the
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 cab. The operating controls and gauges
are positioned within easy reach of the operator.
• The tower is constructed of welded rectangular steel tubing.
The PV-271 is designed for single-pass drilling, and with a maximum weight of 75,000 pounds
(34 tonnes) bit load capacity. The PV-271 can drill a 55-foot (16.8-m) clean hole in a single
pass, or a total depth of 105 feet (32.0 m) through a 2-rod carousel holding four 25 foot
(7.62 m) rods, coupled to make two 50 foot (15.2 m) rods.
The PV-275 is designed for multi-pass drilling, and with a maximum weight of 75,000 pounds
(34 tonnes) bit load capacity. The heavy and durable PV-275 features a 40 foot (12.2 m) tower
and can drill a 37 foot (11.3 m) clean hole in a single pass, or multi-pass drill to a total depth
of 195 feet (59.4 m) through a 4-rod carousel with 40 foot (12.2 m) rods.

Identification of Major Components
Figure 1-5: View of PV-270E Drill
1 Cab
2 Tower raising cyl
3 Hydraulic reservoir
4 Power pack
5 Cooler package
6 Transformer
7 Rear leveling jacks
8 Receiver tank
9 Air cleaner
10 Track assembly
11 ACCB box
12 Starter
13 Cab-side leveling
jack

Standard Equipment
DANGER
! DANGER
Personnel life may be in danger if the following is not complied with. DO

NOT add attachments to the machine that intrude into operator protective
area, reduce visibility, restrict emergency exits or add weight exceeding
certification weight. See the operator manual or contact the dealer for
complete inspection requirements and maintenance instructions.
• WEG Electric motors:

- 700 hp (50 or 60 Hz) 5500V, 6000V or 6600V
- 900 hp (50 or 60 Hz) 4160V, 7200V or 4160V/600V
• Undercarriage:
- Caterpillar 345XL (PV-271) or 345SL (PV-275) undercarriage with
hydraulic track tensioners
- Atlas Copco ACGT3400EXT (PV-271) or ACGT3400STD (PV-275)
undercarriage with hydraulic track tensioners
• Carousel:
- 2-rod carousel for 6-1/4 to 8-5/8 inch (159 to 219 mm) drill rods (PV-271)
- 4-rod carousel for 6-1/4 to 8-5/8 inch (159 to 219 mm) drill rods (PV-275)
• Air Compressor:
— 1,450 cfm
— 1,900 cfm
— 2,600 cfm
• Remote hydraulic tower pinning
• Hydraulic cylinders driven cable feed system
• Hydraulic motor driven rotary head; maximum torque 8,700 ft/lb (11,800 Nm) torque;
speed range 0 – 150 rpm
• Automatic lube system with electric pump and timer
• Optional central hydraulic test station
• No-bump rod changer
• Hydraulically powered breakout wrench (fork chuck)
• Hands-free auxiliary hydraulic wrench
• 8,000-pound (3,629-kg) capacity auxiliary hoist
• Hydraulically retractable dust curtains

• Two 48-inch (1.2-m) and one 60-inch (1.52-m) stroke leveling jacks
• Cooling package (hydraulic/compressor oil cooler) rated up to 125 °F (52 °C)
ambient at standard air conditions
• Wide flange structural steel beam frame with oscillation yoke mounting
• Insulated, pressurized, and air conditioned cab with tinted glass, and an operator
seat with seat belt
• Lighting package (18 lights, 70-watt halogen bulbs)
• Jack position indication
• Tram alarm
Electric Motor
The PV-270E drills use a WEG electric motor (50 Hz or 60 Hz) with additional components
Starter, Transformer and ACCB box. The PV-270E Series drills are equipped with dual system
air filtration. The drill rpm is constant with electric motor. The electric motor is shut down either
by the removable key On/Off switch or by engaging the emergency stop switch.
Tower
The tower is constructed of four main members, welded rectangular steel tubing with cross
bracing on both sides and back. A set of sheaves at the top and bottom of the tower support
the feed cables. The tower assembly features the hydraulically-driven rotary head and the
hydraulic drill feed systems. The feed system consists of the rotary head, two hydraulic feed
cylinders, and a set of cables connected to the top and bottom of the rotary head assembly.
The auxiliary hoist is mounted on the rear side of the tower and a hoist capacity of 8,000
pounds (3,630 kg).
Rotary Head
The rotary head is used to rotate the drill bit and to add and remove drill rod from the drill string.
The drill string is connected to the rotary head.
Two hydraulic motors power the rotation of the rotary head. The rotation pressure gauge will
show the amount of hydraulic pressure being applied to the rotary head motors in the form of
rotation speed. Speeds varying from 0 to 150 rpm can be obtained by using this rotary head.
Refer to “Section 4 - Controls” on page 4-1 for further information about the operator controls.
A replaceable spindle adapter between the rotary head spindle and the drill rod is furnished
as standard equipment, along with replaceable head guides. Pulldown and pullback cables
are attached to mounting plates which are attached to the rotary head housing.

Figure 1-6: Rotary Head
1 Motor 3 Lube pump

2 Suction pump lube filter 4 Lube filter
Controls
Operation is performed using a Rig Control System (RCS) with controllers that are
ergonomically located on the adjustable seat so that the operator can face the drill table while
drilling. Controls on the operator seat send a signal to spool valves, eliminating the need for
hydraulic hoses in the cab and creating a quieter work environment. Full details are provided
in “Section 4 - Controls” on page 4-1.
Feed System
The feed cylinders are double acting, with the cylinder rod at each end of the barrel connected
to a common piston. High strength steel cables are connected to the rotary head and run over
the top and bottom of the carriage assemblies to an adjuster anchor point near the middle of
the tower assembly. The feed cylinder is designed for optimal high-speed feed and retract
rates for the rated pulldown and pullback; this consequently reduces non-drill time and
increases drilling efficiency.
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 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 and pullback. 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 feed cable system has an advantage over
a mechanical feed, such as overall weight reduction in the tower and feed system. It is also
easier to detect wear in the cable system.

The automatic cable tensioning makes sure of accurate head alignment, improves cable life,
and eliminates drill downtime for cable tensioning. The PV-271E and PV-275E 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 is indicated on the RCS touchscreen and shows the amount of
hydraulic down pressure being exerted on the bit by the feed 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 - Controls”
on page 4-1).
Figure 1-7: Feed System
1 Crown tensioner cylinder 2 Base tensioner motor

(top of tower) (bottom of tower)
Drill Rod Handling

Drill rod changing is accomplished from the cab. A hydraulic breakout wrench breaks the joint
with limited impact. Extra drill rods are stored in a carousel-type changer capable of holding
up to four drill rods, two rods on a PV-271 or four rods on a PV-275. Hydraulic cylinders swing
the carousel into and out from the loading position under the rotary head. A hydraulic motor
rotates the carousel to index the drill rod under the rotary head for changing. A No Bump
protection feature is standard to limit rotary head feed pressure in the event the rod changer
is not moved out of the loading position. An auxiliary hoist is provided as standard for drill rod
and accessory handling.

Drill Rod Change

Drill rod changing is accomplished from the cab. 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.
PV-271E (Single-Pass)
The carousel holds two 25 foot (7.6 m) drill rods. Two hydraulic cylinders swing the rod
changer in to and out from the loading position under the rotary head. A single hydraulic
cylinder rotates the carousel to index the drill rod under the rotary head for changing. An
exclusive keylock carousel design securely locks the drill rod at both the bottom and the top
of the carousel to make sure maximum safety for drill rod storage and changing.
PV-275E (Multi-Pass)
The carousel holds four 40 foot (12.19 m) 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 rod under the rotary head for changing. An exclusive
keylock carousel design securely locks the drill rod at both the bottom and the top of the
carousel to make sure of maximum safety for drill rod storage and changing.
An auxiliary hoist is provided as standard for drill rod and accessory handling. A no-bump drill
rod changer is provided, which limits the feed force of the rotary head unless 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.
Carousel
An internal carousel type drill rod changer is mounted in the tower.

Figure 1-8: PV-275 Tower with Four-Rod Carousel
1 Rotary head (not shown) 4 Wrench assembly

2 Rod changer and carousel 5 Sliding breakout fork
3 Rod support

Figure 1-9: PV-271 Tower with Two-Rod Carousel
1 Rod changer and carousel 3 Breakout fork

2 Rod support
Power Pack
The power pack consists of an electric motor directly coupled to an asymmetrical air
compressor on one end and a hydraulic pump drive on the other. It is mounted on its own sub
base which is mounted to the drill main frame. This in-line drive train configuration maximizes
mechanical efficiency. The separate sub base isolates the components from drilling and
propel shock loads and maintains alignment between components.

An air inlet cleaner is standard for the air compressor intake.

The cooler for the hydraulic oil/compressor oil is attached to the main frame. Standard
operational ambient temperature rating for the PV-270E Series drills is up to 125 °F (52 °C).
Air Compressor
The air compressor is directly driven by the electric motor. Air compressors are of the oil
flooded asymmetrical rotary screw design and manufactured by Atlas Copco or Ingersoll-
Rand. 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, by-pass valve, oil filter, positive
gear oil pump, and combination air receiver and oil separator tank. A safety shut down system
is also provided for high discharge air temperature. The oil pump is provided to allow the
operator to close the intake valve when no air is required.
The Electronic Air Regulation System (EARS) is designed to deliver variable air volume control
within the system capacity, while still maintaining constant air pressure. The air pressure
adjustment allows the operator to optimize productivity by using the flow knob to control the
butterfly valve which allows for a reduction in air flow back to the compressor while maintaining
the air pressure setting. A standard oil pump is available to maintain continuous oil flow when
the compressor inlet is closed.
Figure 1-10: Air Compressors
1 HP1450 Airend 3 XL2600 Airend

2 XL1900 Airend
Cooling Package
The single side-by-side coolers package is designed to cool the hydraulic oil and compressor
oil. The coolers are mounted side-by-side in one package and each sections can be
individually removed for easy maintenance. This package provides 125 °F (52 °C) 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. High water
temperature or high compressor temperature will shut down the electric motor.

Figure 1-11: Cooling Package
Hydraulic System
The equipment runs off of a reliable and efficient hydraulic system which offers ease of
serviceability by having the spool valves mounted above the deck. The hydraulic pumps are
mounted for convenient service access on a single three-hole gearbox driven off the electric
motor through a drive shaft. The hydraulic system main pumps work through diverter valves
to control feed/rotation and propel.
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.
The three hydraulic pumps are mounted for convenient service access on a single three hole
pump drive gearbox driven off the electric motor through a drive shaft.
The two main pumps supply hydraulic power to either drilling functions or propel functions. The
auxiliary circuits triple pump supplies oil for all other functions through the 7-spool and
10-spool valves (or 11-spool valves).
Water Injection System Option

The optional water injection system injects a regulated quantity of water into the air flow to the
drill rod. The water content suppresses the dust created by drill operations. The water injection
system has a hydraulic motor drive.

NOTE: The water injection system can not be combined with the dust
collector system.
Dust Collector
A no visible emission dry dust collector is the 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.
NOTE: The dust collector can not be combined with the optional water
injection system.
Dust Decking Misting System Option

The dust decking misting system provides the drilling end of the machine with a fine spray of
mist to assist in suppressing dust created during propelling and drilling. It consists of four
misting nozzles; two at the very front of the drill end of the machine and two towards the back
of the dust curtain.
Figure 1-12: Dust Decking Misting System
1 Nozzles
NOTE: Two shown on cab side. Other side typical.
NOTE: The dust decking misting system can not be combined with the
dust collector system.
Main Frame
The main frame is designed and weld fabricated to Atlas Copco specifications, making the drill
exceptionally stable. The 24-inch x 162 lb/ft (0.61 m x 241 kg/m) wide flange structural steel
beam for both rails and crossbeams. The main frame consists of a track frame which supports
the power pack assembly, the cooler package, drill tower assembly, operator cab assembly,
and leveling jacks. The equipment incorporates three leveling jacks to keep the drill level and
stable while drilling. An optional four leveling jack configuration is available.

Figure 1-13: Main Frame
Undercarriage
The PV-270E 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.
Figure 1-14: Undercarriage

Leveling Jacks
The equipment uses a 3-point hydraulic leveling jack system to keep the drill level and stable
while drilling. An optional four leveling jacks system is available.
Propelling
The propulsion system features independent hydrostatic drive/service braking of each track,
allowing steering by differential operation of the propelling control levers. Each track is
provided with direction speed control levers which control the forward and reverse propel
speed. This system also provides service braking by moving the respective levers towards the
STOP position.
The propulsion system features independent hydrostatic drive and service braking of each
track allowing steering by differential operation of the propel controllers.
Steering
The drill can be steered by adjusting the speed of one track relative to the other.
Operator Cab
The one-piece falling object protective structure (FOPS) cab is certified to ISO 3449 Level 2.
The operator cab is thermally insulated, heated, and ventilated. The cab is equipped with
tinted safety glass windows, kick plates, an adjustable swivel seat equipped with rig control
system (RCS) 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 operator RCS controllers attached to the operator seat.
Braking
Service braking is effected by moving the tramming control lever towards the STOP position.
Because the left and right track systems are independently controlled, one track acts as
secondary braking for the other.
Parking brakes are incorporated into each track motor assembly and are fail-safe,
hydraulically released, spring applied. These brakes will be applied if there is a loss of brake
release hydraulic pressure due to:
• Pressing a red emergency stop switch.

• Turning the main key operated on/off switch off.
• Hose failure resulting in loss of charge pressure when the main pumps cut off the flow
to the tracks.
Night Lighting
A night lighting system consisting of 18 70-watt halogen lights provides the following:

• Drilling end platform area illumination

• Power pack illumination
• Tower illumination
• Tramming illumination
There is also one internal 40-watt light for cab interior illumination.

Section 2 - Safety

PV-270E RCS4 Instruction Manual Section 2 - Safety
2.1 Safety First
General Information
This information is intended as a guide for trained and qualified personnel who are aware of
the dangers involved in handling potentially hazardous equipment. It is not intended to contain
a complete list of all safety precautions which should be observed by personnel using this
equipment.
Before you operate, maintain, or in any other way use this drill:
• READ and STUDY the Safety First manual, Safety Decal manual, and this Instruction
manual.
• Know how to safely use the drill controls and what you must do for safe maintenance.
Failure to obey instructions or heed warnings could result in injury or death.
Those who operate, maintain, and work on equipment must be competent.
The maintenance and service of this equipment involves risks both to personnel and
equipment and must be performed only by qualified personnel exercising due care.
Personnel engaged in the operation, maintenance, or servicing of this equipment are urged to
become familiar with First Aid theory and practices.
During operation of this equipment, local safety and fire protection standards must be
observed.
This safety summary includes general safety precautions and instructions that must be
understood and applied during operation and maintenance to make sure personnel safety and
protection of equipment. Before performing any task, the DANGERs, WARNINGs,
CAUTIONs, NOTICEs, and NOTEs included in that task must be reviewed and understood.
Warnings and Cautions

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance
procedures, practices, conditions, or statements which are considered essential to the
protection of personnel or equipment. WARNINGs and CAUTIONs immediately precede the
step or procedure to which they apply. NOTICEs and NOTEs are used in this manual to
highlight operating or maintenance procedures, practices, conditions, or statements which are
not essential to the protection of personnel or equipment.

Section 2 - Safety PV-270E RCS4 Instruction Manual
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.
! 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.
! 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.
NOTICE
NOTICE
Notice is used to notify people of installation, operation or maintenance
information which is important but not hazard-related.
NOTE: A 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.
Modifications
The equipment is designed to be safe to operate. Do not do anything that may hamper the
safety features.
Do not make unauthorized modifications to this vehicle. Before drilling holes, cutting or
welding, contact your Atlas Copco sales company or dealer for authorization.
Atlas Copco cannot be held responsible for any accidents, incidents, or damage to persons or
property that are related to use of equipment modifications.

General Safety Precautions

In addition to the Safety First manual and Safety Decals manual, the following safety
precautions shall be observed while performing procedures in this manual.
• Keep all controls and gauges in good working order. If they are broken or damaged,
replace them before operating the drill.
• Do a complete walk-around inspection of the drill before starting the drill. During
operation, make periodic checks to be sure the drill is operating properly.
• Only access the drilling platform through the cab. The drilling platform does not have
any other means of access.
• Do not operate the drill with excessively worn or broken parts.
• Keep the operator cab clean and free from mud, grease, oil, snow, ice, cans, bottles,
tools and other debris that could jam controls and cause a slip, trip or fall.
• Position the drill on a solid, level bench or ground surface with load bearing capacity
to adequately support and maintain drill stability while operating.
• 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
of tower. 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.
• Never move the drill with the tower partially raised, unless it is an angle drill with the
proper locking pins in place.
• 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.
• 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.
• To avoid accidents, the following factors must be considered.
— Are there structures, power lines or other equipment which must be moved or
avoided during operation of the drill?
— Is the surface stable enough to support the drill?
— What steps must be taken in order to keep all unnecessary people and
equipment at a safe distance from the drilling area?
• Determine the load-bearing capacity of the ground or other surface on which the drill
will be operating. Avoid soft or unstable ground and areas with high water tables.
• 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.
• 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.
• Before starting the electric motor, make sure that the track brakes are applied (propel
controllers are in STOP or NEUTRAL position).
• Make sure the fluids are at operating temperature before operating drill.
• Engage hydraulic controls slowly in cold weather to avoid shock loading.
• Test emergency stops for proper function before each shift and tramming.
• Use the optional tower emergency lanyard, located on the side of the tower structure
(cab side) only in an emergency.
Propel Safety
When making long moves with the PV-270 on flat level surfaces, lower the tower and propel
the drill using high speed in the cab first (drilling end) direction. A long move for the drill is
considered to be any move other than moving from one hole to the adjacent hole in any given
drilling pattern. Always refer to Figure 3-1 (PV-271E Stability With Drill on Tracks) or Figure 3-
5 (PV-275E Stability With Drill on Tracks) for the propel direction and permissible slope angles
when propelling the drill.
Before Starting the Electric Motor

• Inspect the drill for potential hazards.
• Be sure all protective guards and covers are installed if a drill must be started to make
adjustments or perform inspections. Take care when working around rotating parts.
• Do not disable or bypass any automatic shutoff circuits. They are provided to prevent
personal injury and/or damage to the drill.
• Be prepared to shut off the electric motor if a warning condition flashes on the
monitor when the drill is started after performing repair or maintenance to the electric
motor.
Electric Motor Starting

• DO NOT start the electric motor 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 starting.
• Before starting, make sure no one is working on, or close to, the electric motor or the
electric motor driven components. Always inspect the electric motor before and after
starting.
• Start the electric motor only from the operator station.
• Always start the electric motor according to the “Starting The Drill” procedure
described in this manual to prevent component damage and personal injury. Start the
electric motor only from the operator station.

• Stop the electric motor according to “RCS Shutdown Procedures” on page 5-112 .
• Only use the Emergency Stop button in an emergency. DO NOT start the electric
motor until the problem causing the emergency stop has been located and corrected.
• On initial startup or overhaul, be prepared to stop the drill should a warning condition
flash on the monitor.
• Check the water and oil temperatures during the operation of water and/or lube oil
heaters to ensure proper operation.
Electric Motor Stopping

Stop the electric motor according to “RCS Shutdown Procedures” on page 5-112 whenever
possible.
! WARNING
Only use the emergency stop button in an emergency. Do not start drill
until the problem that caused the emergency has been resolved.
Be prepared to stop the electric motor should a warning condition flash

on the monitor.
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 make sure the uninterrupted and safe operation of the drill by
revealing the need for adjustment caused by normal wear.
Prior to conducting any maintenance work, make sure that the following instructions are
observed:
• The drill should be parked on a firm, level surface.

• Make sure the electric motor is shut down and fluids allowed to cool.
• Stop the electric motor and allow the hydraulic oil pressure to fall before working on
the hydraulic hose installations or connections.
• Disconnect the electrical power and cover exposed terminals before working on the
drill’s electrical system.
• Stop the electric motor and allow compressor air pressure to completely relieve from
the receiver tank before working on the compressor, receiver tank and hose
installations or connections.
• 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 must only be done
under the following conditions:
• There must always be two people present: both being fully instructed on the safety
issues. One of them, from the main operator station, must supervise the safety of the
service man doing the work.
• The supervisor must have immediate access to the emergency stop in all situations.
• The area where the service work is to be performed must be properly illuminated.
• Communication between the service man and the supervisor at the main operator
station must be established in a reliable manner.
• 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.
NOTE: Refer to the manufacturer user documentation for the

maintenance schedules and procedures for the electric motor on the drill.

2.2 Equipment Safety Decals
Safety Manual
One safety manual, located inside the operator cab.
Table 2-1: Safety Decal List
Decal Message Location

Hydraulic Tank: One per tank,
Caution: Excessive fluid level gauge side
Hydraulic Oil
Quick Fill Box: One per box
Warning: Hot Pressurized
Fluid Drain System: One on the
inside lid of the drain system
Receiver Tank: One per left
side of sight glass. One on top
Warning: High Pressure of receiver tank
Drain System: One on the
inside lid of the drain system
Thread Lube: One per thread
Warning: Pressurized Fluid
lube
Drive Shaft Cover: One per
cab side drive shaft. One per
non-cab side drive shaft
Warning: Rotating Parts Drive Shaft: One per cab side
drive shaft cross member.
One per non-cab side drive
shaft cross member


Drive Shaft Cover: One per
cab side drive shaft. One per
non-cab side drive shaft
Drive Shaft: One per cab side
drive shaft cross member.
Warning: Rotating Shaft
One per non-cab side drive
shaft cross member
Tower Bottom: Two per
bottom of tower, one per
tower side
Warning: Rotating Fan Cooler (Fan Side): Two per

Blade cooler
Battery Box: One per battery

box
Warning: Combustible Gas

Rotary Head: One per rotary

Danger: Riding Rotary Head
head
Derrick Bottom: Two per

Warning: Falling Rotary
Head
tower side

Carousel Swing Cylinder: Two

Warning: Falling Carousel
on tower, one per cylinder
Warning: Don’t Modify or Cab: One per cab towards the

Alter non drill end
Cab: One per cab towards the

Danger: Hazardous Voltage
non drill end
Receiver Tank: One per right

Warning: High Pressure Air side of sight glass. One on top
of receiver tank
Derrick Bottom: Two per

tower side
Danger: Don’t Climb Tower
Tower: One per back of tower,
center of cross member near
tower raise shaft
Derrick Raising Cylinder: One

Warning: Falling Derrick per cab side cylinder. One per
non-cab side cylinder


Dust Collector: One per top of
the dust collector
Warning: Flying Fan Blades

Cooler (Fan Side): Two per
cooler
Hoist: One per machine, drill

Warning: Falling Objects
end bumper non-cab
Dust Collector: Two per dust

Notice: Dust Discharge
collector, one per door
Hydraulic Tank: One per
hydraulic tank on the non-cab
Notice: Hydraulic Failure side
Notice: Electric Motor
Failure
Battery Box: One per battery
Notice: Electrical Damage box
Danger: Hazardous
Voltage
Battery/Isolation Switch: One
Warning: Hazardous next to battery or isolation
Voltage switch, depending on
machine options
Boarding Ladders: Two on

Warning: Hazardous Noise frame, one per boarding
ladder, right side of ladder

Cab: One per inside of the

Drill Stability Charts
cab window corners
Enclosure: Four on enclosure

lifting points; two on DE of the
Caution: Enclosure Lifting
enclosure, two on NDE of the
enclosure
Frame: Four on frame, next to

Caution: Frame Lifting
each lifting point of frame

Warning: Hoist Hook Stow bottom of tower, one per
tower side

Warning: Sliding Fork bottom of tower, one per
tower side

Section 3 - Specifications

PV-270E RCS4 Instruction Manual Section 3 - Specifications
3.1 Specifications
Drill Information Sheet

Please enter your drill data on this drill information sheet for future reference.
Model ____________________________________________________________________
Drill Serial Number __________________________________________________________
Year of Manufacture _________________________________________________________
Electric Motor (Mfg./Type of Electric Motor) _______________________________________
Electric Motor Serial Number __________________________________________________
Installed Power (kW) ________________________________________________________
Rated Voltage (V) ___________________________________________________________
Rated Frequency (Hz) _______________________________________________________
Drill Gross Weight (lb or kg)___________________________________________________
Max. Pulldown Force (lbf or kn) _________________________________________________
Max. Pullback Force (lbf or kn) _________________________________________________
Max. Bit Rotation (rpm) _______________________________________________________
Max. Bit Diameter (inch or mm) _________________________________________________
Main Hoist Load (lb or kg) _____________________________________________________
Aux Hoist Load (lb or kg) ______________________________________________________
Max. Operating Air Pressure (psi or kPa) _________________________________________

Section 3 - Specifications PV-270E RCS4 Instruction Manual
Environment Rate Factor Ranges
Duty
• Heavy - Hard Rock

• Normal - Soft Rock
• Light - Sand and Gravel
Ambient Temperature
• Hot- Above 125 °F (52 °C)

• Nominal- Between limits of 125 °F (52 °C) Maximum and 15 °F (-9 °C) Minimum.
• Cold- Between limits of 15 °F (-9 °C) and -40 °F (-40 °C)
• Extreme Cold: Below -40 °F (-40 °C)
Service
• Excellent- Well Prepared Benches, Scheduled Maintenance Program, Advanced

Training of Operators and Mechanics.
• Nominal- Good Operating Conditions, Normal Maintenance, Basic Training for
Operators and Mechanics.
• Poor- Bad Operating Conditions, Limited Maintenance, Limited Training for
Operators and Mechanics.
Application Type
• Construction - Nominal Application

• Aggregates - Light Application
• Gold - Heavy Application
• Copper - Heavy Application
• Coal - Nominal Application
• Iron - Heavy Application

Operational Limitations
Ambient Temperature Range

The standard drill comes equipped for a nominal ambient temperature working range between
limits of 125 °F (52 °C) Maximum and 15 °F (-9 °C) Minimum.
In the event a machine comes equipped with an Arctic Cooler package, the cooler extends the
minimum working range down to 100 °F (37 °C) Maximum and -40 °F (-40 °C) Minimum.
Ground Pressure
PV-270E Series drill utilizes an excavator type undercarriage with a designed ground pressure
limit of 13 psi (89.6 kPa).
Maximum Allowable Slope Angle

Exceeding the slope or grade limitations of the drill and its configuration can cause the drill to
tip over. Always determine the safe operating grade of the drill with the tower up and down.
Stay within the limits shown on the PV-271E and PV-275E Stability and Grade Limits with Drill
on Tracks chart and PV-271E and PV-275E Stability and Leveling Limits with Drill on Jacks
chart.
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-270E Series Stability/
Gradeability chart for further guidance.
! WARNING
Set up the PV-270E Series Blasthole drill on a level and firm surface. If
this is not available, prepare the site and the way to the site before set up
and drilling with the PV-270E Series drill.

Noise Risk Assessment

Factors that could reduce the risk from the noise levels:
• Use a machine with cabin

• Maintenance of door and cabin seal, isolators, mufflers
• Working with the cabin door and windows closed
• Select correct ear protectors or plugs see EN 458
— Educate personnel in how to use ear protection

— Maintain ear protectors regularly (half yearly replacement of seals)
• Glasses reduce the damping effect of earmuff style hearing protection. Use helmet
goggles or ear plugs instead.
• The wrong size or incorrect insertion of ear plugs can reduce the damping effect.
• Take into account the higher noise level due to reflections from walls in mine. This
can be from 1 to 12 dB higher levels depending on:
— The size (height and width) of the mine drift

— The characteristics of the noise source
— Acoustical absorption factor of the rock in the mine
— Low frequency noise levels on canopy machines
• Working hours
• Breaks and quiet areas
Noise can result in:
• Permanent hearing loss

• Tinnitus
• Tiredness, stress
• Other effects such as loss of balance, loss of awareness
• Impairment of speech communication or of the perception of acoustic signals
Sound Pressure Limitations

In accordance with the requirements of Machinery Directive 2006/42/EC and
EN791+A1:2009, the A-weighted emission sound pressure level of the drill at the operator's
station in a closed cab, seated/standing positions, has been tested in accordance with ISO
11201:2010, and the A-weighted sound power level emitted by the drill has been tested in
accordance with ISO 4872.
With the drill operating at high speed, the cooling fan thermostatically controlled at high speed,
and percussive drilling at a depth of >1 meter in an open field with no structural objects
reflecting sound, the A-weighted emission sound pressure level of the drill at the operator's

station was measured to be 66.1 dB(A), and the A-weighted sound power level emitted by the
drill was measured to be 119.0 dB(A), with an uncertainty of 0.3 dB for each of these values.
Vibration Risk Assessment

Many factors affect whole body vibration such as speed, working cycle, ground conditions, etc.
The majority of the vibration risks can be reduced by the user. If machines are specified with
options such as ride control and the correct type of seat is used in accordance with EN ISO
7096 Class EM 3, there will be better possibilities for lower vibration levels. But still the largest
influence can be made by the operator, because the operator has control over speed, working
cycle, route options, etc.
For more information how to estimate the vibration levels at your site see ISO/TR 25398.
Guideline for reducing vibration levels:
• Use the proper type, size of machine with optional equipment and attachment/tools
for the task.
• Keep the ground in good condition.
— Remove large stones and obstacles

— Fill holes and ditches
— Provide machines and schedules times in order to maintaining the condition of
the terrain.
• Adjust the speed, operations and choose a suitable travel path to minimize the
vibration level.
— Reduce speed in rough terrain

— Drive around obstacles and uneven ground
— If work is performed in rough terrain an option could be to use machines with
remote control
• Perform these operations smoothly:
— Steering
— Braking
— Acceleration
• Make sure that the seat is maintained and correctly adjusted.
— Adjust the seat and its suspension for the operator weight and height
— Do not over load seat according to specification
— Inspect and maintain suspension and adjustment mechanism
— Use the seat belt

• Minimize vibrations for long work cycles or a long travel distance.
— If no suspension is available reduce speed to avoid bouncing

— Transport machine between work sites if possible
• Other risk factors may also cause back pain. They can be reduced by:
— Adjust seat and controls to achieve good posture

— Adjust mirrors to minimize twisted posture
— Provide breaks to reduce long periods of sitting
— Avoid jumping from down from the machine
— Minimize repeated handling and lifting of heavy objects
Vibration Exposure Limitations

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/s2. Tests were conducted with machine running at operating
motor speed . Machine was on a concrete surface.

PV-271E Stability and Gradeability Limits

PV-271E (Single-Pass) limits on tracks with 3- or 4-jack configuration.
Figure 3-1: PV-271E Stability With Drill on Tracks
1 Tower up, pitch to drilling end 2 Tower up, pitch to non-drilling end
3 Tower down, pitch to drilling end 4 Tower down, pitch to non-drilling end
5 Tower down, roll to non-cab side 6 Tower down, roll to cab side
7 Tower up, roll to non-cab side 8 Tower up, roll to cab side

The brakes will hold at all grades as specified on the gradeability chart.
PV-271E (Single-Pass) limits on jacks with 3- or 4-jack configuration.
Figure 3-2: PV-271E Stability With Drill on Jacks

PV-271E Pitch and Roll Inclinometers

The pitch and roll inclinometers provide the operator with vital information about the drill during
propelling and drill set-up with the jacks. The inclinometers are located inside the cab.
Figure 3-3: PV-271E Pitch Inclinometer (Jacks or Tracks)
Figure 3-4: PV-271E Roll Inclinometer (Jacks or Tracks)

PV-275E Stability and Gradeability Limits

PV-275E limits on tracks with 3- or 4-jack configuration.
Figure 3-5: PV-275E Stability With Drill on Tracks

The brakes will hold at all grades as specified on the gradeability chart.
PV-275E limits on jacks with 3- or 4-jack configuration.
Figure 3-6: PV-275E Stability With Drill on Jacks

PV-275E Pitch and Roll Inclinometers

The pitch and roll inclinometers provide the operator with vital information about the drill during
propelling and drill set-up with the jacks. The inclinometers are located inside the cab.
Figure 3-7: PV-275E Pitch Inclinometer (Jacks or Tracks)
Figure 3-8: PV-275E Roll Inclinometer (Jacks or Tracks)

Visibility Limitation Charts
NOTE: The following information applies to both visibility charts.
1. Operator is required to survey his/her field of vision when operating the

machine.
2. Optional CCTV system is available to enhance visibility.
3. Appropriate jobsite organization is required to minimize hazards due to
restricted visibility.
4. Optional equipment or modifications of the machine configuration by the user
may result in restricted visibility.
Figure 3-9: Horizontal Tower - Top View
Areas outside of the dash lines are in the danger zone of visibility.

Figure 3-10: Vertical Tower - Top View
Areas outside of the dash lines are in the danger zone of visibility.
Equipment Specifications
Table 3-1: General Specification
General Specifications PV-271E PV-275E

Hole Diameter (Rotary) 6-3/4 to 10-5/8” (171 to 270 mm)
Weight On Bit 75,000 lb (34,000 kg)
Maximum Depth 55 ft (16.8 m) single-pass Maximum depth 195 ft
depth with 105 ft (32 m) (59.4 m)
maximum depth.

General Specifications PV-271E PV-275E

Drill Rod Diameters 6-1/4”, 7”, 7-5/8”, 8”, 8-5/8” (159 mm, 179 mm, 194 mm,
203 mm, 219 mm)
Drill Rod Wall Thickness 1 inch (25.4 mm)
Drill Rod Length 25 ft (7.6 m) 40 ft (12.2 m)
Operating (Working) 165,000 to 175,000 lb (74,844 to 79,380 kg)
Weight
Table 3-2: Tower
PV-271E PV-275E
Tower Design Weld fabricated to Atlas Copco specifications
Construction Four main member, open front, rectangular steel tubing.
Tower Raising Two hydraulic cylinders; live tower (raise and lower with
full carousel and rotary head at top of tower.
Rotation Tophead drive
Rod Changing Two rod internal carousel Four rod internal carousel
with key-lock retention with key-lock retention
Drill Pipe Length 25 feet (7.6 mm) 40 feet (12.2 mm)
Carousel Swing Two hydraulic cylinders
Carousel Index 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; 8,000 lb. (3628.73 kg) bare
drum capacity; 4,000 lb. (1814.4 kg) actual rating
Hose Management Traveling hose carrier with hose tray guide

Table 3-3: PV-271E Standard Drill Pipe
Pipe Pipe
Maximum Hole Depth Hole Depth
Diameter Diameter
Number (feet) (Meters)
(inches) (Millimeters)
6-1/4 159 4 105 32
7 178 4 105 32
7-5/8 194 4 105 32
8 203 4 105 32
8-5/8 219 4 105 32
Table 3-4: PV-275E Standard Drill Pipe
Pipe Pipe
Maximum Hole Depth Hole Depth
Diameter Diameter
Number (feet) (Meters)
(inches) (Millimeters)
6-1/4 159 5 195 59.4
7 178 5 195 59.4
7-5/8 194 5 195 59.4
8 203 5 195 59.4
8-5/8 219 5 195 59.4
Table 3-5: Drill Pipe
Diameter Rig Type Length Wall Thread

6-1/4 inch PV-271E 25 ft (7.62 m) 1 inch (25.4 mm) 4 inch Beco
(159 mm)
PV-275E 40 ft (12.2 m)
7 inch PV-271E 25 ft (7.62 m) 1 inch (25.4 mm) 4-1/2 inch Beco
(178 mm)
PV-275E 40 ft (12.2 m)
7-5/8 inch PV-271E 25 ft (7.62 m) 1 inch (25.4 mm) 5-1/4 inch Beco
(194 mm)
PV-275E 40 ft (12.2 m)
8 inch PV-271E 25 ft (7.62 m) 1 inch (25.4 mm) 5-1/4 inch Beco
(203 mm)
PV-275E 40 ft (12.2 m)

Diameter Rig Type Length Wall Thread

8-5/8 inch PV-271E 25 ft (7.62 m) 1 inch (25.4 mm) 6 inch Beco
(219 mm)
PV-275E 40 ft (12.2 m)
Table 3-6: Rotary Head
Design Two stage, spur gear reduction in cast housing (15.227:1)

Rotation Motors Two (2) variable displacement, axial piston hydraulic motors
(6 cu in/rev.)
Rotation Power 181 hp (136 kW) (100% efficiency)
Rotation Torque 8,700 ft/lb (11,800 Nm) occurs 0-105 rpm
Rotation Speed 0-150 rpm at minimum displacement
Speed Control Infinitely adjustable throughout range; maximum speed set by
manual adjustment of motor displacement
Head Guides Replaceable, Nylatron (moly-disulfide)
Function Rotate the drill bit
Table 3-7: Feed System
Design Hydraulic cylinder driven cable feed

Maximum Hole Depth The PV-271E drills to depths of 55 ft (16.8 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 (32 m).
The PV-275E drills to a maximum depth of 195 ft (59.4
m). A standard carousel holds four 40 foot (12.2 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 dual-rod, dual-piston hydraulic cylinders
Weight On Bit 0 to 75,000 lb (0 to 34,019 kg)
Cylinder Bore 5.0 in (127 mm)
Rod Diameter 3.75 in (95.25 mm)
Stroke
PV-275E 23 ft 3 in (7.1 m)
PV-271E (55 ft SP) 32 ft 3 in (9.8 m)

PV-271E (65 ft SP) 33 ft 3 in (10.1 m)

Sheave Outside Diameter 23.5 in (597 mm)
Hydraulic Pulldown Force 0 to 75,000 lb (0 to 34,019 kg)
Hydraulic Pullback Force 0 to 35,000 lb (0 to 15,876 kg)
No. of Pulldown Sheaves Four
Pulldown Cables Two 1 inch (25.4 mm) diameter
No of Pullback Sheaves Four
Pullback Cables Two 1 inch (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).
Table 3-8: Mainframe
Design Weld fabricated to Atlas Copco specifications

Construction 24” x 162 lb/ft (610 mm x 241 kg/m) Wide Flange
structural steel I-Beam
Leveling Jacks
Non Drilling End (Standard) (One) 7” bore x 60” stroke (177.8 mm x 1,524 mm)
Non Drilling End (Option) (Two) 6” bore x 60” stroke (152.4 mm x 1,524 mm)
Drilling End (Two) 7” bore x 48” stroke (177.8 mm x 1,219 mm)
Access Two access ladders with flexible lower steps
Table 3-9: Powerpack
Electric Motor WEG 6808 700 hp (50 Hz) 5500V, 6000V or 6600V @ 1488
Options rpm
WEG 6808 700 hp (60 Hz) 5500V, 6000V or 6600V @ 1789
rpm
WEG 6808 900 hp (50 Hz) 6000V @ 1488 rpm
WEG 6811 900 hp (50 Hz) 4160V or 7200V @ 1500 rpm
WEG 6811 900 hp (60 Hz) 4160V or 7200V @ 1789 rpm

Air Compressors 1,450 CFM Airend:
NOTE: When WEG 6808, 700 HP, 60 Hz @ 1,789 RPM = 1,250 CFM
compressors are (Ingersoll-Rand compressor)
paired with motors WEG 6808, 700 HP, 60 Hz @ 1,789 RPM = 1,450 CFM (Atlas
running at 60 Hz they Copco compressor)
will run at full
capacity. When paired WEG 6808, 900 HP, 50 Hz @ 1,488 RPM = 1,200 CFM (Atlas
with motors running at Copco compressor)
50 Hz the CFM
1,900 CFM Airend:
ratings will be
diminished. WEG 6808, 700 HP, 60 Hz @ 1,789 RPM = 1,900 CFM
(Ingersoll-Rand compressor)
WEG 6808, 700 HP, 50 Hz @ 1,488 RPM = 1,600 CFM
2,600 CFM Airend:
WEG 6811, 900 HP, 60 Hz @ 1,789 RPM = 2,600 CFM
WEG 6811, 900 HP, 50 Hz @ 1,500 RPM = 2,200 CFM
Cooling System Hydraulic oil / Compressor oil cooler.
Cooling Capability 125 °F (52 °C)
Powerpack Mounting Isolation mounted subframe
Air Cleaners Three-stage air cleaner for air compressor.
Auto Shutdown Electric Motor RTDs temperatures, high compressor
temperature.
Table 3-10: Cooling System
Type Hydraulic oil / Compressor oil cooler.

Fans Hydraulically driven, 54-inch (1371.6 mm) diameter, 8-blade.
Main Fan Fixed displacement, axial piston motor 7.25 cu in/rev (119 cc/rev).
Rating 125 °F (52 °C) ambient at sea level.
Function Cools the hydraulic oil and compressor oil.
Table 3-11: Cooling System (Tier 4)
Type Side-by-side hydraulic oil cooler and compressor oil cooler

Fans Hydraulically driven, 54 inch (137 cm) diameter, 8 blade

Main Fan Fixed displacement, axial piston motor 8 cu. in/rev (131 cc/rev)
CAC Fan Fixed displacement, gear driven motor 0.67 cu. in/rev (11 cc/rev)
Rating 125 °F (52 °C) ambient at sea level
Function Cools the hydraulic and compressor oil
Table 3-12: Low Pressure Air Compressor
Type Low pressure, single stage, oil flooded asymmetrical rotary

screw
Volume 1,900 CFM @ 110 psi (54.0 m3/min @ 7.6 bar)
2,600 CFM @ 110 psi (74.0 m3/min @ 7.6 bar)
Bearing Type Tapered Roller Bearing
Air End Lubrication Positive, Gear Oil Pump
Receiver Capacity Approximately 38 gallons (143 liters)
Air Cleaners Three 3-stage with one primary and one safety element
Dirt Alarm Indicator Electrical Restriction indicators indicate when filters require
service.
Oil Type AC Compressor 150 oil
Operational RPM 1,800 rpm
Power Source Directly driven by electric motor.
Table 3-13: High Pressure Air Compressor
Type High pressure two-stage, over/under, oil flooded asymmetrical

rotary screw
Volume 1,450 CFM @ 350 psi, (41.0 m3/min @ 24 bar)
Bearing Type Tapered roller bearing
Air End Lubrication Positive, gear oil pump
Receiver Capacity Approximately 38 gallons (143 liters)
Air Cleaners Three 3-stage with one primary and one safety element
Dirt Alarm Indicator Electrical restriction indicators indicate when filters require
service.
Oil Type AC Compressor 350 oil
Operational RPM 1800 rpm

Power Source Directly driven by electric motor.
Table 3-14: Undercarriage and Propel, PV-271E Series
Caterpillar 345XL Atlas Copco ACGT3400EXT

Construction Excavator-style lower with 345-class rollers, sprockets, and tracks
Total Length 21’ 3” (6.53 m) 21’ 4.6” (6.52 m)
Ground Contact 17’ 11” (5.46 m) 18’ 1” (5.52 m)
Mounting Oscillating walking beam (5° each side; 10° total)
Side Frame Custom Weld Fabrication
Rated GVW 200,000 lb (90,719 kg) 180,000 lb (81,847 kg)
Take Up Grease slack adjustment, spring recoil
Adjustment
Rollers
Top Rollers Three per side, with sealed for life bearings
Bottom Rollers 13 per side, with sealed for life bearings
Location Equally Spaced between idler and sprocket
Towing Release Track drive manually releases Standard disengagement for
for emergency towing towing
Final Drive Ratio 147.2:1 148:1
Propel Motor (Two)
Type Hydraulic, axial piston
Motor 9.79 cubic in/rev (160.5 cubic cm/rev.)
Displacement
Input hp Rating 170 hp (126.8 kW)
Motor Ground 19.4 in (49.3 cm)
Clearance
Drive Hydrostatic, closed loop motor drive, through speed reducer to
drive sprocket
Propel Speed 0-1.1 mph (0-1.77 km/hr) 0-1.0 mph (0-1.61 km/hr)
Track Pads
Width 35.4 in (899 mm)
Type Triple Bar Grouser

Caterpillar 345XL Atlas Copco ACGT3400EXT

Ground Pressure 13 psi (89.6 kPa)
Brake Plate type, spring applied, hydraulically released
Parking Brake 738 ft/lb (987 Nm) 590 ft/lb (800 Nm)
Static Capacity
Table 3-15: Undercarriage and Propel, PV-275E Series
Caterpillar 345SL Atlas Copco ACGT3400STD

Construction Excavator-style lower with 345-class rollers, sprockets, and tracks
Total Length 19’ 8” (5.99 m)
Ground Contact 16’ 4” (4.98 m)
Mounting Oscillating walking beam 5° each; total 10°
Side Frame Custom Weld Fabrication
Rated GVW 180,000 lb (81,847 kg)
Take Up Grease slack adjustment, spring recoil
Adjustment
Rollers
Top Rollers Three per side, with sealed for life bearings
Bottom Rollers 13 per side, with sealed for life 12 per side, with sealed for life
bearings bearings
Location Equally Spaced between idler and sprocket
Towing Release Track drive manually releases Standard disengagement for
for emergency towing towing
Final Drive Ratio 128.6:1 148:1
Propel Motors (Two)
Type Hydraulic, axial piston
Motor 9.79 in3/rev (160.5 cm3/rev.)
Displacement
Input hp Rating 170 hp (126.8 kW)
Motor Ground 19.4 in (49.3 cm)
Clearance
Drive Hydrostatic, closed loop motor drive, through speed reducer to
drive sprocket

Caterpillar 345SL Atlas Copco ACGT3400STD

Propel Speed 0-1.2 mph (0-1.93 km/hr) 0-1.0 mph (0-1.61 km/hr)
Track Pads
Width 35.4 in (899 mm)
Type Triple Bar Grouser
Ground Pressure 13 psi (89.6 kPa)
Brake Plate type, spring applied, hydraulically released
Parking Brake 738 ft/lb (987 Nm) 590 ft/lb (800 Nm)
Static Capacity
Table 3-16: Operator Cab
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 (measured to be 66.1 dB(A)) with doors
closed and air conditioner running at full speed.
Dimensions 66.85-inch width x 107.74-inch length x 89.37-inch height
(169.8 cm x 273.7 cm x 227 cm)
Doors Two (one hinged on drill deck side, one hinged on
non-drill side of cab)
Heater/Air Conditioner DTAC side mounted unit with adjustable vents
A/C 31,000 BTU/HR
Heater 40,000 BTU/HR
100 CFM (2.83 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 inch of H2O 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 Two wipers with washers standard

Operator Seat Swivel type, adjustable, high back with arm rests and air
ride suspension with RCS controllers and monitor.
Table 3-17: Leveling Jack
Type Hydraulic cylinder with double holding valves

Number Three (standard with drill)
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 7 in. bore dia. x 60 in. stroke/ 5.25 in. rod diameter
(Standard) (177.8 mm x 1,524 mm / 133 mm)
(Two) Non-Drilling End (Option) 6 in. bore dia. x 60 in. stroke/ 4.50 in. rod diameter
(152 mm x 1,524 mm / 114 mm)
Double Holding Valves Set 4500 psi (310.3 bar)
Approx. Rig Lifting Capacity
Drill Side (Same for 3 or 4 jack) 62,500 lb each (28,350 kg)
Non-Drill side (standard 3 jack) 91,000 lb each (41,277 kg)
Non-Drill side (optional 4 jack) 50,620 lb each (22,961 kg)
Jack Pad Shape/Area
(2) Jack Pad Drill side (same for Round 34” diameter (863.6 mm)
3 or 4 jack option)
(1) Jack Pad Non-Drill side Round 44 in (1,117.6 mm) diameter
(standard 3 Jack)
(2) Jack Pad Non-Drill side Triangular 759 in2 (4,897 cm2)
(optional 4 Jack)
Approx. Pad Bearing Pressure (Maximum)
Drill Side (3 or 4 jack) 68.9 psi (475 kPa)
Non-Drill Side (3 jack) 59.9 psi (413 kPa)
Non-Drill Side (optional 4 jack) 66.7 psi (460 kPa)
Jack Position Indication Jack Up indicator RCS Screen
Table 3-18: Hydraulic System Pressures
Rotation System 4,500 psi (31,026 kPa)

Propel System 4,500 psi (31,026 kPa)

Feed System 3,400 psi (23,442 kPa) MAX. pulldown
4,500 psi (31,026 kPa) pullback
Auxiliary Circuits 3,000 psi (20,684 kPa)
Table 3-19: Hydraulic System
Pump Drive 3-hole gearbox driven from driveshaft coupled to electric

motor.
Main Pumps Two variable displacement, axial piston, bi-directional
pumps for feed, rotation and propel
Auxiliary Pump One triple section vane pump for all auxiliary hydraulic
functions
Hydraulic Tank Capacity 150 gallons (567.8 liters)
Hose Management Stauff type clamps for hoses; hard piping where possible
Hydraulic Fittings SAE O-ring face seal
Filtration Two filters in drain line upstream from tank; two filters in
return line upstream from supercharge manifold
Filtration Rating 3 micron
Table 3-20: Hydraulic Reservoir
Capacity 150 gallons (567.8 liters)

Location Next to the cooler package on the dust collector side
Standard Equipment Oil level indicator and oil temperature gauge
Table 3-21: Main Pumps
Quantity Two
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 (118.8 cc), 1,800 x 1.27 = 2,286 rpm, 71.7 gpm
7.25 cu in/rev (118.8 cc), 2,100 x 1.10 = 2,310 rpm, 72.5 gpm
Function Supplies oil to rotary head motors, feed cylinders and propel
motors (one pump per track)

Table 3-22: Main Pumps (700 hp, 50 Hz)
Quantity Two
Type Variable displacement, axial piston, bi-directional pumps for
feed, rotation and propel
Displacement 11.0 cu in/rev (180.3 cc), 1,488 x 1.00 = 1,488 rpm, 71.0 gpm
Function Supplies oil to rotary head motors, feed cylinders and propel
motors (one pump per track)
Table 3-23: Triple Pump (Auxiliary Pump)
Quantity One
Type 3-section, vane, fixed displacement pump for all auxiliary hydraulic
functions
Capacity P1 Section:
P2 Section:
P3 Section:
Function P1 and P3 Section: Cooler package fan motor(s), cable tension
cylinders and Drill/Propel valve.
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)
Table 3-24: CAT Propel Motors
Quantity Two
Type Hydraulic, fixed displacement, axial piston, 9.79 cu in/rev
(160 cc) displacement
Propel Speed 0 to 1.2 mph (0 to 1.9 km/hr)

Function Enables left track drive and right track drive to function
Table 3-25: ACGT Propel Motors
Quantity Two
Type Hydraulic, fixed displacement, axial piston, 9.79 cu in/rev
Propel Speed 0 to 1.0 mph (0 to 1.6 km/hr)
Function Enables left track drive and right track drive to function
Table 3-26: Rotation Motors
Quantity Two
Type Variable displacement, axial piston hydraulic motor, 6 cu in/rev
Speed Range Variable, 0-150 rpm
Rotation Torque 8,700 ft/lb (11,800 Nm)
Rotation Power 181 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 3-27: Main Fan Motor
Quantity One
Type Variable displacement, 7.25 cu in/rev (118.8 cc)
Speed Range Variable, 0-1200 rpm
Function Cools the hydraulic oil and compressor oil
Table 3-28: Hoist Motor
Quantity One
Type Fixed displacement, 1.96 cu in/rev (32.12 cc)
Function Facilitates drill pipe handling
Table 3-29: Rod Indexing Motor (PV-275E)
Quantity One


Function Rotates carousel to index drill rod under rotary head
Table 3-30: Cable Tension Motor
Quantity Two
Function Maintains tension on feed cables
Table 3-31: Water Injection Pump Motor (Option)
Quantity One
Type 8 gpm; Fixed Displacement, 6.2 cu in/rev (101.60 cc)
8 gpm; Fixed Displacement, 9.9 cu in/rev (162.23 cc)
Function Drives Water Injection Pump
Table 3-32: Dust Collector Fan Motor
Quantity One
Type Fixed displacement, hydraulic spring vane motor, 1.49 cu in/rev
(24.42 cc)
Maximum Pressure 2,500 psi (172.4 bars) at 2,500 rpm
Function Drives dust collector fan
Table 3-33: Leveling Jack Cylinder
Type Hydraulic cylinder with double holding valves set @ 4,500 psi
(310.3 bar)
Quantity Three standard. Four 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 7 in. bore dia. x 60 in. stroke/ 5.25 in. rod diameter (177.8 mm x
End Standard 1,524 mm / 133 mm)
(Two) Non-Drilling 6 in. bore dia. x 60 in. stroke/ 4.5 in. rod diameter (152 mm x
End: Option 1,524 mm / 114 mm)
Function Raise, level and lower the drill

Table 3-34: Tower Raising Cylinder
Type Hydraulic cylinder with double holding valves Set @ 4,000 psi
(275.8 bar)
Quantity Two
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 3-35: Tower Pinning Cylinder
Type Hydraulic cylinder

Quantity Two
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 3-36: Angle Drill Pinning Cylinder

Quantity Two
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 Tower pinning for Angle Drill Package Only
Table 3-37: Cable Tension Cylinder

Quantity Two
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
Table 3-38: Feed Cylinder
Type Dual rod, dual piston hydraulic cylinder

Quantity Two

PV-271E (55ft) 5 in. bore diameter x 387 in. stroke/ 3.75 in. rod diameter (12.7
cm x 983 cm / 9.53 cm)
PV-271E (65ft) 5 in. bore diameter x 399 in. stroke/ 3.75 in. rod diameter (12.7
cm x 1,013.46 cm / 9.53 cm
PV-275E 5 in. bore diameter x 279 in. stroke/ 3.75 in. rod diameter (12.7
cm x 708.66 cm / 9.53 cm)
Function Raise and lower the rotary head
Table 3-39: Rod Changer Cylinder

Quantity Two
PV-271E 3 in. bore diameter x 5 in. stroke/ 1.5 in. rod diameter (7.62 cm x
12.7 cm / 3.81 cm)
PV-275E 3 in. bore diameter x 6 in. stroke/ 1.5 in. rod diameter (7.62 cm x
15.24 cm / 3.81 cm)
Function Swing carousel into and away from loading position under rotary
head
Table 3-40: Rod Indexing Cylinder (PV-271E Single-Pass)

Quantity One
3 in. bore diameter x 5 in. stroke/ 1.5 in. rod diameter (7.62 cm x
12.7 cm / 3.81 cm)
Function (PV-271E only). Rotates carousel to index drill rod under rotary
head
Table 3-41: Rod Support Cylinder

Quantity One swing cylinder
One clamp cylinder
3 in. bore diameter x 6 in. stroke/ 1.5 in. rod diameter (7.62 cm x
15.24 cm / 3.8 cm)
Function Positions the rod support during drill rod change

Table 3-42: Sliding Breakout Fork Cylinder

Quantity One
1.5 in. bore diameter x 8 in. stroke/ 1 in. rod diameter (3.81 cm x
20.32 cm / 2.54 cm)
Function Holds drill rod at table level for breakout procedure
Table 3-43: Breakout Wrench (Clamp) Cylinder

Quantity One
4.5 in. bore diameter x 9 in. stroke/ 2 in. rod diameter (11.43 cm
x 22.86 cm / 5.08 cm)
Function Engages and disengages breakout wrench on drill rod
Table 3-44: Breakout Wrench (Rotate) Cylinder

Quantity One
x 22.86 cm / 5.08 cm)
Function Used for breaking drill rod joints
Table 3-45: Breakout Wrench Swing Cylinder

Quantity One
x 22.86 cm / 5.08 cm)
Function Swing breakout wrench into and out of breakout position
Table 3-46: Dust Curtain Cylinder

Quantity Two
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 3-47: Drill Air Control Cylinder (HP Option)

Quantity One
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
Table 3-48: Dust Collector
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 non-cab side leveling jack
Configuration Cyclone
Dimensions 139.1 inch High x 54 inch Diameter (353.3 cm x 137.2 cm)
Filter Elements Nine
Inlet Diameter 12 Inches (30.5 cm)
Dust Hood Connection 12 inch (305mm) O.D. suction hose
Fan Motor Hydraulic vane motor, fixed displacement, 1.49 cu in/rev
(24.42 cc)
Operating Pressure 3,000 psi (206.8 bar)
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 Conveyor belting
Table 3-49: Bean Water Injection System
Type John Bean

Size 8.0 gpm (30.3 lpm)
Hydraulic Motor Drive Fixed displacement, 6.2 cu in/rev (101.62 cc) or optional
9.9 cu in/rev (162.23 cc)

Water Tank Size 400 gallons (1514.17 liters)

Optional 662 gallons (2506 liters)
Function Dust suppression
Table 3-50: Dynaset Water Injection System (Option)
Type Dynaset
Size 13.2 gpm (50.0 lpm)
Water Tank Size 400 gallons (1514.17 liters)
Function Dust suppression
Standard Tools and Manuals

• Hoist Plug for Drill Pipe
• Spindle Sub
• Maintenance and Parts Manuals (three sets)
• CD ROM Serial Parts Manual (three)
Weight
The standard PV-270E operating drill weight is 165,000 to 175,000 lb (74,843 kg to 79,379
kg). Option packages and add-ons are not included in these weights.

PV-270E Dimensions
Below is the legend table for the outline drawings for the PV-271 and PV-275 dimensions.
Table 3-51: PV-270E Dimensions
Description Feet/Inch M
A Height - Tower up, PV-271, 55 ft tower 88’ 10” 27.08
B Length - Tower up 52’ 5.5” 12.94
C Length - Tower down PV-271, 55 ft tower 88’ 1” 26.85
D Length - Undercarriage 21’ 3” 6.48
E Length - Jack center to jack center 26’ 7.5” 8.11
F Height - Jack to ground, non-drill end 1’ 3” 0.38
G Height - Decking to ground 5’ 0” 1.52
H Height - Tower down, non-drill end 22’ 5” 6.84
J Width - Track inside to track inside 8’ 1” 2.46
K Width - Jack center to jack center 12’ 10.5” 3.92
M Width - Overall 23’ 11.5” 7.30
N Width - Track 2’ 11.5” 0.90
O Height - Tower up, PV-271, 65 ft tower 90’ 5” 27.55
P Height - Tower off 16’ 1.5” 4.91
Q Height - Ground to cab top 13’ 10” 4.21
R Height - Ground to tower, drill end tower down 22’ 3” 6.78
S Width - Drill end, less dust collector 20’ 10.5” 6.36
T Height - Tower up, PV-275 71’ 7” 21.83
U Cab width 5’ 7” 1.70
V Width - Decking ext 17’ 7” 4.80
W Width - Under carriage assembly 14’ 0” 4.27
X Width - Decking cab end to under carriage edge 4’ 8.5” 1.43
Y Length - Decking 40’ 5.5” 12.33
Z Width - Tower, drill end, side view PV-271 4’ 6” 1.37
AA Width - Tower front view 7’ 4” 2.19
BB Height - Jack to ground drill end 1’ 3.5” 0.39

Description Feet/Inch M
CC Length - Cabin to under-carriage edge, front view 12’ 2.5” 3.72
DD Length - Cabin to jack center, front view 10’ 6” 3.19
EE Length - Tower support clevis to tower rear edge 9’ 11” 3.02
FF Length - Cabin to tower support clevis, front view 13’ 6” 4.11
GG Length - Tower front view PV-271, 55 ft tower 83’ 0” 25.3
HH Height - Main frame beam, decking front view 2’ 1” 0.63
JJ Height - Ground to cooler 12’ 7.5” 3.85
KK Height - Ground to transformer 13’ 5” 4.08
MM Length - Decking edge to cab edge 1’ 6.5” 0.46
NN Width - Decking edge to cab edge top view 2’ 4” 0.71
PP Width - Tower edge to hose tray side view 1’ 0.5” 0.32
QQ Height - To oscillator yoke bottom 1’ 8” 0.51
RR Length - Tower front view PV-271, 65 ft tower 84’ 6.5” 25.77
SS Length - Tower front view PV-275 65’ 9” 20.04
TT Width - Tower drill end, PV-275 5’ 4.5” 1.64
UU Length - Tower down PV-275 70’ 10” 21.60
VV Width - Ladder 19’ 8” 5.99
WW Width - Decking, std 13’ 9” 4.19
XX Length - Tower down PV-271, 65 ft tower 89’ 7.5” 27.32




Section 4 - Controls

PV-270E RCS4 Instruction Manual Section 4 - Controls
4.1 Rig Control System
The Rig Control System (RCS) provides a graphic user interface (GUI) representation of all
parameters useful to the operator.
General Information
The RCS provides the following advantages:
• Reduced noise in the cab

• Clean operating environment
— cab sealed with no hydraulic hoses

— no bulkhead connections
— no leaks in cab
• On-screen display of:
— All drilling pressures

— Power head position
— Electric Motor J1939 data
— Calibration and adjustment of system parameters available at the AC Service
access level
• Automatic operational and safety interlocks
• Automatic identification and display of system warnings and faults
• Access to diagnostic menus and troubleshooting capabilities that are viewed directly
from the display (only available at the Site Service access level)
• Options include:
— Auto leveling
— Autodrill system
— Common Communication Interface (CCI)
— Measure While Drilling system (MWD)

Section 4 - Controls PV-270E RCS4 Instruction Manual
— Rig Remote Access system (RRA)

— Global Positioning System (GPS)
— Teleremote
— Desktop viewer
— Rock formation analysis and data logging
Operator Menus
The system is comprised of a Central Computer (CC) and a number of electronic modules that
communicate with the CC using CAN (Controller Area Network) technology.
The Main screen appears when the system is powered up. From this screen the operator has
access to a number of control system menus. Some of these menus allow the operator to
change settings and make selections. Other menus only provide information to the operator.
The direct selection menus are accessed by a button on the display screen or on the control
panel keypads. Each menu has an alpha numeric identifier found in the upper left corner. The
main menu is identified as Main.
Figure 4-1: Main Screen
1 Ready access at operator

level
2 Alpha-numeric identifier
3 Language symbol
4 Contrast field
5 User symbol
The Main menu has several fields. Each field is accessed by touchscreen or by the arrow
buttons on the display.
• Language Symbol (globe symbol) - The operator can select the language desired
on the display. Select the options list to the right of the language symbol and press
enter. A list of all language options will be shown. Using the arrow buttons, select the
required language and press the Enter button.

• Contrast Field - Using the arrow buttons to toggle, access drop-down options list at
the right. Select the desired screen contrast option. Press Enter.
• User Symbol (man with hard hat) - Enter a password to access menus for service
and maintenance. There are three system access levels:
— Operator Access (OP Level) - No pass code is required for operator access.
This level provides the operator with read-only access to many menu screens
with the ability to adjust a certain few operating parameters, but no calibrations.
This allows the operator to adjust the machines functionality to his comfort zones.
No write access is given for changing calibrations of the machines outputs or
devices at the Operator Access level. The operator ability to read all screens can
aid maintenance personnel with troubleshooting.
— Site Service Access (SE Level) - A site Service Access (SE) pass code is
required for this access level. In addition to having access to everything
available at operator level, site service technicians and supervisors have active
access to more screens for troubleshooting and parameter adjustments. The
supervisor can set certain parameters and view actuations and parameter
screens that are not available to the operator. These screens offer many
advantages for troubleshooting and identifying faults that may arise.
— To gain Level Access, enter the appropriate system pass code at the USER field
on the Main display screen. Using the touchscreen or the arrow buttons, move
the cursor to the user field. Next using the arrow buttons, enter code for operator
(OP), serviceman (SE), or Atlas Copco (AC) personnel. This will change the
access description to the service access. On this screen at service level are
several more access choices. At the SE level, actual machine calibrations can be
modified and changed. This should only be done by Atlas Copco authorized,
trained personnel.
Figure 4-2: Access Code
— AC Service Access (AC Level) - A pass code is required for this access
level. This level of access is given to AC personnel and provides slightly higher
level access. This level allows for changing coefficients on the drill rig such as
actuations. The RCS4 Event Log only stores up to 250 entries. Events will not be

continuously logged after 250 entries have been stored on the event log. At this
access level, the drill calibrations can be modified and changed. This should only
be done by Atlas Copco authorized, trained personnel. The fields listed below
provide read-only access at the Operator level.
Figure 4-3: AC Access Level

GUI Display
Figure 4-4: Monitor
1 Touch buttons for changing screens (F keys) 3 Arrow buttons

2 Escape button (ESC) 4 Enter button
There are five shortcut buttons the left side of the display used to access screens containing
frequently used information. They are also used to advance to the proper working screen.
These buttons are mapped to display screens based on the operating mode selected.
Switching modes will bring up different screens.
1. Press the F1 button from the main screen to display the active working screens
for Setup mode, Propel mode, and Drill mode.
2. Press the F2 button from the various work screens to display the quick-access
parameter screen. This screen shows: Access to input field for delay codes,
Ordered air pressure and Options. There are sub menus for GUI, Parameters,
Override functions and Consumable. Use the touchscreen or arrow keys to
navigate to these fields. Press Enter to modify. There are two options to escape
out of the current screen. There is the touch infrared escape tab on the screen
or the soft key located on the bottom left of the display. When finished, press
the ESC button to back up one page per push to return to the work screen.
3. Press or touch the Override button to bring up a screen providing the ability to
override certain functions. Override is not a recommended practice for common
use. It should be used only for troubleshooting, special situations or
emergencies. Interlocks (shown in bold) can be overwritten by the operator.

Some functions are indicated on the screen but are not given override
capabilities by the operator, that are not bold or gray in color.
4. Press the F3 button to bring up the electric motor parameter screen. The
operator or maintenance personnel can view all electric motor primary
information.
5. Press the F4 button to select the GPS moving map option screen.
6. The Fn button is not used at this time.
System Button
1. Access the System screen by touching the square or highlight it with the arrow
buttons.
2. Press Enter to access the Modules or Levers screens (Menu M1).
3. Select Modules to view the operational status of the CANBUS. Each I/O
module is shown as a box on the network.
4. Select Levers to view the status and functionality of the levers. Note that
Modules and Levers menu is identified as M1. Selecting either will move a level
deeper into the main menu. Touching the Levers button brings up the Levers
screen shown below.
Figure 4-5: Accessing Modules

Accessing the Modules menu (M1.1) displays all of the electronic I/O modules that are part of
the system and their status. The CAN 0/Central Can are one CANBUS, consisting of the
display computer, the I/O modules, the decoders, and the CC.
Figure 4-6: Modules
• CAN1 is the display computer and electric motor ECM (ECU). The electric motor
ECM is identified as D601. All electric motor protection is handled by the electric
motor ECM. Only electric motor starting, normal electric motor shutdown, and
emergency shutdown (non-electric motor related) are controlled through the RCS
System. The electric motor J1939 CANBUS is connected to RCS display
computer as a read-only means to display the electric motor parameter data,
SAE faults, and status.
• There is a portion of the Bus called Central CAN. It consists of the display
computer and the decoder modules. These are actually connected to CAN 0.
• All modules and decoders are nodes on the network. Any node that has any
issue, an off-line or error communication, or an open input will appear as red.
Touch the red module to determine the reason. Often the reason is a missing
output load. Less frequently is the loss of CAN communication. A system fault
such as a break in CAN communication or power supply to the I/O module will be
indicated by the affected I/O module being shown in red. Status LED will be
flashing rapidly. The normal flash rate is one flash per second. All nodes that are
operational and on-line will appear green in color. Use the arrow buttons to move
between the I/O module to select any particular on-line module. Pressing the
Enter key or touching the selected I/O module will display more information about
that particular I/O module.

5. With the touchscreen or arrow buttons, highlight the Levers button and press
Enter to open the levers value screen (M1.2). From this screen the operator or
technician can operate a lever and visually see corresponding outputs and
status. If there is no change in the values seen, it would indicate a problem may
exist.
6. Press Esc to step backward through the menus to the log-in screen to return to
the Drill screen.
Figure 4-7: Levers
The levers are proportional controls. The farther the lever is moved off center, the more output
signal it sends. The X value represents the lever movement proportionally. And the Z value is
the trigger or rocker switch. Both X and Z output values are proportional to amount of
movement. The 0 value represents neutral position. Mid Pos is the switch input to indicate
when lever is in neutral/off position. The Mid Pos should change from a 1 to a 0 before the
value changes to a number other that 0.
Turning the pulldown and holdback knobs will result in a positive or negative feedback in the
twist knob fields. When the knob indicator is fully counterclockwise, the indication should be 0.
Drill Work Screen

Pressing F1 from the Main screen brings up the active screens. The Drill screen shown in
Figure 4-8 gives the operator a GUI representation of the standard work screen and identifies
the icons on it. The work screen below is shown in Setup mode and Drill screen active.

Figure 4-8: Drill Screen
1 Bit air pressure 10 Hole target depth

2 Penetration rate 11 Carousel, carousel index not stowed
3 Water pump outlet 12 Rod support open/closed
4 Air flow outlet 13 Breakout wrench stowed
5 Reset hole depth 14 Bit in/out of hole
6 Head position in tower 15 Rotation torque
7 Hole depth indication 16 Pulldown force
8 Head in safe to propel zone 17 Rotary head (bit speed)
9 Hole number
Along the bottom of the screen is the icon tray. It is a series of icons indicating active faults, or
conditions. Each State icon will come on at the left end when its mode is selected by the
operator. The above icons shown left to right are: Drill mode, Setup mode, Propel mode,
Joystick Neutral Detection, Power Head Position Calibration Warning.
Operating Modes
There are four operating modes for the RCS4. The four operating modes are Park mode,
Setup mode, Drill mode, and Propel mode.
Each control panel button has a light-emitting diode (led) that comes on when the panel button
is active. None are active unless the control panel On/Off button on the left control panel is
activated.

Figure 4-9: Operator Modes
1 Setup mode 7 Activate breakout wrench

2 Hoist joystick in Setup mode 8 Propel mode
3 Drill rotation joystick in Drill mode 9 Drill mode
4 Activate Cab Hoist button 10 Operator panel On/Off
5 Propel, Jacks, Breakout joystick 11 Tower raise/lower joystick in Setup mode
6 Activate jack 12 Feed up/down joystick in Drill mode
Park Mode
Park: RCS4 is a computer control system that is activated after the key switch has been
started. The drill will be in Park state/mode after the electric motor is started and unless the
control panels have been activated. The control panels must be intentionally activated by an
operator for any output commands or machine actuations to occur.
Once the control panels are activated by pressing the left control panel On/Off button, the
operator must choose a mode of operation. For example, press the Setup mode button to
enable the Setup mode.
Setup Mode
While the Setup mode is active, the Tower Raise/Lower joystick on the right control panel is
active and mapped to the tower raising and lowering functions. Moving the joystick raises and
lowers the tower. Tower raising/lowering speed is proportional to the amount of lever
movement from threshold to maximum. Pressing and holding the switch and pushing the
joystick away from operator raises the tower. Pressing and holding the switch and pulling the
joystick toward the operator lowers the tower.
While in Setup mode, the Activate Hoist button on the left control panel is pushed to activate
the hoist/winch. When activated, the Hoist joystick is mapped to operate the appropriate spool

valve for using the hoist/winch to raise and lower loads. The Activate Hoist button has an LED
that comes on when the hoist control is active. Pressing and holding the digital toggle button
and pushing the joystick away from the operator lowers the hoist load. Pressing and holding
the switch and pulling the joystick toward the operator raises the hoist load. The Activate Hoist
button must be pressed again to deactivate the hoist when it is not in use.
The drill can be leveled in Setup mode and/or Drill mode. When the Activate Jacks button
(located on the left control panel) is activated, the on-screen level indicator is shown on the
display screen. The lower joystick on the left control panel is mapped to the appropriate valve
spools for operating the jacks. Anytime the Leveling Jack joystick is active, the jacks can be
actuated. This joystick is a dual axis, spring centered control. The switch provides proportional
control of jack extend speeds. Always deactivate the jacks (deactivate Activate Jack button)
when not in use.
Figure 4-10: Setup Mode
1 Leveling Jack joystick 3 Activate Jack button

2 Joystick switch 4 Joystick pattern for jacks functions
1. Press the switch while the Leveling Jack joystick is in the center position to
activate all the jacks at once.
2. Move the Leveling Jack joystick to pattern position 1 to activate the two-spool
valves that supply oil to the NDE jack cylinders. Press the switch slightly to
extend or retract the cylinders slowly. Press the switch farther to increase the
speed.
3. Move the Leveling Jack joystick to position 2 or 3 to activate the corresponding
drill-end jack. The proportional switch controls extend speed.
4. Move the Leveling Jack joystick down to the center position between 2 and 3
to activate both drill-end jacks. The switch provides proportional speed control.

Drill Mode
When Drill mode is selected (Drill mode button on the left control panel), the hydraulics are
shifted and the controls are mapped to perform drilling functions. The drill can also be leveled
in Drill mode and/or Setup mode.
While the Drill mode is active, the Drill Feed Up/Down joystick on the right control panel is
active and mapped to the feed up and feed down drilling functions. Moving the joystick raises
and lowers the rotary head/drill string. Drill feed direction and speed is proportional to the
amount of joystick movement from threshold to maximum. Pressing and holding the switch
and pushing the joystick away from the operator feeds the rotary head/drill string up. Pressing
and holding the switch and pulling the joystick toward the operator feeds the rotary head/drill
string down.
While the Drill mode is active, the Drill Rotation joystick on the left control panel is active and
mapped to drill string rotation functions. Moving the joystick rotates the drill string. Drill rotation
direction and speed is proportional to the amount of joystick movement from threshold to
maximum. Pressing and holding the switch and pushing the joystick away from operator
rotates the drill string counterclockwise. Pressing and holding the switch and pulling the
joystick toward the operator rotates the drill string clockwise.
While in Drill mode, the Activate Breakout Wrench button on the left control panel is pushed
to activate the breakout wrench. When activated, the lower joystick on the left control panel is
mapped to the appropriate valve spools for operating the breakout wrench functions. The
Activate Breakout Wrench button has an LED that indicates the breakout wrench control is
active.
Anytime the Activate Breakout Wrench joystick is active, the breakout wrench can be actuated.
This joystick is a dual axis, spring-centered control. The switch must be depressed and held
in while operating the breakout wrench. Always deactivate the breakout wrench (deactivate
Activate Breakout Wrench button) when not in use.
Figure 4-11: Breakout Wrench
1 Breakout wrench stow

2 Break jaws
3 Breakout wrench unstow
4 Release jaws
1. Push the joystick away from you, with the switch depressed, to command the
breakout wrench to swing out of the way and move to the stow position.
2. Pull the joystick towards you, with the switch depressed, to command the
breakout wrench to swing in and engage the drill pipe (move to the unstow
position).

3. Move the joystick to the right, with the switch depressed, to rotate the breakout
wrench counterclockwise and break (loosens) the thread joint.
4. Move the joystick to the left, with rocker switch depressed, to rotate the
breakout wrench clockwise and open the breakout wrench jaws.
Propel Mode
When the Propel mode is selected the propel control joystick is mapped to the propel
functions.
Operator Controls
The RCS system controls include computer display, joysticks, pushbuttons, and knobs. All
operational functions can be controlled from the operator seat within the cab of the drill.
Figure 4-12: RCS Operator Controls

RCS Control Panel Layout
Figure 4-13: RCS Control Panel Layout
Left Control Panel Right Control Panel

Operator Input Actions

The operator controls allow the operator to perform a set of input actions. For example, input
action for a joystick could be: joystick forward or joystick backward. The basic operator input
actions used to control the drill are shown below.
Table 4-1: Input Actions
Control Description Action
Left single axis Multi-function single axis, non self- centering, Forward - Back
joystick friction hold, analog joystick with digital rocker
button located on the left control panel.
Left joystick digital Press and hold digital rocker button while Press, hold, and push
rocker button moving the left joystick.
Right single axis Multi-function single axis, non self- centering, Forward - Back
joystick friction hold, analog joystick with digital rocker
button located on the right control panel.
Right joystick digital Press and hold digital rocker button while Press, hold, and push
rocker button moving the right joystick.
Left dual axis joystick Dual axis, spring centered analog joystick with Forward - Back - Left -
return to zero rocker switch located on the left Right, Rocker Button
control panel. Up - Down
Left control knob Potentiometer located on the left side of the Turn clockwise and
(Right control panel) right control panel counterclockwise
Right control knob Potentiometer located on the right side of the Turn clockwise and
(Right control panel) right control panel counterclockwise
Function buttons Digital function/mode buttons are located on Push

the left and right control panels
RCS Left Control Panel Overview

• One multi-function single axis, non self-centering, friction hold analog joystick with
center detection switch. Digital rocker switch for drill rotation in Drill mode and hoist
functions in Setup mode.
• One dual-axis, spring-centered analog joystick with analog return to zero rocker
switch used for propel functions in Propel mode, leveling jack functions in Setup
mode, and breakout wrench functions in Drill mode.
• One set of mode/function buttons on the left control panel.
• Two return to zero panel position adjusting paddles.

Figure 4-14: Left Control Panel Controls
1 Joystick with switch for hoist and drill

rotation functions
2 Joystick with switch for propel,
leveling jacks, and breakout wrench
functions
3 Mode/function buttons
4 Adjusting paddles
Left Control Panel Buttons

The following is a list of the left control panel button functions. Each button has a light-emitting
diode (LED) that comes on when the function is active.
NOTE: The numbers and names are for functional illustrating purpose
only. The numbers and names are not on the actual controls.

Figure 4-15: Left Control Panel Buttons

Table 4-2: Left Control Panel Buttons
Button Function
#0 Control panel on/off button activates panels.
#1 Shifts controls to Setup mode. All active joystick functions are mapped to
setup activities (Tower Raise and Lower, Hoist, Leveling Jacks).
#2 Tower vertical pinning (disengage) unlock.
#3 Tower angle pinning (disengage) unlock.
#4 Strut (tower) pinning (disengage) unlock (Not applicable).
#5 Shifts controls to Drill mode. All necessary controls are now mapped to
the drilling functions.
#6 Shifts controls to Propel mode. All controls needed for propelling the drill
are active.
#7 Tower vertical pinning (engage) lock.
#8 Tower angle pinning (engage) lock.
#9 Tower strut pinning (engage) lock (Not applicable).
#10 Activates dust flap up function.
#11 Activates hoist control. The left hoist joystick is mapped to raise and lower
hoist when button #11 is active. It must be deactivated to return to
another function.
#12 Activates dust flap down function.
#13 Auto navigation option. The auto interlock function button #25 on the right
control panel must be held down while activating the auto navigation
button on the left control panel.
#14 Auto drill option. The auto interlock function button #25 on the right
control panel must be held down while activating the auto drill button on
the left control panel.
#15 Activate Jack function. Activates jacks control. The left propel, leveling
jacks, and breakout wrench joystick is mapped to level the drill when
button #16 is active. It must be deactivated to return to another function.
#16 Dust hood up function (not applicable).
#17 Activate breakout wrench. The left propel, leveling jacks, and breakout
wrench joystick is mapped to control breakout wrench movement when
button #17 is active. It must be deactivated to return to another function.
#18 Dust hood down function (not applicable).

RCS Right Control Panel Overview

• One multi-function, single-axis, non self-centering, friction hold analog joystick with
center detection switch. Digital rocker switch for tower raise/tower lower functions in
Setup mode and drill feed speed up/down functions in Drill mode.
• One control knob is used to increase or decrease feed pressure in the Drill mode.
• One control knob is used to increase or decrease holdback force while in the Drill
mode.
• One set of mode/function buttons on the right control panel.
• Two return to zero panel position adjusting paddles.
Figure 4-16: Right Control Panel Controls
1 Joystick with switch for tower raise/lower

and drill feed up/down functions
2 Control to increase/decrease feed pressure
3 Control to increase/decrease holdback
force
4 Mode/function buttons
5 Adjusting paddles
Right Control Panel Buttons

The following is a list of the right control panel button functions. Each button has an LED that
comes on when the function is active.
NOTE: The numbers and names are only for functional illustrating
purpose. The numbers and names are not on the actual controls.

Figure 4-17: Right Control Panel Buttons
Table 4-3: Right Control Panel Buttons
Button Function
#1 Deck fork disengage function. Activates sliding deck fork to retract and
disengage from drill pipe.
#2 Air throttle open function - Optional. (Activates drill throttle open option for
high pressure drills only).
#3 Cable reel wind-in function. (Not Applicable)
#4 Carousel index clockwise function. Activates carousel to index clockwise.
#5 Carousel swing-in function. Activates carousel to swing into (stow)
position.
#6 Deck fork engage function. Activates sliding deck fork to extend and
engage the drill rod.
#7 Air throttle close function - optional (Activates drill throttle close option for
high pressure drills only)

Button Function
#8 Cable reel wind-out function. (Not Applicable)
#9 Carousel index counterclockwise function. Activates carousel to index in
a counterclockwise direction.
#10 Carousel swing out function. Activates carousel to swing out (under rotary
head) position.
#11 Water injection on/off function. Activates/deactivates Water Injection
pump.
#12 Dust collector on/off function. Activates/deactivates dust collector.
#13 Air regulation on/off function. Activates/deactivates drill air control.
#14 High/low engine speed function. Activates engine throttle and controls
engine rpm (high/low).
#15 Water injection flow Increase function. Water injection pump must be
active (#11) before increasing the water flow with button #15.
#16 Dust collector cleaning function. Activates/deactivates dust collector
cleaning system (pulsation). Dust collector On/Off function (button #12)
must be active for button #16 to function.
#17 Air flow increase. Air regulation function (#13) must be active. Press air
flow increase button #17 to increase air flow.
#18 Rotation torque increase. Increases the amount of pressure applied to
rotary head rotation motors to increase torque on bit during drilling.
#19 Water injection flow decrease. Water injection pump must be active (#11)
before decreasing the water flow with button #19.
#20 Thread lubrication. Activates/deactivates the thread grease engage
function.
#21 Air flow decrease. Air regulation function (#13) must be active. Press air
flow decrease button #21 to decrease air flow.
#22 Rotation torque decrease. Decreases the amount of pressure applied to
rotary head rotation motors to limit torque on bit during drilling.
#23 Rod support close function. Engages (closes) rod support during drill
change.
#24 Rod support open function. Moves rod support out of the way (open).
#25 Auto function. The Auto button must be activated before activating auto
level, auto navigator, and auto drill.

RCS Control Panel

The control panel is located to the right of the operator seat. It contains an Emergency Stop
(E-Stop) button, horn button, optional Jack Auto Level Override button, and a key switch.
Figure 4-18: RCS Control Panel
1 E-Stop button
2 Horn button
3 Jack auto level override button (option)
4 Key switch
Emergency Stop
The red Emergency Stop (E-Stop) button shuts off the electric motor when it is pushed in. The
E-Stop button on the right control panel does not have a light inside the button. The two
standard E-stop buttons on the outside of the cab have a red light inside the button. When the
key switch is in the run position, the E-stop light illuminates. The E-Stop button must be pulled
out to start the electric motor.
Horn Button
The Horn button activates the horn to alert anyone near the drill that the electric motor is about
to be started or to alert personnel in the work zone that the drill is about to be moved.
Jack Auto Level Override Button

The Jack Auto Level Override button is only available when the drill has the Jack Auto Level
function. This button is used only when the drill is out of limits and must use the manual jack
leveling to bring the drill back into limits.
Key Switch
The Off/On/Run/Start key switch turns on all electrical power to the electric motor and controls
the stop and run operations. Turn the Off/On/Run/Start key on to allow the RCS system to

power up (boot up). When the RCS system is powered up, turn the key to the Start position to
energize the electric motor. When the electric motor starts, release the Off/On/Run/Start key
switch immediately.
RCS Operator Dash Switches and Circuit Breakers
RCS Dash Switches

The following is a list of the dash switch functions:
NOTE: The numbers are for functional illustration purpose only. The
numbers are not on the actual controls.
Figure 4-19: Switches, Controls, and Hour Meter
1. Drilling light (standard)

2. Tram light (standard)
3. Maintenance light (standard)
4. Interior/dome light (standard)
5. Reading light (standard)
6. Down-the-hole (DTH) lube - not shown (option)
7. Spare
8. Spare
9. Temperature controller knob a/c and heater (standard)
10. Spare
11. Spare
12. Hour meter, power on machine (standard)
13. Spare
14. Spare

15. Spare
16. Spare
17. Windshield washer/wiper - non-drilling end glass (standard)
18. Windshield washer/wiper - drilling end side glass (standard)
19. Windshield washer/wiper - drilling end glass (standard)
20. Instrument illumination - plus/minus (standard)
21. A/C on control (standard)
22. A/C fan 3-speed control (standard)
23. Spare
24. Spare
25. 12 volt plug-in receptacle - (option)
Circuit Breakers
Figure 4-20: Circuit Breaker Panel
The following is a list of circuit breakers and functions:
• CB-1 (15 Amp) - Propel lights

• CB-2 (15 Amp) - Drill lights
• CB-3 (15 Amp) - Key switch circuit
• CB-4 (20 Amp) - Attention horns
• CB-5 (15 Amp) - E-Stop circuit

• CB-6 (15 Amp) - Light dimmer, Standard E-Stop

• CB-7 (25 Amp) - Window washer/wipers
• CB-8 (15 Amp) - Air rid chair, DHD lubrication (option), Video camera (option), and
Boarding ladder (option)
• CB-9 (15 Amp) - RCS Display D501, WLAN, GPS (option)
• CB-10 (15 Amp) - Chair: Operator Control D500:1, D500:2, (option: CCI, RRC-OU)
• CB-11 (50 Amp) - Cab conditioning heat and cooling
• CB-12 (20 Amp) - Racor fuel filter, thread grease (option)
• CB-13 (15 Amp) - High pressure sodium lights
• CB-14 (15 Amp) - RRC-MU, fan control relay
• CB-15 (15 Amp) - Spare
• CB-17 (20 Amp) - 24/12 VDC converter
USB Slot
There is a USB slot on the chair to insert a memory stick for saving drill parameters or loading
the drill program.
! CAUTION
Do not use this USB slot for anything other than saving drill parameters
or loading the drill program. Plugging in any device such as a cell phone
can result in damage to the RCS display.

Figure 4-21: USB Slot
Radio Remote Control
! WARNING
Operating the Radio Remote Control requires special training. Only

trained personnel are allowed to use it. Incorrect use or disregard of the
safety regulations in force could result in serious personal injury or
damage to property.
The Radio Remote Control (RRC) system allows the operator to work in a safer, more efficient
way in unsecured environments.
The RRC system has a working distance of 197 feet (60 meters).
Figure 4-22: Remote Operator Unit
1 E-Stop button

Fault Finding Using the RCS

Fault finding on the RCS4 is done directly on the display screen. The system will show
on-screen fault information.
The fields listed below provide read-only access at the Operator level.
The System Symbol (stethoscope symbol) contains the menus used for fault finding.
• Logging
• Setup
• Rig
• Drill
• Compressor
Active Faults and Conditions

Fault finding on the RCS is done directly on the screen. The system will show on-screen active
faults and conditions.
Along the bottom of the active display screens is an icon tray. It is a series of icons indicating
active faults or conditions. Each state icon will come on at the left side when its mode is
selected by the operator. The icons shown left to right are: Drilling mode, Setup mode, Propel
mode, Joystick Neutral Detection, Radio Remote Control (RRC), RCS no contact with
modules, Joysticks not calibrated warning, and Rotary Head Position not calibrated warning.
Figure 4-23: Fault Icons
1 Drill mode 5 Radio remote control

2 Setup mode 6 No contact with modules
3 Propel mode 7 Joysticks not calibrated
4 Joystick neutral detection 8 Rotary head position not calibrated

4.2 Emergency Stop Controls
Emergency Stop Buttons

There are eight standard E-Stop buttons on the PV-270 drill and up to two remote E-Stop
buttons. The locations are:
• In the cab, right side of operator seat

• Lanyard on tower main chord, bottom of tower cab side
• On hand rail, top of stairs at drill end, non-cab side
• Ground level, next to stairs at drill end, non-cab side
• Non-cab side of power pack, on the outside of electrical box
• On hand rail, top of boarding ladder for cab
• Ground level, kick plate of decking, cab side next to boarding ladder for cab
• Ground level, non-drill end, cab side
When depressed, any of these buttons will shut down the system. Pulling the tower lanyard
shuts the drill down in the same manner as the E-stop buttons.
The monitor screen displays which E-stop button is pushed in. Select the main screen, rig,
guards, and the E-Stop buttons will be displayed. The E-stops showing 1 are not pushed in,
the E-stops showing 0 have been pushed in.
When the situation requiring the shutdown is corrected, all E-stops must be pulled out before
the drill restarts. The display will indicate when an E-Stop button has been depressed and
which one it is in the circuit.
! WARNING
In the event of unusual noise, leaks, cooling fan non-operation or any

other non-listed problem, IMMEDIATELY SHUT THE DRILL DOWN USING
THE E-STOP BUTTON to prevent damage to the drill. Notify the immediate
supervisor of the problem and do not run the drill unless the problem is
corrected.

Remote Hoist Emergency Stop Button

The remote hoist operates through a remote control unit connected by an umbilical cable into
a cable connector socket. It is enabled/disabled by a switch located on the frame under the
deck on the non-cab side drilling end. There is an E-Stop button built into the remote hoist
control unit.
NOTE: The Activate Cab Hoist button located on the left control panel
must be switched off for the remote hoist to function.
Figure 4-24: Remote Hoist Emergency Stop
1 Remote hoist switch 5 E-Stop

2 Remote hoist cable connector socket 6 Remote hoist control
3 Proportional switch 7 Umbilical cable
4 On/Off toggle 8 Trigger
Optional Fire Suppression Systems

The drill may be equipped with either automatic and/or manually activated fire suppression
systems. There will be a fire suppression system pressure switch with the Ansul system. The
pressure switch is located inside the electrical box next to the power pack on the non-cab side.

Figure 4-25: Fire Suppression System
1 Electrical box next to power pack (NCS) 2 Fire suppression system pressure switch


Section 5 - Operation

PV-270E RCS4 Instruction Manual Section 5 - Operation
5.1 Operating Safety
General Information
The following operational hints should be observed:
• Always perform safety checks prior to starting and using the drill.
• After starting the electric motor, wait until the hydraulic oil and the airend oil are up
to normal operating temperatures before operating the drill.
• Never allow uncontrolled movement of the tracks.
• Do not lubricate the drill while the electric motor is running.
• Always operate the drill at full power, when under normal drilling and propelling
conditions.
• If 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 a risk of
overturning and when loading onto a transporter where there is a risk of overturning.
• Never propel or stop the drill on a slope or surface that is liable to collapse.
• Never stop the drill against a high wall that is liable to collapse or cause a crushing
risk.
• Always sound the horn (option) before moving the drill in either direction to alert
personnel and allow sufficient time before putting the drill in motion.
• When the hoist is not in use, stow the hoist hook to the base of the machine.
! WARNING
Do not use leveling jacks to take out drill rod from the hole. There is
presence of a hazard which can cause severe personal injury, death or
substantial property damage if the warning is ignored.

Section 5 - Operation PV-270E RCS4 Instruction Manual
5.2 Pre-Start Inspection
Walk Around Inspection

Before every shift and prior to starting the PV-270E series drill, a walk around inspection of the
overall drill should be performed. 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.
Hydraulic System
! WARNING
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
A careful inspection of all hydraulic components should be made to detect any signs of oil,
possible oil 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.
Compressor System
! WARNING
High pressure can cause severe injury or death. Completely relieve

pressure before removing the filler plug, fittings or receiver cover.
A careful inspection of all compressor components (air end, air end pump, valves, hoses,
fittings and filter) should be made to verify there are no compressor oil leaks or any
irregularities. This is particularly important when the drill is new.

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.
Check all bolted assemblies for tightness. Inspect the entire drill for any loose, worn or missing
parts and replace them as needed. Inspect fluid lines, hoses, filler openings, drain plugs,
pressure caps, tower cables, hoist wire cables, electric motor, safety shrouds, and the area
under the drill for signs of leakage.
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.
Operator Areas
Keep operator areas clean. Clean cab windows, mirrors, and all lights. Check that all lights
function.
Make sure the operator 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 cab and the operator platform area.
Secure these items in the tool box, tool cabinet or remove them from the drill.
Pre-Operational Inspection
Smart Operating Tips

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 are in addition
to the 8- to 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 the drill. Refer to the instructions given in Section 6 for the correct maintenance
procedures and oil specifications.
! CAUTION
Do not perform any function that could put someone in danger. Safety
should be the main concern for operators and helpers during every
aspect of drilling.

Complete the pre-operational inspection below.
• Inspect for loose, damaged, or bent items on the tower.

• Inspect for hydraulic leaks in the tower.
• Inspect the undercarriage for missing, loose, broken, or bent parts.
• Inspect the water tanks for damage or leaks.
• Inspect the drive motors, hosing, and final drive for leaks and loose, damaged, or
missing parts.
• Inspect the HOC/COC cooler for damage or leaks.
• Inspect the drill deck area for leaks and damaged or missing parts.
• Inspect the cable tensioning system for damage or leaks.
• Inspect cables for tension, wear, or damage.
• Inspect the pump drive, pumps, valves and hosing for leaks, damaged or missing
components.
• Check the lubricant level in pump drive gearbox.
• Inspect the couplings on each end of the electric motor for any signs of failure,
damage or leaks.
• Inspect the hydraulic reservoir tank for damage, leaks or apparent missing
components.
• Check the fluid level in the hydraulic tank sight glass.
• Inspect the compressor assembly for loose, missing or damaged parts.
• Inspect the compressor assembly for oil leaks.
• Check the oil level in the compressor receiver tank sight glass.
• Inspect the compressor receiver tank safety valves for leaks, loose parts or damage.
• Inspect the compressor air inlet system for damage, air leaks, missing parts, loose
mountings, etc.
• Inspect the fire suppression system for readiness, leaks, and damaged or missing
components.
• Inspect the cab for broken windows, broken or damaged door hinges, latches, knobs
and torn seals.
• Inspect the seat pod for visible damage to the controllers, chair, or touchscreen.
• Check the area around the drill for any unauthorized vehicles, people, power line
obstructions, or any other obstructions in the immediate drill area.
• Top off any low fluid levels. Report any damage, leaks, broken or missing
components, as well as any obvious malfunctions or safety hazards to your
immediate supervisor.

5.3 Rig Control System (RCS)
! WARNING
Operation and maintenance of the RCS drills requires special training

through Atlas Copco. Do not attempt to drill, operate, repair, or perform
maintenance on the drill if you are not trained or experienced with the
RCS4 drill operating system controls and programs.
Operator Modes
There are four states or operating modes that apply to the RCS4 system.
• Park mode: RCS is a computer control system that is activated after the key switch
has been turned on. The drill will be in Park state/mode after the electric motor is
running and until the control panels have been activated. The control panels must be
intentionally activated by an operator for any output commands or machine
actuations to occur.
NOTE: Activate the control panel by pressing the control panel On/Off
button, then select a mode of operation such as the Setup mode.
• Setup mode: Press the Setup mode button. The right main joystick is activated and
mapped to the tower raising and lowering functions. Press the toggle switch and
push the joystick away from you to raise the tower. Pull it toward you to lower the
tower.
• Drill mode: Press the Drill mode button. The two control panel upper joysticks actuate
feed and rotation. The drill can be leveled in the Drill mode. Press the Activate Jacks
button to enable the jack controls. Always deactivate the Activate Jacks button when
jack controls are not in use.
• Propel mode: Press the Propel mode button. The multi-function propel control lever
is mapped to propel functions. The brake is not released until the rocker button is
pushed. Once the rocker button is pushed, wait two seconds to move the lever off
center. Otherwise, the RCS4 will give a Loss of brake pressure fault. The operator

can also watch the brake pressure gauge on the propel screen to see when brake
release pressure reaches above the minimum of 350 psi, then move the lever.
Figure 5-1: Rig Controls
1 Left joystick: Hoist function is Setup 8 Control panel on/off button

mode; Rotation function in Drill mode
2 Digital rocker switch 9 Digital rocker switch
3 Setup mode button 10 Right joystick: tower raise/lower in Setup
mode; Drill feed up/down in Drill mode
4 Digital rocker switch 11 Rotary control knob: increase/decrease
holdback pressure
5 Multi-function joystick: Propel, Jacks, 12 High/low engine speed button (Diesel
Wrench engines only)
6 Propel mode button 13 Rotary control knob: increase/decrease
pulldown pressure
7 Drill mode button
Operator Menus on RCS4 Display

The operator GUI display consists of an infrared touchscreen display panel and two sets of
buttons. The operator can navigate around the system by touchscreen and/or by pushing the
buttons.

Figure 5-2: GUI Display
1 Function buttons
2 Escape button
3 Navigation buttons
4 Enter button
There are five buttons on the left side. Four are marked F1 through F4. These buttons are
shortcut keys to screens containing frequently used information. They are also used to
advance to the proper working screen.
• Press the F1 button from the Main screen to bring up the active work screens for
Propel, Setup, and Drill modes.
• Press the F2 button from the various work screens to bring up the Quick-Access
Parameter screen. This screen provides access to the input field for delay codes,
ordered air pressure and options. There are sub menus for GUI parameters and
override functions.
• Press the F3 button to bring up the Electric Motor parameter screen.
• Press the F4 button to select the optional GPS moving map screen.
• The Fn button is not used at this time.

The six buttons across the bottom are used to navigate between the fields on the screen and
for entering information. The escape button is marked Esc. The navigation buttons for cursor
movement are the left, up, down, and right arrows.
F1 Screen
Press the F1 button to display the Drill screen. In Drill mode, the display screen shows the drill
monitoring functions.
Figure 5-3: Drill Monitor Functions
1 BIT air pressure 9 Hole number

2 Penetration rate 10 Hole target depth
3 Water pump outlet 11 Carousel, Carousel index not stowed
4 Air flow output 12 Rod support open/closed
5 Reset hole depth 13 Breakout wrench stowed
6 Head position in tower 14 BIT in/out of hole
7 Hole depth indication 15 Rotation torque
8 Head in safe to propel zone 16 Pulldown force

Along the bottom of the screen are a series of icons. Each icon is visible when its mode is
selected.
Figure 5-4: Mode Icons
1 Drilling mode 4 Joystick neutral detection

2 Setup mode 5 GPS navigation (optional)
3 Propel mode 6 Rotary head position calibration
A green icon indicates the icon is enabled. A yellow icon indicates a fault condition. The yellow
icon above is a fault condition indicating the rotary head is not calibrated. The program does
not know where the rotary head is located and the interlocks are not functional. If the operator
moves the rotary head, it could make contact with the carousel or rod support.
NOTICE
NOTICE
This length sensor icon will become active any time the computer loses
track of the powerhead position or when the computer is rebooted.
Whenever the powerhead calibration warning icon is active, it is an
absolute warning that the computer does not know for sure where the
powerhead is within its length of travel. Any time this icon is active, the
first priority of the operator is to open the rod support, make sure the
carousel is in the stowed position, and then to move the powerhead
through its travel to activate the calibration switches. This re-calibrates
the powerhead position and will send the true location of the powerhead
to the computer.
The RCS software is programmed and configured so that when this powerhead calibration
icon becomes active for any reason, no powerhead movement will occur until the rod support
is moved to the open position.
Then, after opening the rod support and until properly calibrated, feed will only move at half
speed. This is an effort to prevent the powerhead from contacting the rod support from either
below upward, or from above moving downward.
Once the rod support is recognized by the computer as being opened, the head must be
moved through its travel zone to re-calibrate its location. There are two switches in the tower
for re-calibrating the head position. These are the upper calibration and a lower calibration

switches. Once the computer recognizes the true powerhead position, this icon will turn off and
speed will resume in the normal mode.
Scroll to the next screen, press F1 again. This screen (Figure 5-5) shows the Tower angle
position, Drill spirit level, Tower movement indications (Raise/Lower), Tower pinning
indications (Angle drill), and Tower pinning indications (Vertical drill).
Figure 5-5: Tower Angle Positioning Screen
1 Tower angle position 4 Joystick neutral

2 Tower movement indications (raise/lower) 5 Setup mode
3 Tower pinning indications 6 Drill level
NOTE: If the machine does not have angle drill, the top tower pinning
indication light will not be on the screen. Only the bottom tower pinning
indication light will be displayed for tower vertical pinning.
Scroll to the next screen, press F1 again. This screen (Figure 5-6) shows Brake release
pressure, Jack indication lights, Drill bit out of the hole, and Drill level.

Figure 5-6: Brake Release Pressure Screen
1 Brake release pressure 4 Joysticks neutral

2 Jacks indication light (4 green lights) jack fully retracted 5 Propel mode
3 Drill bit out of hole (green light) 6 Drill level
Green jack light, jack is fully retracted (stowed). Yellow jack light, jack is in transit. Red jack
light, jack is on the ground.
Green drill bit out of hole light, rotary head at top of tower and safe to propel.
F2 Screen
Press F2 from the various work screens to bring up the Quick-Access Parameter screen. This
screen shows Access to input field for Delay Codes, Ordered Air Pressure, Options, and Sub
menus for GUI parameters and Override functions. Use the touchscreen or arrow keys to
navigate to these fields and press Enter to modify. Use arrow keys to increase or decrease the
numbers in the field.
The box on the right shows the operator a real time readout of the various hydraulic pressures
on the machine.

Figure 5-7: Quick-Access Parameter Screen
Press F2 again to access the collaring screen only if you have the auto drill feature. This
screen allows the drill operator to enter numbers for each collaring input for three different
formations using the drill bit drop-down arrow.
Figure 5-8: Collaring Screen
When finished, press the Esc button to back up. Continue pressing the Esc button to return to
the Drill screen.

F3 Screen
Press F3 to bring up the Electric Motor Prime Mover and Fluid Levels screen. The operator or
service personnel can monitor all of the primary electric motor information.
Figure 5-9: Electric Motor Prime Mover and Fluid Levels Screen
1 Resistor temperature detector (RTD) winding temperature 8 Water tank level

2 Outside winding temp 9 Mega watt hour (MWh)
3 Electric motor hour meter 10 Power factor (PF)
4 Bearing temperature motor (DE and NDE) 11 Frequency 50 or 60 Hz
5 Lube grease tank level 12 Voltage 3-phase ABC
6 Airend compressor temperature 13 Amperage 3-phase ABC
7 Hydraulic oil temperature 14 Inside winding temp
F4 Screen
Press F4 to bring up the optional GPS Navigation System. If the drill does not have GPS, this
button has no function.
If the drill has GPS, reference the RCS4 Navigation manual and latest revision for a complete
description of the navigation system.

RCS4 Screen Displays

The system is comprised of a control panel (also called Central Computer or Display) and a
number of electronic modules, all of which are individual computers that communicate with the
CC using CAN technology. (CAN = Controller Area Network)
• The Main screen appears when the RCS system is powered up. From this screen the
operator has access to a number of control system menus. Some of these menus
are Active, i.e. Different settings and selections can be made in these menus. Other
menus are Passive and only provide visual information to the operator.
• The most important menus for the operator are called direct selection menus, which
means that they are directly accessible using a button on the perimeter of the screen
or on the keypads on the control panel. The operator cannot change any calibrations.
Operator can enter operational data such as operator log in, hole number, and target
depth.
• Each menu page has an alpha-numeric identifier that is found in the upper left corner.
Figure 5-10: Main Menu Screen

The Main menu has several fields that are accessed by touchscreen or by using the arrow
buttons on the display to toggle from field to field, they are:
• Language (globe symbol) - The operator can select the language desired on the
display. Select the options list to the right of the language symbol and press enter. A
list of all language options will be shown. Using the arrow buttons, select the required
language and press the enter button.
• Contrast - Using the arrow buttons to toggle, access the options list drop down at the
right. Select the desired screen contrast option. Press enter.
• User (man with hard hat) - Here is the location to enter a password to access menus
for service and maintenance personnel. No password is required for operator menus.
• Fields shown below are read-only access at the operator level.
—System Symbol
—Logging
—Setup
—Rig
—Drilling
—Compressor
System Button
• Access the System screen by touching the square or highlight it with the arrow keys.
• Press Enter to access the Modules and Levers screens (Menu M1).
• Select Modules to view the operational status of the CANBUS and press Enter. Each
I/O module is shown as a box on the network.
• Select Levers to view the status and functionality of the levers. The Modules and
Levers menu is identified as M1. Selecting any access will move a level deeper into
the main menu. Touching the access buttons for Modules and Levers brings up the
screens in Figure 5-11.

Figure 5-11: System Screens
Accessing the Modules menu (M1.1) displays all the I/O modules that are part of the system
and their status. There are two CANBUS networks connected to the display. The first network
includes the I/O modules and decoders (control panel). The second network includes the
MC@ (compressor) and Drive (electric motor).
Figure 5-12: Modules Menu

The display computer, M2C, and Drive are connected by CANBUS. The motor management
relay is identified as D601) All motor protection is handled by the Drive D601 (GE 369 Multilin).
Only motor starting, normal motor shutdown and emergency shutdown (non-motor related)
are controlled via the RCS system. The J1939 CANBUS is connected to RCS display
computer as a read only means to display the motor’s parameter data, status, and also
compressor control.
• With the touchscreen or arrow buttons, highlight the levers button and press Enter to
open the levers value screen (M1.2) (Figure 5-13). From this screen, the operator or
technician can operate a lever and visually see corresponding outputs and status. If
there is no change in the values seen, it would indicate a problem may exist.
• Press Esc to step backward through the menus to the log-in screen to return to the
operator screen.
All modules and decoders are nodes on the network. Any node that has any issue, an off-line
or error communication, or an open output will appear as Red. Touch the red module to
determine the reason. Often the reason is a missing output load. Less frequently is the loss of
CAN communication. A system fault such as a break in CAN communication or power supply
to the module will be indicated by the affected module being shown in red. Status LED will be
flashing rapidly. The normal flash rate is one flash per second. All nodes that are operational
and on-line will appear green in color. Use the arrow keys to move the cursor to select any
particular on-line module. Press the enter key to display more information about that particular
module.

Figure 5-13: System Levers Value Screen
The levers are proportional controls. This means the farther the lever is moved off center, the
more output signal it sends. An X value represents the lever movement proportionally. A Z
value is the switch or rocker switch. Both X and Z output values are proportional to the amount
of movement. A 0 value represents neutral position. Mid Pos is the switch input to indicate
when lever is in neutral/off position. The Mid Pos should change from a 1 to a 0 before the
value changes to a number other than 0.
Turning the pulldown and holdback knobs will result in a positive or negative feedback in the
twist knob fields. When the knob indicator is straight up, the indication should be 0.

Logging
• Access the Logging screen by touching the square or highlight it with the arrow
buttons.
• Press Enter to access the Event Log and Statistics screens (Menu M2).
• Select event log to view the events that have occurred on the drill. The event log will
store up to 250 events.
• Select Statistics to view the accumulated hours for each parameter listed. The Event
Log and Statistics menu is identified as M2.
NOTE: Selecting any access will move a level deeper into the main menu.
Touching the access buttons for Event Log and Statistics brings up the
screens in Figure 5-14.
Figure 5-14: Logging Screens

Figure 5-15: Logging Event Log Screen
• With the touchscreen or arrow buttons, highlight the Event Log (M2) button (Figure
5-15) and press Enter to open the event log (M2.1). From this screen, the operator
or technician can view up to 250 events on the drill.
• Press Esc once to step backward to return to the M2 screen.
• With the touchscreen or arrow buttons, highlight the Statistics button and press Enter
to open the Statistics screen (M2.3) (Figure 5-16).

Figure 5-16: Logging Statistics Screen
• With the touchscreen or arrow buttons, highlight the Statistics (M2) button and press
Enter to open the Statistics screen (M2.3) (Figure 5-16). From this screen, the
operator or technician can view the accumulated hours for each parameter listed.
—Rotation hours
—Machine hours
—Lube Pump hours
—Electric Motor hours
—Accumulated hole length
—Tram hours
—Air on hours

Setup
• Access the Setup screen by touching the square or highlight it with the arrow buttons.
• Press Enter to access the Sensors and Actuations screens (Menu M3).
• Select Sensors to view the Jack Sensors and Other Sensors (M3.1) and press Enter.
Selecting any access will move a level deeper into the main menu.
• Select Sensors to view the status and functionality of the jacks and other sensors.
• Select Actuations to view the actuation list of the outputs (M3.2). The Sensors and
Actuations menu is identified as M3.
NOTE: Touching the access buttons for Sensors and Actuations brings
up the screens shown in Figure 5-17.

Figure 5-17: Setup Screens
• With the touchscreen or arrow buttons, highlight the Sensors button and press Enter
to open the Sensors screen (M3.1) (Figure 5-18). From this screen, the operator or
technician can select the Jack Sensors or Other Sensors.
• With the touchscreen or arrow buttons, highlight the Jack Sensors button and press
Enter to open the Jack Sensors screen (M3.1.1).

• With the touchscreen or arrow buttons, highlight the Other Sensors button and press
Enter to open the Other Sensors screen (M3.1.2).
• Press Esc to step backward to access the Actuations screen or backward through
the menus to the log-in screen to return to the operator screen.
Figure 5-18: Setup Sensors Screen

• With the touchscreen or arrow buttons, highlight the Jack Sensors button and press
Enter to open the Jack Sensors screen (M3.1.1) (Figure 5-19).
Figure 5-19: Setup Jack Sensors Screen
—The Jack Sensors screen shows the value, module, and contact information. The
value is a digital input that changes from a 1 to a 0. The module shows the
number of the module the sensor is accessing. The contact information gives the
address of the sensor and which module the sensor is connected.
—The Jack Sensors are Jack up (CS Drillend), Jack up (NCS Drillend), Jack up
(CS), Jack up (NCS), Jack on ground (CS Drillend), Jack on ground (NCS
Drillend), Jack on ground (CS), and Jack on ground (NCS).

• With the touchscreen or arrow buttons, highlight the Other Sensors button and press
Enter to open the Other Sensors screen (M3.1.2) (Figure 5-20).
Figure 5-20: Other Sensors Screen
—The Other Sensors screen shows the value, module, and contact information. The
value should change from a 1 to a 0. The module shows the number of the
module the sensor is accessing. The contact information gives the address of the
sensor and which module the sensor is connected.
—The Other Sensors are Tower angle, Hoist move remote, Remote hoist activated,
Vertical pins unlocked (CS and NCS), Angle pins unlocked (CS and NCS),

Vertical pins locked (CS and NCS), Angle pins (CS and NCS). Each of these
sensors will show a Value number, Module location, and Contact address.
• With the touchscreen or arrow buttons, highlight the Actuations button and press
Enter to open the Actuations screen (M3.2) (Figure 5-21).
Figure 5-21: Setup Actuations Screen
The Actuations screen shows the actuated value, module, and contact information. The
actuated value are two types of outputs, proportional values in percentages and digital values
of 1 or 0. The module shows the number of the module the sensor is accessing. The contact
information gives the address of the sensor and which module the sensor is connected.

The output on the Actuations screen are Vertical pins, Angle pins, Tower move, Jack up (CS
and NCS Drillend), Jack up (Non-Drillend), Hoist move, Pulldown cable tension (CS and NCS),
Cable tension release, and Propel alarm. Each of these output will show a value number,
module location, and contact address.
Rig
• Access the Rig screen (Main) by touching the square or highlight it with the arrow
buttons.
• Press Enter to access the Guards, Sensors, and Actuation screens (Menu M4).
• Select Guards to view the value status of the Guard Sensor list (M4.1). Press Enter.
• Select Sensors to choose between the Sensor 1 or Sensor 2 list (M4.2).
• Select Actuations to view the value status of the Actuations list (M4.3).
NOTE: Selecting any access from the M4 screen will move a level deeper
into the main menu. Touching the access buttons for Guards, Sensors,
and Actuations brings up the screens shown in Figure 5-22.

Figure 5-22: Rig Screens
• With the touchscreen or arrow buttons, highlight the Guards (M4) button and press
Enter to open the Guards screen (M4.1) (Figure 5-23).
operator screen.

Figure 5-23: Rig Guards Screen
—The Guards screen shows the value, module, and contact information. The digital
inputs Values should change from a 1 to a 0. The Module shows the number of
the module the sensor is accessing. The Contact information gives the address
of the sensor and which module the sensor is connected.
—The guard sensors are Cab emergency stop 1, Emergency stop, Remote propel
emergency stop 2, Remote emergency stop 4, Remote emergency stop 5, Hoist
emergency stop 6, Emergency stop Fire Detect System, Compressor filter,
Hydraulic tank level OK, and Temp guard compressor active.

• With the touchscreen or arrow buttons, highlight the Sensors (M4) button and press
Enter to open the Sensors 1 or Sensors 2 screen (M4.2) (Figure 5-24).
• Select one of the sensors to go deeper into the menu or press Esc to step backward
through the menus to the log-in screen to return to the operator screen.
Figure 5-24: Rig Sensors Screen

• With the touchscreen or arrow buttons, highlight the Sensors 1 (M4.2) button and
press Enter to open the Sensors 1 screen (M4.2.1) (Figure 5-25).
operator screen.
Figure 5-25: Rig Sensors 1 Screen
—The Sensors screen 1 shows the value, module, and contact information. The
analog value should show actual values in psi, degree, or percentage. The
module shows the number of the module the sensor is accessing. The contact
information gives the address of the sensor and which module the sensor is
connected.

—The Sensors 1 sensor list is Propel brake valve, Pitch angle sensor, Roll angle
sensor, Grease tank level, Supercharge manifold pressure, Pump NCS press A,
Pump NCS press B, Hot oil shuttle press (CS and NCS), and Return hyd manifold
pressure.
• With the touchscreen or arrow buttons, highlight the Sensors (M4) button and press
Enter to open the Sensors 1 or Sensors 2 screen (M4.2) (Figure 5-26).
• With the touchscreen or arrow buttons, highlight the Sensors 2 (M4.2) button and
press Enter to open the Sensors 2 screen (M4.2.2) (Figure 5-27).
operator screen.
Figure 5-26: Rig Sensors Screen

Figure 5-27: Rig Sensors 2 Screen
—The Sensor 2 screen shows the value, module, and contact information. The value
should show analog (actual values) in psi, digital values change from1 to 0 or 0
to 1, Temperature degree or numbers. The module shows the number of the
module the sensor is accessing. The contact information give the address of the
sensor and which module the sensor is connected.
—The Sensors 2 sensor list is Drain hyd manifold press, Pump CS press A, Pump
CS press B, Oil temp, Lube cycle complete, Breakout wrench stowed, Hydraulic
drain filter #1 ok, Hydraulic drain filter #2 ok, Hydraulic return filter #1 ok,
Hydraulic return filter #2 ok, and Electric Motor running.

• With the touchscreen or arrow buttons, highlight the Actuations (M4) button and
press Enter to open the Actuations screen (M4.3) (Figure 5-28).
operator screen.
Figure 5-28: Rig Actuations Screen
—The Actuations screen shows the actuated value, module and contact information.
The actuated value are two types of outputs, proportional values in percentages
and digital values of 1 or 0. The module shows the number of the module the
sensor is accessing. The contact information give the address of the sensor and
which module the sensor is connected.

—The Actuations output list is Non-Cabside track, Cabside track, Dust flaps,
Breakout fork, Breakout wrench swing, Breakout wrench jaw, Cable reel motor,
Diverter valve, Propel brake, RCS electric motor shutdown, and Lube pump.
Drilling
• Access the Drill screen by touching the square or highlight it with the arrow buttons.
• Select Sensors to view the status and functionality of the drill sensors list (M5.1).
• Select Actuations to view the actuation list of the outputs (M5.2.1).
NOTE: Touching the access buttons for Sensors and Actuations brings
up the screens shown in Figure 5-29.
Figure 5-29: Drill Screens

to open the Drilling Sensors screen (M5.1) (Figure 5-30).
Figure 5-30: Drilling Sensors Screen
—The Drilling Sensors screen shows the value, module, and contact information.
The Actuated value are two types of outputs, proportional values in percentages
and digital values of 1 or 0. the module shows the number of the module the
sensor is accessing. the contact information give the address of the sensor and
—The Sensors list has Head displ. encoder, Bit speed, Head near tower top, Head
above carousel top, Head below carousel top, Water tank level, Holdback

pressure, Fan motor inlet pressure, Inlet pressure (7-spool), Carousel stowed,
Carousel index stowed, Rod support open, Rod support closed, and Rod support
jaw closed.
press Enter to open the Actuations 1 Output screen (M5.2.1) (Figure 5-31).
operator screen.
Figure 5-31: Drill Actuations 1 Screen

The Actuations screen shows the actuated value, module and contact information. The
actuated value should change from a 1 to a 0 or 0 to 1. The module shows the number of the
module the sensor is accessing. The contact information give the address of the sensor and
The Actuations 1 output list is Carousel swing, Carousel rotation, Rod support arm, Feed
force, Rotation torque control, Water injection/Dust collector, Dust collector pulsator, Feed
rate, and Rotation speed.
Compressor
• Access the Compressor screens (Figure 5-32) by touching the square or highlight it
with the arrow buttons.
• Select Sensors to view the status and functionality of the compressor sensors list
(M6.1).
• Select Actuations to view the actuation list of the outputs (M6.2).
Figure 5-32: Compressor Screens

to open the Compressor Sensors screen (M6.1) (Figure 5-33).
Figure 5-33: Compressor Sensors Screen
— The Drilling sensors screen shows the value, module, and contact information.
The actuated value are two types of outputs, proportional values in percentages
and digital values of 1 or 0. The module shows the number of the module the
sensor is accessing. The contact information give the address of the sensor and
— The Sensors list has Bit air pressure, Compressor temperature, Temp guard
compressor active, COC filter ok, Ears error code, Air flow, and Air tank pressure.

press Enter to open the Actuations screen (M6.2) (Figure 5-34).
operator screen.
Figure 5-34: Compressor Actuations Screen
The Actuations screen shows the actuated value. The Actuated value are two types of outputs,
proportional values in percentages and digital values of 1 or 0. The module shows no
information. The contact shows no information.
The Actuation output list has ears on/off, air pressure, and air flow.

Control Panels
Figure 5-35: Left and Right Control Panels
Left control panel Right control panel
NOTE: Numbers and names on control panels are for illustration

purposes only. The numbers and names are used to correspond to
application functions described in this section.

5.4 Starting The Drill
• Before starting or moving the drill, check inside, outside, and underneath the drill for
people or obstructions.
• Check for warnings or lockout tags on the controls. If there is a tag attached to the
switch, do not start the electric motor until the warning tag has been removed by the
person who installed it.
• Start the motor from the operator position only.
• Avoid leaving the controls with the motor running. Never leave the drill platform while
the motor is running
! CAUTION
If any controls, instruments or devices do not function correctly, look for

fault warnings and report any drill defects to the proper personnel.
Defects must be corrected before starting and operating the drill.
After all pre-operational inspection items are complete and any needed services or corrections
have been completed, you may proceed to the start sequence outlined below.
1. Make sure all emergency stop buttons are in the OUT position.
Figure 5-36: Emergency Stop Buttons

2. Turn the Off/On/Run/Start to the On position and allow the RCS system to
power up. When the RCS system is powered up, the Main menu will be
displayed.
Figure 5-37: Main Menu
3. Press the F3 button to view the engine screen and verify incoming voltage.
4. Depress the horn button to alert personnel that the electric motor is about to be
started. After the RCS system is powered up, turn the key to the Start position
to energize the electric motor. Once the electric motor energizes the contacts,
release the Off/On/Run/Start key switch immediately.
NOTICE
NOTICE
The maximum number of starts per hour allowed is three. The time
between starts is 20 minutes.
5. Listen for unusual noises from the motor, compressor, and power pack area.
6. Make sure the cooler fan is turning.
7. Observe the hydraulic system for any obvious leaks.
! WARNING
In event of unusual noise, leaks, cooling fan non-operation, or any other

non-listed problem, IMMEDIATELY SHUT THE DRILL DOWN to prevent
damage to the drill. Notify your immediate supervisor of the problem and
do not run the drill until the problem is corrected.
8. Continue running the electric motor and warm the hydraulic systems to the
minimum prescribed operating temperature of 75 °F (23.9 °C) for hydraulics.

9. When minimum operating temperatures have been reached, you are ready to
begin drilling operations.
Activating the RCS Control Panels

When the RCS system is powered up and the Main menu screen is shown on the display, the
LED on the Setup mode button will be lit. This condition is called Park. The Park condition is
active when the electric motor is running but the control panels have not yet been activated.
The control panels must be intentionally activated for any of the output commands or drill
actuations to occur.
Figure 5-38: Control Panel Activation Button
The amber LED indicates the panels are active. Each button has an LED. None will function
unless the Control Panel button is activated.
Operating Modes or States

Park condition is when the Control Panel button is off and no buttons are active. The panels
are activated by pressing the Control Panel button on the left control panel, the operator must
then choose a mode or state of operation. For examples, pressing the Setup button enables
the Setup mode, pressing the Drill Mode button enables the Drill mode, and pressing the
Propel mode button enables the Propel mode.

RCS Drill Operation Sequence
Propel
When propelling a PV-270E drill for long distances, stow the second rod in the carousel and
use the bit in hole-head at middle tower function.
1. To activate the above function, the following conditions must be met:
•The rotary head must be located in the middle of the tower with the first rod installed.
•The rod support arm must be closed (The RCS program does not require the rod
support jaw to be closed but it is recommended that the jaw is closed to add extra
support to the drill rod).
•The breakout wrench must be in an un-stowed condition.
2. Activate the bit in hole, head at middle tower function in the F2 parameter
screen.
3. Unlock the vertical pins and lower the tower to the rest position.
4. Activate the Propel mode.
NOTE: The Bit in hole, head at middle tower function needs to be selected
again as over rides are deactivated when changing between operating
modes.
To activate the Propel mode, follow the below procedure:
1. Visually locate the first drill hole.

2. Make sure there are no vehicles, obstacles, power lines, or unauthorized
personnel near or on the drill.
3. The operator must press the control panel On/Off button (Figure 5-39) to
activate the control panel buttons for both the left and right control panels to
function.
4. Press the Propel mode button to select Propel mode. When Propel mode is
selected, the hydraulics are shifted and the controls are mapped to the propel
functions.

Figure 5-39: Propel Controls, Left Control Panel
1 Control panel on/off button

2 Propel joystick when in Propel mode
3 Analog rocker switch
4 Propel mode button
5. The Propel screen (Figure 5-40) on the computer display shows the monitoring
of the propel brake release pressure, the drill level, jacks, and drill bit position.
If the jacks are still on the ground and/or the drill bit is still in the hole, indicator
lights will be red and the Propel function will be prohibited. Green lights on the
Jack position indicators of the screen will indicate the jacks are off the ground
and fully retracted. When drill bit is out of the hole, the indicator light will be
green and the drill can proceed to the Propel function.
NOTE: The control panel on/off button must be activated to propel.

Figure 5-40: Propel Screen
1 Propel brake release pressure 3 Drill bit in hole indicator

2 Jack position indicators 4 Drill level
6. While in the Propel mode, the Jack and Propel joystick with interlock switch
becomes the propel control (Figure 5-41).
Figure 5-41: Propel Buttons and Joystick

NOTICE
NOTICE
Propel speed is proportional to the amount of controller movement.
NOTE: If the drill is not in Propel mode and the control panel on/off button
is not activated, nothing will happen when the Jack and Propel joystick is
moved. When the control panel on/off button is activated and not in
Propel mode, the Jack and Propel joystick will have other functions.
•The Jack and Propel joystick is a dual axis spring centered analog joystick. It has
one analog return to zero rocker switch. In order to propel the drill, the switch
must be depressed and held in while propelling.
•With the switch depressed, pushing the joystick away from the operator, commands
the tracks to move the drill in a non-drilling end direction.
•With the switch depressed, pulling the joystick towards the operator, commands the
tracks to move the drill in a drilling end direction.
•Turns are accomplished by moving the joystick to the left or right, forward or back.
•Brakes are released in Propel mode when the Propel joystick switch is depressed.
NOTE: Releasing the switch while propelling will cause the drill to Stop
suddenly. Continue propelling, bring joystick to neutral position, depress
switch and move joystick with switch depressed in the direction of travel.
•Using the Propel joystick, propel the drill to the first drill hole location. If equipped,
(option) use directions given on the GPS Navigation Operational Instructions
manual.
Setup
After correctly positioning the drill on the drilling hole location, select Setup mode on the left
control panel. In Setup mode, the operator can perform the following operations:
• lower the jacks and level the drill

• raise the tower and pin the tower (includes vertical and angle pins)
• lower and raise the dust curtains flap with buttons
• raise and lower the hoist (winch)

Figure 5-42: Setup Mode Controls
1 Hoist joystick (in Setup mode) 6 Leveling jacks joystick (in Setup mode
2 Tower vertical lock/unlock pins buttons 7 Dust flaps up/down buttons
3 Tower angle lock/unlock pins buttons 8 Control panel on/off button
4 Hoist button 9 Setup mode button
5 Activate jacks button 10 Tower raise/lower joystick in Setup mode
1. The left control panel On/Off button must be activated to enable both the left
control panel and right control panel (Figure 5-42) to function.
2. Press the Setup mode button located on left control panel. When Setup mode
is selected, the hydraulics are shifted and the controls are mapped to the setup
functions.
Electric Motor - The display screen will display the Setup screen (Figure 5-43). The Setup
Screen shows the Tower Pinning conditions and the Spirit Level. The Setup icon will be green.

Figure 5-43: Electric Motor Setup Screen
With the tower vertical and both vertical and angle pins locked, the operator display screen
shows vertical and angle pins lock icon as green. The tower indicator shows red.
• Tower locking indicator: red=locked, green=not locked. The red light shown indicates
the tower cannot be raised or lowered. Tower indication light will change to green to
indicate system is ready to move tower.
• Angle pins locking indicator: red=unlocked, green=locked. The green light shown
indicates both angle pins are locked. A red light here would indicate that one or both
angle pins are not locked.
• Vertical pins locking indicator: red=unlocked, green=locked. The green light shown
indicates both vertical pins are locked. A red light here would indicate that one or both
vertical pins are not locked.
Leveling Procedure (Manual)

While in Setup mode (Setup mode button), the Jack and Propel joystick with interlock switch
and push-pull movement for jacks direction becomes the Jacks control (Figure 5-44). The
control panel on/off button must be switched on to activate Setup mode.

Figure 5-44: Leveling Controls
1 Setup mode button

2 Joystick rocker switch
3 Jack activate button
4 Leveling jacks joystick (in Setup mode)
1. To manually activate the leveling jacks, the operator must push the Jack
activate button (Figure 5-45).
Figure 5-45: Jacks Activation Controls

! CAUTION
The Leveling Jack joystick is mapped to level the drill when the Activate
Jack button is active. It must be deactivated to return to another function.
Always de-activate the Activate Jack button when the jacks are not in use.
2. To lower all jacks (extend cylinders and raise rig) at the same time, hold the
rocker switch on the Jack joystick up. To raise all jacks (retract cylinders and
lower rig) at same time, hold the rocker switch on the Jack joystick down. The
Jack Joystick and the rocker switch are proportional.
3. Use the joystick to level the drill. The switch is used for up or down direction.
4. When leveling the drill, first lower all jacks until all jacks are on the ground. Then
raise the lowest point to near zero by moving the joystick to the proper
quadrant.
NOTICE
NOTICE
Drilling operations require the tracks to be completely clear of the ground
when the drill is leveled. The height must be sufficient to provide total
clearance of the tracks to prevent excess drive system wear during
drilling operations.
5. Evenly extend the leveling jacks. Keep the drill level as indicated by the drill
bubble level.
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 leveling jack controller.
b. Extend the non-drilling end leveling jack (or option two jacks non-drilling
end) with the non-drilling end leveling jack controller and level the drill front
to back until the drill bubble level is centered.
Auto Level Option

The Auto Level option (Figure 5-46) allows the operator to automatically level the drill. While
in Setup mode, the jack joystick rocker switch becomes the jacks control.

Figure 5-46: Auto Level Controls
1 Setup mode button 4 Leveling jack joystick (in Setup mode)

2 Joystick rocker switch 5 Control panel on/off button
3 Jack activate button (off) 6 Auto button
The left control panel On/Off button must be activated to enable the Setup mode on the left
control panel and the Auto button on the right control panel. The Activate Jack button on the
left control panel must be off to operate the Auto Level option.
1. Activate Setup mode.

2. While in Setup mode, press and hold the Auto button.
3. To level the drill, hold the Jack joystick in the center position (Figure 5-47).
Move and hold the rocker button on the Jack joystick in the up direction to
extend all four leveling jacks (raise the drill) to automatically level the drill.

Figure 5-47: Jack Joystick Position (In Setup Mode)
1 Raise rig (extend cylinders) 2 Lower rig (retract cylinders
4. Once Auto Level is active there will be an icon in the bottom tray of the display
screen (Figure 5-48). When the Auto Level Active icon is seen, release both the
rocker switch on the Jack joystick and the Auto button.
Figure 5-48: Auto Level Active Icon
5. To stop Auto Level operation, press the Jack joystick rocker button up or down.
Jack movement will stop and the Auto Level icon will disappear.
6. Pushing the button on the Jack joystick down will retract all four of the leveling
jack cylinders and automatically lower the tracks to the ground.
The Auto Level option can also be used to retract the jack cylinders and lower the drill.
1. Press and hold the Auto button.

2. To lower the drill, hold the Jack joystick in the center position. Move and hold
the rocker button on the Jack joystick in the down direction to simultaneously
retract all three leveling jacks or (option four leveling jacks).
3. Once lowering the drill in Auto Level is activated, there will be an Auto Level
icon in the bottom tray of the display screen. At this time, release both the
rocker switch on the Jack joystick and the Auto button.
4. To stop lowering the drill in the Auto Level operation, press the Jack joystick
rocker switch up or down. Jack movement will stop and the Auto Level Icon will
disappear.

5. When jacks are fully retracted, the jack icons in the propel screen will be green.
The Jack Auto Level Bypass button (Figure 5-49) is used to level the drill rig if out of angle
limits exceed 6°.
Figure 5-49: Jack Auto Level Bypass Button
The conditions are when;
• The drill rig angle has exceeded 6° of slope at the initial set-up location of the hole.
• The drill rig angle has exceeded 6° for greater than 1 second during Auto Leveling or
De-leveling.
Jack Auto Level Bypass procedure.
1. Activate the Setup mode on the left control panel.

2. Activate the manual Jack button.
3. While in Setup mode, press and hold the Jack Auto Level Bypass button.
4. Manually operate the four axis jack joystick controllers as needed to bring the
drill rig within limits.
Tower Raising and Pinning (Vertical Drill)

To raise and pin (lock) the tower for vertical drilling, the drill must be in Setup mode and the
left control panel On/Off button must be activated. In Setup mode, the right Tower Raise/Lower
joystick is the main control for tower raising/lowering functions (Figure 5-50).
NOTE: Strut lock/unlock buttons #4 and #9 are not used on PV-270 series
drills.
While in Setup mode, tower locking functions are performed through the Tower Vertical Lock
button or Tower Angle Lock button, located on the left control panel.

Figure 5-50: Tower Raising and Pinning Controls
1 Setup mode button 4 Control panel on/off button

2 Tower vertical lock button 5 Tower raise/lower joystick with rocker switch
3 Tower angle lock button (in Setup mode)
! CAUTION
Make sure the drill is leveled and supported by all leveling jacks before
tower is raised. Structural damage to the drill is possible.
1. Level the drill on all leveling jacks before the tower is moved.
2. Press and hold the digital rocker switch on the Tower Raise/Lower joystick
before moving the joystick to enable tower movement.
! CAUTION
Tower structure can be damaged by hard contact between the tower base
and the tower support structure.
3. Raise the tower to vertical position using the Tower Raise/Lower joystick
(Figure 5-51). Push the joystick away from center position while pressing the
rocker switch to raise the tower. Use the joystick to feather or slow the tower
when getting near the vertical stop blocks.

Figure 5-51: Tower Raise/Lower Joystick Positions
1 Tower raise position
2 Tower lower position
3 Tower raise/lower (in Setup mode)
4. After the tower has been raised, lock the tower vertical locking pins using the
Tower Vertical Lock button, angle locking pins using Tower Angle Lock button,
and strut pinning engage pins with the Strut Lock button on the left control
panel. The display screen will show the active condition of vertical, angle, and
strut pins (Figure 5-52). When the pins are completely extended (locked
position), the screen indicators will be green.

Figure 5-52: Active Condition of Vertical, Angle, and Strut Pins
1 Red indicates tower can not be raised/lowered

2 Angle locking pins
3 Vertical locking pins
5. Visually verify the tower to make sure that the tower vertical locking pins and
angle locking pins are locked in place after raising the tower. All locking pins
must be in the locked position during drilling operations.
! WARNING
Severe Damage can occur to the drill when drilling is done with angle
locking pins or vertical locking pins disengaged.

Lower Tower/Unpinning (Vertical Drill)

To lower and unpin (unlock) the tower, the drill must be in Setup mode and the control panel
On/Off function must be activated. In the Setup mode, the right Tower Raise/Lower joystick is
the main control for raising/lowering functions.
While in Setup mode, tower unlocking functions are activated with the left Tower Vertical
Unlock button or left Tower Angle Unlock button (Figure 5-53).
Figure 5-53: Lower Tower/Unpinning Controls
1 Setup mode button

2 Tower vertical unlock button
3 Tower angle unlock button
5 Tower raise/lower joystick with rocker switch (in Setup mode)
NOTICE
NOTICE
The tower must always be placed in the vertical position before it is
lowered.
1. Physically verify the tower is in the vertical position and the vertical locking pins,
angle locking pins, are in place and locked. For safety reasons the vertical
locking pins and angle locking pins are interlocked to prevent both sets of pins

from unlocking at the same time. The Setup screen will display the locking pins
(Figure 5-54). The tower vertical pin (lower) icon will be green when extended
(locked), yellow when disengaged or in transit and will be red when retracted
(unlocked).
! DANGER
DANGER
Angle locking pins and vertical locking pins must never be unlocked at
the same time! Serious damage or injury can occur if both sets of pins are
unpinned at the same time.
Figure 5-54: Tower Locking Pins Display

2. Unlock tower vertical locking pins by pressing Tower Vertical Unlock button
located on the left control panel.

! CAUTION
Damage can occur if an attempt is made to move the tower with only one
vertical lock pin unlocked.
3. Physically verify both vertical locking pins are unlocked.

4. Press and hold the digital rocker switch on the right main joystick. Pull on the
joystick to enable tower movement and lower the tower.
Figure 5-55: Right Main Joystick Positions
1 Tower raise/lower (in Setup mode)
Tower Lower/Raise and Pinning (Angle Drill Option)

Angle drill is an optional feature. Degrees beyond vertical, PV-271E has a drilling angle of 0
to 20 degrees and the PV-275E has a drilling angle of 0 to 30 degrees if local conditions and
techniques require. If angle drilling is required, the tower must be lowered to the correct angle
outlined in the following sequence.
! CAUTION
Structural damage to the drill is possible if the tower is raised without the
drill being leveled.

NOTE: The control panel On/Off button on the left control panel must be
on for Setup mode to activate.
Press the Setup mode button on left control panel to activate the Setup mode. In the Setup
mode, the Tower Raise/Lower joystick located on the right control panel is the main control for
raising and lowering the tower.
In Setup mode, tower locking functions are handled by the left Tower Vertical Lock button and
left Tower Angle Lock button.
Figure 5-56: Tower Locking Controls
1 Setup mode button 4 Control panel on/off button

2 Tower vertical unlock button 5 Tower raise/lower joystick with
3 Tower angle unlock button rocker switch (in Setup mode)
NOTICE
NOTICE
The tower must always be placed in the vertical position before it is
lowered to the angle drill position.
1. Perform the Tower Raising/Pinning (Vertical Drill) instructions to raise and pin
the tower.
2. Physically verify the tower is in vertical position, verify vertical locking pins and
angle locking pins are in place and locked. For safety reasons the tower angle
locking pins and vertical locking pins are interlocked to prevent both sets of pins
from unlocking at the same time. The Setup screen (Figure 5-57) will display

the locking pins. The tower strut pin (upper) icon will be green when engaged,
yellow when in transit, and red when disengaged. The tower angle pin (lower)
icon will be green when extended (locked), yellow when disengaged and in
transit or red when retracted (unlocked). The vertical locking pins will be green
when extended (locked), yellow when disengaged and in transit, or red when
retracted (unlocked).
Figure 5-57: Tower Locking Pins

3. Press the left Tower Angle Unlock button to unlock the tower angle locking
pins.
! DANGER
DANGER
Angle locking pins and vertical locking pins must never be unlocked at
the same time! Serious damage or injury can occur if the tower is moved
in any direction with all pins in the unlock position.

4. 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 angle lock pin disengaged.
5. Press and hold digital rocker switch on Tower Raise/Lower joystick located on
the right control panel and pull on the joystick to enable tower movement.
Lower the tower until the proper angle is indicated on the Setup mode operator
display.
6. If a pin is stuck between the lock or unlock position, use the tower wiggle
feature.
a. Press and hold the button for the pin direction to be moved. This refers to
the left Tower Angle Unlock button and Tower Angle Lock button.
b. With your other hand, activate the right control panel digital rocker switch
Tower Raise/Lower joystick and move the joystick in one direction.
c. If pin is not free, move the joystick in the other direction.
7. Make sure the correct angle has been reached. Lock the angle locking pins with
the left Tower Angle Lock button.
NOTE: Due to the possibility of slight differences in manufacturing

tolerances, wear or slight damage, you may find it necessary to gently
wiggle Tower Raise/Lower joystick to fully lock both angle pins.
8. After the Setup screen angle pin indicator display shows the pins to be locked,
make sure all cab controls are in the neutral position. Walk out to the tower
support area and physically verify all angle locking pins and vertical locking pins
are in the locked position. Always verify the pins are locked.
9. The rod support extend/retract must be controlled by the operator. Visually
verify the rod support is supporting the drill rod.

Figure 5-58: Rod Support Controls
1 Tower raise/lower joystick with rocker switch (in Setup mode)

2 Rod support open button
3 Rod support closed button
Rod Support
The design of the rod support on the PV-270 supports the drill rod during the following
operations:
• Aligning the drill rod with deck bushing.

• Collaring or at the start of the drill hole.
• Stabilizing the drill rod while drilling when bit load is increased.
• Stabilizing and aligning the drill rod to guide the rod while making/breaking a
threaded joint connection (rod, bit sub, stabilizer, hammer, crossover sub, etc.).
• Stabilizing and aligning the drill rod to guide the rod while adding/removing from the
carousel cups.
If the machine is equipped with RCS and operating, there is a selectable automatic rod support
feature to automatically actuate both opening and closing when the rotary head travels up and
down the tower.

Figure 5-59: Rod Support Extended (Closed Position)
The red bar in indicates the rod support is extended (closed position). Fully open the rod
support by pressing the Rod Support Open (rod support retracted) button located on the right
control panel. The red bar should change to a green square on the right side to indicate the
rod support is retracted (open position).
Dust Flaps
While in the Setup mode, dust flap functions are controlled by the Dust Flap Up button and
Dust Flap Down button on the left control panel. The control panel On/Off button must be on
to activate Setup mode.

Figure 5-60: Dust Flaps Controls
1 Setup mode button 3 Dust flap up button

2 Control panel on/off button 4 Dust flap down button
Press and hold down the Dust Flap Up button to raise the dust curtains. Release the button to
stop the movement of the dust curtain. Press and hold down the Dust Flap Down button to
lower the dust curtain. Release the button to stop the movement of the dust curtain.
Hoist
To raise and lower the hoist, the drill must be in Setup mode and the control panel On/Off
function must be activated. In Setup mode, the left Hoist/Drill Rotation joystick is the main
control for hoist raising/lowering functions.
While in Setup mode, hoist functions are enabled with the left Hoist/Drill Rotation joystick and
activated with the left Activate Cab Hoist button.

Figure 5-61: Hoist Controls
1 Setup mode button 3 Hoist joystick with rocker switch (in Setup mode)
2 Control Panel off/on button 4 Cab hoist activate button
1. While in the Setup mode, push the left Activate Cab Hoist button to activate the
hoist.
2. When activated, the Hoist/Drill Rotation functions joystick is mapped to operate
the appropriate spool valve for using the hoist to raise and lower loads.
3. The digital rocker switch on the Hoist/Drill Rotation joystick must be depressed
and held before moving the joystick to enable hoist cable movement. Joystick
movement will control direction and speed of hoist cable
4. The Activate Cab Hoist button has an LED that indicates the hoist control is
active.
5. The Activate Cab Hoist button must be de-activated to return to another
function. Always de-activate the Activate Cab Hoist button when the hoist is not
in use.

Hoist Load/Speed Charts
Table 5-1: Standard Winch 8,000 lb Maximum Load
Layer Line Pull Line Speed Rope Capacity

(lb) (kg) (fpm) (mpm) (ft) (m)
1 8,000 3,636 140 43 58 18
2 7,200 3,273 156 48 122 37
3 6,550 2,977 172 52 193 59
4 6,000 2,727 187 57 270 82
5 5,540 2,518 203 62 353 108
Table 5-2: CE Winch 8,000 lb Maximum Load
Layer Line Pull Line Speed Rope Capacity

(lb) (kg) (fpm) (mpm) (ft) (m)
1 8,000 3,636 63 19 30 9
2 7,600 3,440 70 21 65 19
3 6,900 3,120 77 23 100 30
NOTE: These numbers are based on theoretical efficient and straight line
pulls. System inefficiencies will reduce the actual load that can be lifted.

5.5 Drill Mode
RCS Drill Mode

When in Drill mode, drilling is performed by using both the left and right main joysticks,
Pulldown, and Holdback Potentiometers (Figure 5-62). Operator left and right control panel
buttons have individual LEDs that come on as an indication that the function is active.
Drill mode is selected by pressing the Drill mode button, the hydraulics are shifted and controls
are mapped to perform drilling functions. The Drill Feed joystick and the Drill Rotation joystick
actuate the feed and rotation functions.
NOTE: The drill can be leveled in Drill mode. This is done by activating the
jack controls by pressing Activate Jack button on the left control panel.
This activates the Leveling Jacks joystick. Anytime the Activate Jack
button is active, the jacks can be actuated. Always de-activate the jacks
when not in use.

Figure 5-62: Drill Mode Controls
1 Control panel on/off button 5 Jack activate mode button

2 Drill mode button 6 Pulldown feed pressure rotary control
knob
3 Drill rotation joystick with rocker switch 7 Drill feed up/down joystick with rocker
(in Drill mode) switch (in Drill mode)
4 Leveling jacks joystick 8 Holdback force rotary control knob
Rotation
In Drill mode, the Drill Rotation joystick with rocker switch on the left control panel controls
rotation (Figure 5-63). The digital rocker switch must be depressed and held before moving
the joystick to enable rotation. Activate the digital rocker switch and push the joystick forward
from the neutral (center) position. This will start the drill string rotating in a counterclockwise
(CCW) direction. Pulling the joystick backwards from the neutral (center) position will start the
drill string rotating in a clockwise (CW) direction. Rotation is proportional to the joystick
position.

Figure 5-63: Rotation Controls, Left Control Panel

2 Drill mode button
3 Drill rotation joystick with rocker switch (in Drill mode)
Once the rotary head is rotating, the digital rocker switch can be released. If direction change
is required, the rocker switch must be activated when the joystick is moved through the center
position.
Feed
In Drill mode, the right Feed Up/Down joystick controls the feed speed and up/down direction.
The Pulldown (Feed Force) Pressure rotary control knob is used to control feed pressure.
Feed flow will start when the Feed Up/Down joystick is pushed forward or pulled backward.
The digital rocker switch must be depressed and held before moving the joystick to enable
feed. Once the rotary head is moving, the digital rocker switch can be released.

Figure 5-64: Feed Controls, Right Control Panel
1 Pulldown feed pressure rotary control knob

2 Drill feed up.down joystick with rocker switch (in Drill mode)
3 Holdback force rotary control knob
Feed Flow - In Drill mode, pushing the right Feed Up/Down joystick forward from the neutral
(center) position will increase feed speed up direction. Pulling the joystick backwards from
neutral (center) position will increase feed speed down direction. Feed flow is proportional to
the lever position.The digital rocker switch must be depressed and held before moving the
joystick to enable feed flow. Once the rotary head is moving, the digital rocker switch can be
released. Moving the joystick through the center position without activating the digital rocker
switch will stop feed.
Feed Pressure - The Pulldown (left side of panel) rotary control knob rotated clockwise (CW)
will increase feed pressure. Rotating the Pulldown rotary control knob counterclockwise
(CCW) will decrease feed pressure. The working area of the Pulldown rotary control knob is
270 degrees.
Holdback (Option) - The Holdback (right side of panel) rotary control knob rotated clockwise
(CW) will increase holdback force. Rotating the Holdback rotary control knob counterclockwise
(CCW) will decrease holdback force.
Air Regulation
Drill Air control is activated by the right Air On/Off button. The left control panel Off/On button
must be on for drill regulation to activate.

Figure 5-65: Air Regulation Controls
1 Control panel on/off button 4 Engine speed high/low button

2 Drill mode button 5 Air flow increase button
3 Ari regulation on/off button 6 Air flow decrease button
• The Air On/Off button activates the Air On/Off (toggle) function. When it is on, drill air
pressure will flow in the amount pre-set in the GUI program. It must be on to activate
the Air Flow Increase button and the Air Flow Decrease button.
• When more air flow than the pre-set amount of air flow is required, press the Air Flow
Increase button to override the pre-set amount.
• When less air flow than the pre-set amount of air flow is required, press the Air Flow
Decrease button to override the pre-set amount.
RCS 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 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.

NOTICE
NOTICE
Heavy components must be handled with care when 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 drill bits.

Figure 5-66: Rotary Drill String Tools and Accessories
1 Rotary Head 7 Drill Split Bushing 13 J-Wrench

2 Auxiliary Hoist 8 Starter Rod or Stabilizer 14 Rod Retainer Cup
(Tower Mounted) (Not Shown)
3 Lifting Bail 9 Tricone Bit 15 Table Centralizer Bushing
4 Breakout Wrench 10 Rotary Head Spindle 16 Drill Bit Sub
5 Drill Rod 11 Auxiliary Hoist Cable with 17 Sliding Fork Wrench (Drill
Safety Hook Rod Retainer)
6 Drill Rod Centralizer Bushing 12 Spindle Sub 18 Bit Basket

Starter Rod / Stabilizer Installation

The procedure below is for installing the starter rod or stabilizer. 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 (or stabilizer). Use
the hoist to raise the starter rod and line it up over the table. Perform the
previously shown instructions for operating the hoist.
! 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 (or stabilizer).
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.
NOTE: Remember to deactivate the Hoist button when the hoist is not in
use.
5. Lubricate thread joints properly.

6. Install centralizer bushings around the starter rod.
7. In Drill mode, use the right Drill Feed Up/Down joystick and feed rotary head
down to engage threads on pin end of starter rod. With the left Drill Rotation
joystick, use slow clockwise rotation and tighten starter rod securely.
8. Raise starter rod above table.
Tricone Bit Installation Procedure

The procedure below is for installing the tricone drill bit on the starter rod or stabilizer (option).
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 bushing.
2. Install the rotary (tricone) bit basket in the drill table.
3. Insert the tricone bit into the bit basket.
4. Lubricate the threads on tricone bit.

! WARNING
Be sure a good joint has been made by looking at the connection between
the tricone bit and the starter rod.
5. Use the right Drill Feed Up/Down joystick located on the right control panel, to
lower the starter rod (or stabilizer) down onto the threads on the bit. With the
left Drill Rotation joystick, located on the left control panel, use slow clockwise
rotation and tighten securely.
6. Use the Drill Feed Up/Down joystick to raise the rotary head up until the tricone
bit clears the bit basket.
7. Remove the bit basket and store it out of the way.
8. Use the Drill Feed Up/Down joystick to lower the starter rod until the bit is below
the table.
9. Install centralizer bushing.
RCS Rotary Drilling Procedure

Make sure the rotary bit, starter rod (stabilizer) or bit sub and drill rod are installed correctly.
The operator must press the left control panel On/Off button to enable both control panels.
1. The left Drill mode button must be pressed to activate and enable drilling
functions. The F1 drill screen should show on the display screen.
2. Electric Motor - rpm will be constant.

Figure 5-67: Rotary Drilling Controls
1 Control panel on/off button 4 Drill feed up/down joystick with rocker switch
(in Drill mode)
2 Drill mode button 5 Holdback force rotary control knob
3 Drill rotation joystick with rocker switch (in 6 Pulldown feed pressure rotary control knob
Drill mode)
NOTE: The engine speed button (high/low) on the right control panel
below the holdback knob does not function on drills with an electric
motor.
3. Press F2 on the display screen to bring up the Quick-Access Parameter screen

to verify drill parameters.
4. Press F1 on the display screen to bring back the Drill screen.
5. While in Drill mode, press and hold the digital rocker switch on the right Drill
Feed Up/Down joystick and gently pull the joystick towards you to start the drill
string moving in the downward position until the drill bit touches the ground.
Feed flow is proportional to the joystick position.
6. Turn on the air compressor air flow by pressing the right Air On/Off button (refer
to previously mentioned Airend Regulation). Make sure the correct air pressure
for collaring the hole is being supplied by pressing the Air Flow Increase button
or Air Flow Decrease button as previously mentioned.

Figure 5-68: Air Flow Controls
1 Pulldown feed force rotary control knob 4 Air flow increase button
2 Holdback force rotary control knob 5 Air flow decrease button
3 Air regulation on/off button
7. While in Drill mode, press and hold the digital rocker switch on the left Drill
Rotation joystick and gently pull the joystick towards you to start clockwise
(CW) drill string rotation at a rate of 30 to 40 rpm.
8. Use the Pulldown Feed Force control knob to slowly rotate CW to increase feed
pressure until the drill string starts moving downward. Observe the drill string
and make sure a positive rate of feed at the desired feed pressure and rotation
speed has been established.
9. The first several foot 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.
10. Monitor the bit air pressure on the display screen (F1) to make sure neither the
hole nor the bit air nozzles have become plugged with rock or debris. A sudden
marked increase of air pressure will indicate a plugged bit or plugged hole.
11. After about six feet (two meters) of penetration, increase the feed pressure and
rotation speed to the nominal values determined by site management. Make
sure a positive rate of feed has been established and observe the drilling
operation, making feed, rotation, and air pressure changes as needed during
drilling.
12. Control the dust by using water injection during drilling operations as needed to
make sure minimal dust being released into the atmosphere.

NOTE: The control panel On/Off button on the left control panel must be
on.
Figure 5-69: Water Injection Controls
1 Control panel on/off button 4 Water injection flow increase button

2 Drill mode button 5 Water injection flow decrease button
3 Water injection on/off button
a. The right Water Injection On/Off button activates the Water Injection On/Off
(toggle) function. When it is on, water pressure will flow in the amount pre-
set in the RCS parameters. It must be on to activate the Flow Increase
button and Flow Decrease button.
b. When more water flow than the pre-set amount of water flow is required,
press the Flow Increase button to override the pre-set amount.
c. When less water flow than the pre-set amount of water flow is required,
press the Flow Decrease button to override the pre-set amount.
NOTICE
NOTICE
When an occasional puff of dust is coming out of the dust hood during
drilling operations, the water volume is sufficient. Too much water will
cause cuttings to ball up and plug the drill hole.
13. Monitor torque and pulldown on the display screen (F1) and make any
necessary corrections to the feed and rotation circuit during drilling.

Figure 5-70: F1 Screen
1 BIT air pressure 13 Breakout wrench stowed

2 Penetration rate 14 BIT in/out of hole
3 Water pump outlet 15 Rotation torque
4 Air flow outlet 16 Pulldown force
5 Reset hole depth 17 Radio remote control (option)
6 Head position in tower 18 Joystick position
7 Hole depth indication 19 Propel mode
8 Head in safe to propel zone 20 Setup mode
9 Carousel, carousel index not stowed 21 Drill mode
10 Hole number 22 Rotary head (BIT speed)
11 Rod support open/closed 23 Tank pressure
12 Hole target depth
14. During drilling operations, monitor the bit air pressure and cuttings flow to make
sure the hole is being bailed correctly, air circulation is being maintained and
the hole has not become plugged.
NOTE: A void or rock fracture that causes loss of air circulation will not
cause any displayed air pressure changes, but will quickly allow the hole
to become plugged. The first indication of a plugged hole due to a void or
fracture is normally a rapid increase in rotation or torque pressure
without an air pressure change. Rotation pressure must be monitored
continuously to avoid getting the drill string stuck in the hole.

15. Drill the hole down to the maximum or required depth attainable for the drill rod.
When that depth has been reached, stop the feed, raise bit at bottom of hole
and allow the drill string to rotate for 15 seconds to clear the hole.
16. When the hole is complete, turn off the water injection, slow the rotation with
Drill Rotation joystick to 20 to 30 rpm, raise the drill rod up with Drill Feed Up/
Down joystick to give the drill bit sufficient ground clearance to propel, and turn
off the air.
17. Raise the leveling jacks. The setup screen display will be red if the jacks are on
the ground, yellow if they are off the ground in transit, and green when they are
fully retracted.
18. Propel the drill to the next hole using the previously described method and
repeat the drilling process.
Changing Rotary Bit

The procedure below is used when changing or replacing a rotary bit during the rotary drilling
process.
1. Feed the drill rod up until the 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 the drill rod onto the bit.
15. Use slow forward rotation to tighten the bit into the drill rod.
16. Tighten securely.
17. Raise the drill rod assembly above the table.
18. Remove the bit basket.

19. Lower the drill rod until the bit is below the table.
20. Install the centralizer bushing.
21. Turn on drill air (compressor ON cable control).
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.
RCS Rod Changing Sequence

1. Drill the hole down to the maximum or required depth attainable for the current
drill string.
2. When that depth has been reached, stop the feed, raise bit at bottom of hole
and allow the drill string to rotate for 15 seconds to clear the hole.
3. Turn off the water injection with the right Water Injection On/Off button if it is
being used.
4. Slow the drill string rotation with the Drill Rotation joystick to 20 to 30 rpm and
raise the drill string with the Drill Feed Up/Down joystick until the flats on the pin
end of the drill rod are aligned with the sliding deck fork wrench on the table.
5. Turn off the air with the Air On/Off button.
Figure 5-71: Deck Fork Controls
1 Air regulation On/Off button 3 Deck fork engage button

2 Water injection On/Off button 4 Deck fork retract button

6. Secure the drill rod in the sliding deck fork wrench using the drill rod built-in
wrench flats and the Deck Fork Engage button. (Rotation may need to be used
to align the drill rod flats with the deck fork wrench flats).
7. Using reverse (counterclockwise) rotation, unscrew rotary head from drill rod.
(Use the left Drill Rotation joystick for rotation and the right Drill Feed Up/Down
joystick for feed up).
8. If the reverse (counterclockwise) rotation torque is not sufficient to loosen the
threads, the breakout wrench must be used.
9. While holding the drill rod with the sliding table fork, do the following:
a. Press the Drill mode button located on the left control panel. When Drill
mode is selected, the hydraulics are shifted and the controls are mapped to
the breakout wrench functions.
Figure 5-72: Drill Mode Controls
1 Drill rotation joystick with rocker 4 Drill mode button

switch (in Drill mode)
2 Breakout wrench joystick with 5 Control panel On/Off button
rocker switch (in Drill mode)
3 Breakout wrench activate button
10. In Drill mode, the dual axis analog joystick with digital rocker switch and push/
pull movement becomes the Breakout Wrench joystick function control. It is
located on the left control panel control.
11. To activate the breakout wrench, press Activate Breakout Wrench button.
NOTE: If drill is not in Drill mode button and control panel On/Off button
is not activated and Activate Breakout Wrench button is not activated,

nothing will happen when Breakout Wrench Joystick is moved. When the
control panel On/Off button is activated and not in Drill mode, the
Breakout Wrench joystick will have other functions (Propel functions and
Leveling Jack functions).
12. While holding the drill rod with the sliding table deck fork (Deck Fork Engage
button on the right control panel), pull the Breakout Wrench joystick towards the
operator to swing in (un-stow) the breakout wrench and engage the wrench
flats on the drill rod.
Figure 5-73: Breakout Wrench Joystick Functions
13. After engaging the breakout wrench, move the Breakout Wrench joystick to the
right, with rocker switch depressed, to pin the breakout wrench and rotate the
breakout wrench counterclockwise and break (loosen) the thread joint.
14. When the thread joint has been loosened, move the Breakout Wrench joystick
to the left, with rocker switch depressed, to rotate the breakout wrench
clockwise, opens the breakout wrench jaws and un-pin the breakout wrench.
15. Push the Breakout Wrench joystick away from operator, with rocker switch
depressed, and move the breakout wrench out of the way to the stow position.
16. Using reverse (counterclockwise) rotation, unscrew rotary head from drill rod.
(Use the left Drill Rotation joystick for rotation and the right Drill Feed Up/Down
joystick for feed up. Unscrew the drill rod using rotation from the power head.
17. Once the rotary head has been unscrewed from the drill rod, run the rotary
head up the tower high enough to swing the carousel in without interference
from the rotary head.

! CAUTION
Make sure rotary head is clear of carousel. Contact between the rotary
head and carousel can cause damage to carousel.
18. Make sure carousel will clear the rotary head by physically checking the
carousel position. Press the Carousel Swing In button and swing the carousel
in to its loading/unloading position under the rotary head.
Figure 5-74: Carousel Controls
1 Carousel index CW button 4 Rod support open (retracted) button

2 Carousel swing out (stowed) button 5 Rod support close (extended) button
3 Carousel swing in (under rotary head) 6 Carousel index CCW button
button
19. Press the Rod Support Close button and extend the drill rod support on the drill
rod to be added.
20. Start forward rotation with Drill Rotation joystick at 20 to 30 rpm.
21. While observing the drill rod in the carousel, gently lower the rotary head until
contact is made with the drill rod.
22. A slight downward movement of the drill rod in carousel will verify contact.

! CAUTION
Do not force the rotary head down further once contact has been made.
Using excess force can damage the carousel.
23. When contact has been made, continue forward rotation at 20 to 30 rpm. Allow
the rotary head to screw onto the drill rod. The drill rod will rise in the carousel
cup as it screws onto the rotary head spindle.
24. The drill rod and carousel will show a slight bending movement when the
spindle is tight.
25. When the drill rod has screwed onto the rotary head spindle, stop rotation.
Nudge the left Drill Rotation joystick momentarily in reverse (CCW) direction to
relieve torque pressure on the carousel.
26. Raise drill rod clear of the carousel cup using the right Drill Feed Up/Down
joystick.
NOTICE
NOTICE
A clearance of 2 inches (50.8 mm) between the drill rod and carousel cup
is sufficient for any rod change operation.
27. Using the right Carousel Swing Out button, move the carousel to the stowed
position.
28. Using the Drill Feed Up/Down joystick, slowly feed drill rod down to the point of
contact with the pin section of the drill rod being held in the sliding table fork.
29. Apply grease to drill pipe threads by hand or use auto thread greaser (option).
30. Using 20 to 30 rpm forward (clockwise) rotation, tighten the threads with the
Drill Feed Up/Down joystick only snug enough to shoulder the drill rod thread
joint, squeezing out the excess thread lubricant in the process.
31. Dis-engage the deck fork button on the right control panel.
32. Press the right Air On/Off button and turn on the drilling air system.
33. Return to the drill process and turn on the water injection, if it is being used, with
the right Water Injection On/Off button.
NOTICE
NOTICE
Make sure the rod support disengages from the drill rod automatically.
34. When the hole is complete, turn off the water injection. Raise the drill string to

the joint between the first and second drill rod to deck level while maintaining
20 to 30 rpm forward rotation of the drill string.
35. When the drill string is high enough to engage the Deck Fork Engage button,
stop rotation and turn off the compressor.
! DANGER
DANGER
Do not unscrew the rod joint with the drilling air turned on. This can cause
glass damage to the cab or injury to drill personnel from flying debris.
36. Use the wrench flats on the drill rod to secure the drill string with the sliding
table fork by pressing the Deck Fork Engage button.
37. Press the Rod Support Close button and extend the rod support to the drill rod
to be removed.
38. Using reverse rotation with the Drill Rotation joystick, loosen the drill rod joint
and unscrew it from the second drill rod.
NOTICE
NOTICE
If the rotation torque is not sufficient to break the joint connection, the
auto breakout wrench must be used.
39. While unscrewing drill rod, raise rotary head slightly to compensate for the
length change between the drill rod joints.
40. Raise the drill rod to a height that will allow the lower end of the drill rod to clear
the carousel cup. Two inches (50.8 mm) is sufficient. If the rod is raised too
high, it will interfere with the top locking ring and not load into or lock correctly
in the carousel.
41. Swing the carousel to the load/unload position under the rotary head.
42. Line up the drill rod wrench flats with the carousel cup receiving the flats.
43. Lower the drill rod into the carousel cup leaving the drill rod positioned off the
bottom of the cup about 2 inches (50.8 mm).
44. By positioning the drill rod slightly above the carousel cup, as the drill rod
unscrews from the rotary head, it will drop into the cup. This allows positive
engagement of the drill rod in the carousel cup and upper lock plate. Positive
engagement will lock the drill rod in place in the carousel.

! WARNING
Make sure all drill rods in the carousel are secured. Drill rods not
positively secured in the carousel can fall out during operations, causing
damage, injury, or even death.
45. Unscrew the drill rod from the rotary head using reverse rotation with the Drill
Rotation joystick.
NOTICE
NOTICE
The carousel cup has a small amount of movement forward and reverse
to allow the use of inertia to loosen the rotary spindle from the drill rod.
Do not hit the carousel repeatedly to loosen the rod. This will damage the
carousel. If the rod does not come loose with a maximum of three tries,
the rod must be repositioned to use the breakout wrench system.
46. When the rod has been stowed in the correct carousel cup, raise the rotary
head slightly to make sure there is clearance on top of the carousel and open
the rod support to its full retracted position with the Rod Support Open button.
47. Swing the carousel to the stowed position and make sure it is fully stowed.
48. Bring the rotary head down to the remaining drill rod being held in the sliding
table wrench.
49. Start forward rotation of 20 to 30 rpm.
50. Screw the rotary head spindle onto the drill rod.
! CAUTION
While screwing the spindle on the drill rod use precision drilling, do not
force the rotary head down but allow the drill rod to be picked up as it
screws on. Use precision drilling otherwise it will cause thread damage
51. After the rotary head spindle has been screwed on the drill rod, stow the sliding
fork. Raise the rotary head and drill string to the top of the tower and repeat the
process with the next drill rod if necessary.
RCS Drill Leveling Monitor

During all drilling operations, the drill level status is monitored by the on board computer
system. Should the ground be soft or a jack leak off and cause the level of the machine to drift

beyond level, a fault warning will flash on the display screen. If this occurs, use the jack
controller, level the machine and resume drilling. Nothing further is required.

Drill Rod Loading on a PV-271

There are two times when drill rod should be loaded. The first is at initial startup, and the
second is when the drill rod becomes non-usable due to wear or damage and must be
replaced. Atlas Copco recommends the following method.
Equipment Needed
• Lifting crane (one each) of approved capacity to lift the required drill rod weight.
• Lifting straps (two each) of approved capacity to lift the required drill rod weight. Two
lifting straps of equal length.
• Tag line (line used to control the movement of the load).
• Safety harnesses (two each) and other required PPE.
• Man lift (one each) for accessing in and out of the tower.
Loading Drill Rod From the Ground

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.
! WARNING
All lifting equipment must be adequately sized for lifting and be in good
condition. Drill rods are extremely heavy. Extreme care must be
exercised in handling the drill rod safely. Death or serious injury can
occur if safe work practices are not obeyed.
Make sure all tower and rod handling systems are purged and free of air
before commencing the rod installation.
Make sure the rod catcher chains are disconnected and secured.
NOTICE
NOTICE
Minimum safe manpower requirements for this task is five persons.
1. Level the drill at the lowest possible condition (tracks not on the ground).
NOTE: Refer to “RCS Drill Leveling Monitor” on page 5-92.
2. Perform these functions before starting the rod installation.
a. Tower (up and down)

b. Rotary head (up and down)

c. Carousel (swing and indexing)
d. Rod support (in and out)
3. Raise the tower to the vertical position and lock the tower pinning.
NOTE: Refer to “Tower Raising and Pinning (Vertical Drill)” on page 5-57.
4. Open the rod support by using the Rod Support Open button on the right control
panel.
Figure 5-75: Carousel and Rod Support Controls
1 Carousel index clockwise button

2 Carousel swing in (stow) button
3 Carousel swing out (under rotary head) button
5 Rod support close (engage drill pipe) button
6 Carousel index counterclockwise button
5. Make sure the rotary head is at the top of the tower.

6. Unstow or open the carousel.
7. Level the drill with the tower in the vertical position.
8. Lower the tower to the horizontal position.
NOTE: Refer to “Lower Tower/Unpinning (Vertical Drill)” on page 5-61.
9. Uncouple one side of the lower rod catcher (if equipped) and secure the chain.
! WARNING
Do not stand or work directly under the drill rod or put hands and fingers
in pinch points. Serious injury can occur if sudden uncontrolled
movement occurs.

Figure 5-76: Carousel Parts
1 Upper carousel lock plate 5 Top of carousel

2,3 Drill rod ref 6 Rod support
4 Drill rod cups 7 Bottom of carousel
10. Install both lifting straps to the drill rod.

11. Install the tag line to the drill rod approximately three feet above the box end.
12. Remove the plastic thread protector plug and cap installed on the drill rod.
13. Apply grease to the threads on the ends of the drill rod.
14. With the crane, lift the drill rod up level. If the drill rod is not level, lower and
relocate the lifting strap to level the load.
15. Position the drill rod into the carousel rod cup and carousel rod locking plate.
a. Manually align the carousel cup to the flats on the drill rod.
b. Make sure the tool joint undercut does not hang up on the carousel rod lock
plate.
c. Make sure the drill rod is secured in the carousel.

Figure 5-77: Carousel
1 Upper carousel lock plate 2 Drill rod

NOTE: Make Sure the shoulder does not hang up on the locking ring.
d. Remove the lifting straps and the tag line from the drill rod.
16. Index the carousel to receive the next drill rod.
17. Repeat steps 10 through 15.
18. Reconnect the chain on the lower rod catcher (if equipped).
19. Remove personnel from the tower.
21. Make sure the carousel is fully extended out and index the carousel to align the
drill rod to the rotary head.
22. Close the rod support by using the Rod Support Close button on the right
control panel.
23. In Drill mode, use the right Drill Feed Up/Down joystick and feed the rotary head
down to engage threads on the pin end of the drill rod. With the left Drill Rotation
joystick, use slow clockwise rotation and tighten drill rod securely. Select
Precision Drilling for this purpose on the F2 screen.
24. Slowly use counterclockwise or clockwise rotation momentarily to release any
torque pressure on the rod cup after tightening the drill rod to the rotary head.
25. Raise the rotary head slowly until the drill rod clears the carousel rod cup. Move
the carousel into the fully stowed position in the tower.
26. Connect the crossover sub/saver/deck bushing/bit. Grease the threads prior to
connecting these components.
27. Connect the drill rod to crossover sub and tighten securely. Make sure that the
drill is level.
28. Lower the rotary head down unless the bit is touching the ground.
29. Open the rod support when not needed by using the Rod Support Open button
on the right control panel.
30. Drill down with the rotary head, the length of the drill rod.

NOTE: Refer to “RCS Rotary Drilling Procedure” on page 5-80.
31. Engage the sliding fork wrench onto the pin end of the drill rod and disconnect
the rotary head spindle sub from the drill rod in the hole.
32. Raise the rotary head above the carousel.
34. Connect the second drill rod to the drill rod which is secured in the sliding fork
wrench. Grease the threads as needed.
35. Tighten the second drill rod to the first drill rod.
a. Retract the sliding fork wrench from the drill rod.

36. Open the rod support when not needed by using the Rod Support Open button
on the right control panel.
37. Continue drilling down the length of the second drill rod and stop. Engage the
sliding fork wrench into the second drill rod pin end and disconnect the rotary
head from the second drill rod.
NOTE: Do not drill down past the point where the sliding fork wrench will
engage into the pin end of the drill rod which connects to the rotary head
spindle sub.
NOTE: If additional drill rod(s) are required continue with the following
steps.
38. Move the rotary head to the top of the tower.

39. Secure the deck bushing by extending the sliding fork wrench out just far
enough to hold the deck bushing in place, but do not engage the drill rod.
40. Raise the drill by extending the jacks, keeping the drill level. Raise the drill high
enough to clear the drill rod in the ground when the tower is laid over to the
horizontal position.
41. Unlock the tower pinning and lower the tower to the horizontal position.
42. Repeat steps 9 through 15 to add more drill rods.

46. Keeping the drill in level, lower the drill by retracting the jacks.
a. Lower the drill over the drill rod in the ground.

b. When the drill rod is through the deck bushing, fully engage the sliding fork
wrench back into the pin end of the drill rod.
47. To add the additional drill rods repeat steps 20 through 24.
a. Lower the rotary head and the drill rod. Attach drill to the drill rod in sliding
fork wrench and tighten.
b. Repeat steps 46 and 46a.
NOTE: If no drill rod is needed, go to step 47.
48. Lower the rotary head down and reconnect to the drill rod in the sliding fork
wrench.
49. Tighten the rotary head to the drill rod.
50. Disengage the sliding fork wrench from the drill rod.
51. Raise the rotary head up the tower unless the stabilizer or drill bit is at the
bottom of the tower.
52. Close the rod support by using the Rod Support Close button on the right
control panel.
53. Remove the equipment from the drill area.
Removing Worn or Damaged Drill Rod on a PV-271
! WARNING
exercised in handling drill rod safely. Death or serious injury can occur if
safe work practices are not obeyed.
NOTICE
NOTICE
Equipment Needed
• Lifting crane (1 each) of approved capacity to lift the required drill rod weight.
• Lifting straps (2 each) of approved capacity to lift the required drill rod weight. Two

• Tag line (used to control the movement of the load)

• Safety harnesses (2 each) and other required PPE.
• Man lift (1 each) for access in and out of tower.
NOTE: Refer to Drill Leveling Monitor.
NOTE: Replacing four drill rods, do steps 2 through 47. Replacing two
drill rods, do steps 27 through 47.
2. Drill down a new hole with the rotary head and the full length of the two drill
rods.
NOTE: Refer to the Rotary Drilling Procedure.
NOTE: Do not drill down past the point where the sliding fork wrench will
engage into the pin end of the drill rod which connects to the rotary head
spindle sub.
! WARNING
Do not unscrew the rotary head spindle sub from the rotary head while
breaking loose the joint between the spindle sub and drill rod.
3. Engage the sliding fork wrench into the upper drill rod pin end.
4. Use the breakout wrench mounted on side of tower to break the drill rod joint.
Retract and extend the breakout wrench cylinder back and forth unless the joint
breaks loose.
5. Move the breakout wrench out of the way.
6. Use the reverse rotation and unscrew the rotary head spindle sub from the drill
rod.
7. Open the rod support by using the Rod Support Open button on the right control
panel.



9. Secure the deck bushing by extending the sliding fork wrench out just far
enough to hold the deck bushing in place, but do not engage the drill rod.
10. Raise the drill by extending the jacks and keeping the drill level.
11. Raise the drill high enough to clear the drill rod in the ground when the tower is
laid over to the horizontal position.

! WARNING
movement occurs.

Figure 5-79: Carousel Parts
1 Upper carousel lock plate 5 Top of carousel

2,3 Drill rod ref 6 Rod support
15. Raise the crane lifting hook up and over the carousel and lower down to attach
lifting straps.
16. Install both lifting straps to drill rod evenly spaced from each end of drill rod.
17. Install both lifting straps to the crane lifting hook with safety latch.
19. Slowly lift the drill rod up and out of the carousel. Make sure shoulder does not
hang up on the upper carousel lock plate.
1 Upper carousel lock plate 2 Drill rod


20. With the crane, lift the drill rod up level. If the drill rod is not in level, lower and
21. Lower the drill rod to the ground or truck, block the drill rod, and secure.
22. Remove the lifting straps and tag line from the drill rod.
23. Index the carousel to remove the next drill rod.
NOTE: Refer to Raising Tower/Pinning (Vertical Drill).
28. Make sure the carousel is fully stowed.

29. Keeping the drill level, lower the drill down by retracting the jacks.
30. Lower the drill down over the drill rod in the ground.
31. When the drill rod is through the deck bushing, fully engage the sliding fork
wrench back into the pin end of the upper drill rod.
32. Lower the rotary head down and reconnect to the upper drill rod in the sliding
fork wrench.
33. Tighten the rotary head with the spindle sub to the upper drill rod.
34. Disengage the sliding fork wrench from the upper drill rod.
! WARNING
If upper joint comes loose instead of lower one, stop the rotation
immediately. The drill rod can come loose and fall.
35. Move the rotary head up.

36. Engage the sliding fork wrench into the lower drill rod pin end.
a. Close the rod support using the Rod Support Close button on the right
control panel.
37. Use the breakout wrench mounted on side of tower to break the drill rod joint.
Retract and extend the breakout wrench cylinder back and forth unless the joint
breaks loose.
39. Rotate the rotary head spindle sub counterclockwise and unscrew it from the
drill rod.

40. Raise the rotary head up above the carousel.

41. Make sure the carousel is indexed properly. Swing the carousel in line with the
drill rod.
42. Feed the rotary head down unless the hex area on box end of the drill rod is
above the carousel cup. The box end must align with the rod cup. The upper
pin end of the drill rod must be seated in the upper carousel holding slot.
43. Use full counterclockwise rotation to break the joint between the spindle sub
and the drill rod. Slowly use drill feed up position to detach threads.
44. Move rotary head above the carousel, index the carousel into position to accept
the next drill rod.
45. Stow the carousel.
46. Open the rod support using the Rod Support Open button on the right control
panel.
47. Move the rotary head to the bottom of the tower and attach with rotary head to
drill rod in the sliding fork wrench.
48. Tighten the rotary head to drill rod.
49. Disengage the sliding fork wrench from the drill rod.
50. Raise the rotary head and drill rod up the tower.
51. After the rotary head spindle sub is past the rod support, stop feed up.
52. Close the rod support using the Rod Support Close button on the right control
panel.
53. Raise the rotary head up the tower unless the bit sub or stabilizer flats are
aligned with the sliding fork wrench.
54. Engage the sliding fork wrench into the flats of the bit sub or stabilizer.
55. Engage the breakout wrench on the drill rod.
56. Use the breakout wrench mounted on side of the tower, break the drill rod from
the bit sub or stabilizer joint. Retract and extend the breakout wrench cylinder
back and forth unless the joint breaks loose.
58. Use the reverse rotation and unscrew the drill rod from the bit sub or stabilizer
in the sliding fork wrench.
61. Remove the deck bushing/bit sub or stabilizer/bit from the tower bottom and
place on the ground. Secure the components from moving.
62. Remove any loose items from the tower bottom.


65. To load new rods, refer to Drill Rod Loading PV-271 RCS4.
Drill Rod Loading on a PV-275

There are two times that drill rod loading is required. The first is at initial startup and the second
is when the drill rod becomes non-usable due to wear or damage and must be replaced. The
process below is the Atlas Copco recommended method.
Equipment Needed
• Lifting crane (one each) of approved capacity to lift the required drill rod weight.
• Lifting straps (two each) of approved capacity to lift the required drill rod weight. Two
• Man lift (one each) for access in and out of tower.
Loading Drill Rod From the Ground

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.
! WARNING
Make sure all tower and rod handling systems are purged and free of air
before commencing rod installation.

NOTICE
NOTICE
Minimum safe manpower requirements for this task equals five persons.
2. Perform these functions before commencing the rod installation.

3. Tower (up and down)
4. Rotary head (up and down)
5. Carousel (swing and indexing)
6. Rod support (in and out)
panel.
Figure 5-81: Rod Support Controls

9. Make sure the rotary head is at the top of the tower.

11. Level the drill with the tower in the vertical position.
12. Lower the tower to the horizontal position.

! WARNING
movement occurs.
Figure 5-82: Carousel and Rod Support
1 Upper lock plate 5 Top of carousel

2 Drill rods 6 Rod support
4 Drill rod
14. Install both lifting straps to drill rod.

16. Remove the plastic thread protector plug and cap installed on the drill rod.
17. Apply grease to the threads on the ends of the drill rod.

18. With the crane, lift the drill rod up level. If the drill rod is not in level, lower and
19. Position the drill rod into the carousel rod cup and carousel upper lock plate.
20. Manually align the carousel cup to flats on drill rod.
21. Make sure the tool joint undercut does not hang up on carousel upper lock
plate.
22. Make sure the drill rod is secured in the carousel.
23. Remove lifting straps and tag line from the drill rod.
24. Index the carousel to receive the next drill rod.
25. Repeat steps 10 through 15 unless the carousel is full.
29. Make sure the carousel is fully extended out and index the carousel to align the
drill rod to the rotary head.
30. Close the rod support using the Rod Support Close button on the right control
panel.
31. In Drill mode, use the right Drill Feed Up/Down joystick and feed rotary head
down to engage threads on pin end of the drill rod. With the left Drill Rotation
joystick, use slow clockwise rotation and tighten drill rod securely.
32. Select Precision Drilling for this purpose on the F2 screen.

33. In Precision Drilling use the top side of the switch button for rotation and drilling.
This reduces the speed for rotation and drill feed operation.
34. Slowly use counterclockwise rotation momentarily to release any forward
torque pressure on rod cup after tightening the drill rod to the rotary head.
35. Raise the rotary head slowly unless the drill rod clears the carousel rod cup.
36. Move the carousel into the fully stowed position in the tower.
37. Connect crossover sub/saver/deck bushing/bit.
38. Grease the threads prior to connecting these components.
39. Connect the drill rod to crossover sub and tighten securely.
40. Check that the drill is level: if not, level the drill as needed.
41. Remove crane and equipment from the drill area.
42. Refer to “RCS Rotary Drilling” on page 5-76.
Removing Worn or Damaged Drill Rod From a PV-275
! WARNING
! WARNING
NOTICE
NOTICE
Equipment Needed
• Lifting crane (one each) has approved capacity to lift required drill rod weight.
• Lifting straps (two each) has approved capacity to lift required drill rod weight. Two

• Man lift (one each) for access in and out of tower.
NOTE: Replacing 1 to 4 drill rods from the carousel.
2. Remove all loose equipment and parts from the tower bottom.
panel.

4. Move the rotary head to the top of the tower without a drill rod.

! WARNING
movement occurs.

1 Upper lock plate 5 Top of carousel

2 Drill rods 6 Rod support
4 Drill rod
8. Raise the crane lifting hook up and over the carousel and lower down to attach
lifting straps.
9. Install both lifting straps to drill rod evenly spaced from each end of drill rod.
10. Install both lifting straps to the crane lifting hook with safety latch.
12. Slowly lift the drill rod up and out of the carousel. Make sure shoulder does not
hang up on the upper carousel lock plate.
13. With the crane, lift the drill rod up level. If the drill rod is not level, lower and
14. Lower drill rod to the ground or truck, block drill rod and secure.
15. Remove the lifting straps and tag line from the drill rod.
16. Index the carousel to remove the next drill rod.
17. Repeat steps 8 through 13 if needing to remove more than one dill rod.
18. To load new rods, refer to Drill Rod Loading PV-275 RCS4.

RCS Shutdown Procedures
Shutdown the Electric Drill During Normal Conditions

To shutdown the electric drill under normal conditions, perform the procedure below.
1. Move the rotary head to the top of the tower before the shutdown procedure.
The rotary head must be above the upper limit switch for the rod support. This
procedure enables the RCS program to recognize where the rotary head is
located during the start up procedure. If the program cannot recognize where
the rotary head is at startup, damage will occur to the rotary head and the rod
support.
2. Press the right Air On/Off button off. This will shut off the drill air.
Figure 5-86: Air Regulation On/Off Button, Right Control Panel
1 Air regulation on/off button
3. Turn off non essential systems, if necessary.

4. Turn the key switch to the OFF position to stop the electric motor.
Shutdown Electric Drill During Emergency Conditions

The emergency shutdown 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 control of the shutdown devices, such as a fire or other outside caused problem,
initiate an emergency stop with the following procedure:
1. Push in the E-Stop button and exit the drill.

NOTICE
NOTICE
If the operator or other personnel are not in immediate danger and
preservation of the equipment is the primary concern, proceed as
follows:
a. The computer F3 display screen shows the operating temperatures of the

systems they monitor. The operator should be able to avoid a shutdown
condition by checking the computer display screen frequently.
1 Resistor temperature detector (RTD) winding 7 Hydraulic oil temperature

temperature, 3-phase ABC
2 Outside winding temperature 8 Water tank level
3 Electric motor hour meter 9 Voltage RTD, 3-phase ABC
4 Bearing temperature motor (DE and NDE) 10 Amperage RTD, 3-phase ABC
5 Lube-grease tank level 11 Inside winding temperature
6 Airend-compressor temperature
b. When one of the emergency stops or shutdown devices is energized, it

immediately shuts off power to the electric motor.
c. Every attempt should be made by the operator to shut the drill down under
a normal shutdown, if possible, to prevent damage to the drill.

Special Conditions of Use
Cold Weather Conditions
• Refer to Refill Capacities/Lubricants in Section 6.

• Use heaters to warm all fluids before starting drill.
• Perform and obey warm-up procedures upon start-up before operating the drill.
Hot Weather Conditions
• Monitor temperature gauges.

• Keep cooling fins on oil cooler clean and free of accumulated dirt.
Water and Muddy Conditions
• Clean the drill of accumulated material and thoroughly grease all lubrication points.
Refer to Refill Capacities/Lubricants in the maintenance section for information
regarding lubricants, hydraulic fluids, etc.
Dusty Conditions
• Keep air cleaner elements clean and free of accumulation of dirt.

• Wear a protective mask.
High Altitude Conditions
• Be aware that electric motor power will be reduced.

• Keep cooling fins on oil cooler clean and free of accumulated dirt.
Inclement Weather
Obey these requirements or local mine site requirements, whichever has the lowest
limitations.
• Lower the tower in case of lighting hazard.

• Stop drilling, lower tower, and park the rig when winds reach 45 mph (72 km/h) or
higher. Lowering the tower improves stability.
Preservation and Storage

Observe the following when storing the drill for short periods of time:
• Replace and secure all weatherproof covers.

• Change all lubricants and fluids that may have deteriorated with use. Refer to Refill
Capacities/Lubricants in the maintenance section for information regarding
lubricants, hydraulic fluids, etc.
• Check that the storage site is not subject to flooding or other natural hazards.
• Wherever practical, start and run electric motor and operate all drill functions at
regular intervals.
Rod Support Explanation

The rod support on the PV-271 and PV-275 supports the drill rod during the following
operations:
• Aligning the drill rod with deck bushing.

• Collaring or at the start of the drill hole.
• Stabilizing the drill rod while drilling when bit load is increased.
NOTE: Remove the rod support when the drill rod joint is below the deck
bushing during dual pass operation on PV-271 machines.
• Must be open before the rod joint moves through the rod support position.
• Stabilizing and aligning the drill rod to guide the rod while making/breaking a
threaded joint connection (rod, bit sub, stabilizer, hammer crossover sub, etc.).
• Stabilizing and aligning the drill rod to guide the rod while adding/removing from the
carousel cups.
• When the tower is in the horizontal position the rod support must be engaged when
moving hole to hole.
NOTE: If moving between pit locations it is advised the second rod is

stowed in the carousel on PV-270 machines and use the bit in hole-head
at middle tower function.
When using the rod support in both vertical and angle operations listed above, it will work as
a rod catcher in the event of a failed joint connection.
If the machine is equipped with RCS and operating, there is a selectable automatic rod support
feature to automatically actuate both opening and closing when the rotary head travels up and
down the tower.

Towing
Towing the Drill

Make sure that all jacks and dust curtains have been fully retracted. Make sure drill rods are
secured and tower is fully horizontal.
! WARNING
Before disconnecting drive or brakes, secure drill to the appropriate

sized tow vehicle that will tow the drill, with the correct tow bar for the
drill.
• The drill should never be towed faster than it can propel itself. The drill should never
be trammed or towed in excess of 1.3 mph (2.09 km/h). If the speed is exceeded then
you run the risk of raising the temperature in the drives and the rollers.
• If temperatures and towing speed are kept within specifications, towing should not
have adverse affect on the track system. Temperatures and brake release pressure
must be monitored during the process. The roller temperature should never exceed
175 °F (79.4 °C). Use temperature gun to make sure.
• Check the height difference between the top of tow vehicle and bottom of tower. Be
aware of height difference when approaching a hill or dips as not to make contact
between the tower and tow vehicle.
• Always be aware of potential contact with any outside items. Examples of these are,
but not limited to, power lines, exhaust of the tow vehicle, other pieces of equipment,
etc.
• Obey the prescribed method for disengaging brakes while towing according to the
type of tracks on the drill: CAT or ACGT.
• After towing the drill is completed and final drive is connected, make sure that the
final drives are fully engaged and operational. Remove the tow bar from tow vehicle
and the drill. Place tow bar in a secure and safe location.
CAT Tracks
This section contains a description of the disconnect that is integrated into the gear drive and
the proper engaging and disengaging procedure. Please observe the related Notes on Safety.
Description of Disconnect Mechanism
The disconnect of the Planetary Gearbox allows the machine to be towed. The gear drive and
hydraulic motor are disconnected when the mechanism is activated.

! WARNING
The integral parking brake in the gear drive is nonfunctional when the
gear drive is in the disengaged position.
Disengaging Procedure
! CAUTION
Prior to operating the disconnect the machine has to be on level ground

and completely secured from any movement, i.e. via tow bar to pulling
vehicle. The machine should not be moved unless it is secured to the
towing vehicle to prevent runaway.
! CAUTION
Make sure that the disconnect mechanism is only operated with the
machine at a stand still.
! WARNING
The gear drive temperature should be checked prior to any work being
done. This is important if the gear drive has been recently operated since
it may be hot and cause injury.
1. Make sure that the area surrounding the disconnect is cleaned prior to
operation.
! CAUTION
Observe that dirt or other contaminants do not enter the gear drive.
2. Remove the two hex head bolts M8 x 30.

3. Remove the two hex head bolts M8 x 8 and store.
NOTE: Hex head bolts (M8 X 8) will be required again after engaging
process has been completed.

Figure 5-88: CAT Track Disconnect Mechanism
4. Install the two hex bolts M8 x 30 into the threaded holes in the shift sleeve that
previously contained the hex head bolts M8 x 8. Tighten the bolts (M8 x 30) until
they are flush with the shift sleeve.
The input shaft and sun gear are now disconnected and the machine is ready to be towed.
! CAUTION
The maximum gear drive towing speed of 50 rpm must not be exceeded.
! CAUTION
During the towing the max. gear drive temperature shall not exceed 194
°F (90 °C). Check with temperature gauge.
! CAUTION
Before the machine is separated from the towing vehicle, either the gear
drive has to be reengaged or suitable measures must be taken to secure
the machine from movement.
Engaging Procedure
! WARNING
The gear drive temperature should be checked prior to any work being
done. This is important if the gear drive has been recently operated since
it may be hot and cause injury.

! CAUTION
Prior to operating the disconnect the machine has to be on level ground

and completely secured from any movement, i.e. via tow bar to pulling
vehicle. The machine should not be moved unless it is secured to the
towing vehicle to prevent runaway.
! CAUTION
Make sure that the disconnect mechanism is only operated with the
machine at a standstill.
1. Make sure that the area surrounding the disconnect is cleaned prior to
operation.
! CAUTION
Observe that dirt or other contaminants do not enter the gear drive.
2. Remove the two hex head bolts M8 X 30.

3. Press in shift sleeve manually until it makes contact with the surface of the end
cover.
! WARNING
Do not operate the hydraulic motor to obtain engagement.
! CAUTION
The gear drive might require minor repositioning to allow for proper
spline alignment on the input shaft and sun gear to engage.
4. Install the two hex head bolts M8 X 30 into the through holes and into the cover
threads. Tighten the bolts until they are flush with the shift sleeve.
5. Install the two hex head bolts M8 X 8 into the threaded holes in the shift sleeve
that previously contained the hex head bolts M8 X 30.

Figure 5-89: CAT Tracks Engaged Condition
NOTE: Check the shift sleeve to make sure it is flush against the end
cover and that all components are returned to their original position.
The gear drive should now be reengaged and the machine can be disconnected from the
towing vehicle.
ACGT Tracks
Unlocking the Parking Brake
The transmission is fitted with a disengaging gear. The disengaging gear is used to change
the transmission into neutral, i.e. the motor and transmission are disengaged without releasing
the brake. This neutral position is of special importance when the machine is to be towed:
• at higher speeds
• over longer distances
• without actuating the hydraulics.
The transmission must be protected from undue heating during traveling.
Undercarriages with drive units that are fitted with parking brakes cannot be moved when the
hydraulic system is not functioning. For this reason, it is possible to fit the undercarriage with
an unlocking mechanism.

Figure 5-90: Transmission Disengaging Gear
1 Shows flange engaged

2 Shows flange disengaged
Procedure for Disengagement of Gearing

The disengagement flange (A) is secured with two bolts (tightening torque 53 Nm).
To disengage both bolts have to be removed. The disengagement flange can now be moved
to the distance of 16 mm, as shown in the drawing, by means of two bolts screwed into the
withdrawal hole (C). To avoid further movement, the flange must be secured with 2 bolts.
! WARNING
ATTENTION! To avoid damage of gear teeth, it is absolutely necessary

that disengagement and re-engagement is carried out with the machine
at a standstill.
Re-engagement is carried out in the reverse steps.
Remote Hoist
The remote hoist operates through a remote control unit connected by an umbilical cable into
a cable connector socket. The remote hoist is enabled/disabled by a toggle switch located on
the frame under the deck on the non-cab side drilling end on an electrical box. There is a
remote E-Stop button built into the remote hoist control unit.
NOTICE
NOTICE
The Remote Hoist Control E-Stop should be in extended position when
Remote Hoist is enabled. Push in to emergency stop the electric motor.

Figure 5-91: Remote Hoist Controls
1 Remote hoist switch 5 Slider

2 Remote hoist cable connector socket 6 E-Stop
3 Umbilical cable 7 Remote hoist control
4 On/off toggle 8 Rocker switch
NOTE: The left Activate Cab Hoist button must be turned off to enable the
remote hoist function.
1. Remove caps.
2. Plug the umbilical cable into the cable connector socket.
3. Activate the E-Stop button on the remote hoist control by pulling it out.
4. Move the remote hoist toggle switch on the electric box to the Hoist position.
5. Move the remote hoist cable control toggle to the On position.
6. Squeeze switch and move slider to raise hoist or lower hoist.
To remove and store hoist control cable unit:
1. Move remote hoist toggle switch to the Run position.

2. Disconnect the umbilical cable from the cable connector socket on the electric
box.
3. Replace caps.
4. Store the remote hoist control and umbilical cable in the cab.
Drill Information
During all drilling operations, the drill level status is monitored by the on-board computer
system. Should the ground be soft or a jack leak off and cause the level of the machine to drift
beyond level, a fault warning will flash on the display screen. If this occurs, use the jack
controller, level the machine and resume drilling. Nothing further is required.

Figure 5-92: Single-Pass Carousel, PV-271
1 Carousel 3 Drill rod

2 Rod changer 4 Cup
Two rod carousel for 25-ft (7.6 m) rods, 55-ft (16.7 m) single-pass depth.

Figure 5-93: Multi-Pass Carousel, PV-275
1 Drill rod 3 Carousel

2 Rod changer 4 Cup
Four rod carousel for 40-ft (12.19 m) rods, 195-ft (59.4 m) maximum depth.
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 propelling 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 2-
rod carousel for 25-foot (7.6 m) rods for a 55-foot (16.7 m) single-pass application or 105 foot
(32.3 m) maximum depth. The PV-275 Multi-Pass has a 4-rod carousel for 40-foot (12.19 m)
for a 195-foot (59.4 m) maximum depth. Refer to Drill Rod Handling, for drill rod loading
information.
Carousel Control
The carousel can be indexed using the right control panel.
1. With the tower in vertical position, swing the carousel open all the way.
Carousel Swing is controlled using the Carousel Swing In and Carousel Swing
Out buttons on the right control panel.
2. Rotate (or index) the carousel to an empty drill rod holding cup. The carousel
is indexed in the forward position (clockwise) using the index CW button and in
the reversed position (counterclockwise) with the index CCW button. This is
true for the PV-271 Single Pass and the PV-275 Multi-Pass.
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.
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 less than 500 psi (34.5 bar) and prevents
the drill rod from extending further. Both jack pads must be firmly on the ground so the pilot
valve plungers extend and closed. 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 Over Pressure Control System reduces the chance of a tip over, the
operator must not overfeed the drill to this extent.

Figure 5-94: Overpressure Control System
1 Drill end leveling jack

2 Pilot valve plunger
3 Overpressure control pilot valve
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 collapses.
NOTE: Liability for tipping a drill over lies solely with the operator.
Overpressure System Test

Do not test the Overpressure Control System with a drill rod in the rotary head. Only test the
system with the rotary head against the lower tower stops.
1. Level the drill with the tracks 1 to 2 inches (25.4 to 50.8 mm) off the ground. The
drill weight must be fully supported by the leveling jacks.
2. Raise the tower and pin it in the vertical position.
3. Feed the rotary head down against the bottom stops of the tower.
4. Slowly increase pulldown pressure to least 2,500 psi (172.4 bar) down
pressure.
5. Slowly lift the cab side leveling jack off the ground. Feed pressure must vent
immediately when the jack pad is lifted, verify that feed pressure drops below
500 psi (34.5 bar). The rotary head will normally travel upwards slightly when
pressure vents. If pressure vents immediately, proceed to step 6.
6. f feed pressure does not vent, reduce system pressure with the feed controls,
level the drill and contact your supervisor for system repairs immediately.
7. 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 as in step 5,
the system is working.
8. If it does not vent pulldown pressure, shut down the drill immediately and report
any problems encountered to your supervisor.

Section 6 - Maintenance

PV-270E RCS4 Instruction Manual Section 6 - Maintenance
6.1 Maintenance Safety
Pre-Start Inspection
• Inspect the drill for potential hazards.
• Make 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.
• Do not disable or bypass automatic shutoff circuits. They are provided to prevent
personal injury and drill damage.
• Never start an electric motor with the governor linkage disconnected.
Lockout and Tagout

Add lockout/tagout tags on the drill after shutting off the electric motor.
Remove the tags after any repairs or maintenance on the drill. Follow the site specific lockout/
tagout procedures.
! WARNING
Do not operate the equipment until repairs have been made and all the
lockout and tagout tags have been removed by authorized personnel.
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 make sure of uninterrupted and safe operation of the drill by
revealing the need for adjustment caused by normal wear.
Prior to conducting any maintenance work, make sure that the following instructions are
observed:

Section 6 - Maintenance PV-270E RCS4 Instruction Manual
• The drill should be parked on a firm, level surface.

• Make sure to shutoff the electric motor and allow the components to cool.
• Disconnect the battery cables and cover exposed terminals before working on the
drill electrical system.
• Stop the electric motor and allow the hydraulic oil pressure to fall before working on
the hydraulic hose installations or connections.
• Stop the electric motor and allow compressor air pressure to completely relieve from
the receiver tank before working on the compressor, receiver tank, and hose
installations or connections.
• Thoroughly wash all fittings, caps, plugs, and the like with nonflammable and
nontoxic cleaning solution before servicing to prevent dirt from entering while
performing the service.
Service Condition Requirements

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:
• There shall always be two people present; both being fully instructed on the safety
issues. One of them from the main operator station shall supervise the safety of the
service man doing the work.
• The supervisor shall have immediate access to the E-Stop button in all situations.
• The area where the service work is to be performed shall be properly illuminated.
• Communication between the service man and the supervisor at the main operator
station shall be established in a reliable manner.
• Perform repair and maintenance work on the drill only when the drill is shutoff
completely and the starting means are isolated.

6.2 Maintenance Schedule
Electric Motor Maintenance

Refer to the manufacturer’s Operation and Maintenance Manual for your specific electric
motor for the required maintenance schedules and procedures.
Maintenance Schedule Information

The maintenance schedule shows those items requiring regular service and the interval at
which they should be performed. A regular service program is 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. Before each consecutive interval is performed, all of the
maintenance requirements from the previous interval must also be performed.
NOTE: Refer to the manufacturer’s Operation and Maintenance Manual

for the maintenance schedules and procedures for the electric motor.
Table 6-1: Maintenance as Required
Description Action Lubrication

Air cleaners (compressor, Check visual restriction Refer to Parts List.
cab) indicators.
Check connections and
ducts for leaks.
Empty dust cup.
Clean the pre-cleaner
tubes.
Check the rain guard.
Change elements as Refer to Filter Elements
required. and Kits Chart.

Description Action Lubrication

Compressor air hose and Inspect hoses and re- Refer to section 7 - Dixon
clamps tighten clamp bolts. Boss Clamp Installation.
Housekeeping Clean the drill.
Loose bolted connections Check and tighten to Refer to Torque
proper torque. Specifications.
Feed cable and wire rope Check wear and stretch Refer to Maintenance As
conditions. Required.
Adjust feed cables as Refer to Maintenance As
required. Required.
Hydraulic tank oil filters Change elements only as Refer to Filter Elements
required. and Kits Chart.
Hydraulic tank pressurized Change breather only as Refer to Filter Elements
breather filter required. and Kits Chart.
Receiver separator tank Replace separator element Refer to Filter Elements
element as required. and Kits Chart.
Grease drum Fill the grease drum. AC Grease 130
Table 6-2: Scheduled Maintenance
Maintenance Interval (Operating Hours)
Description 100 1,500

8-10
50 - 250 500 1,000 - 5,000 6,000
(Daily)
150 2,000
Test the overpressure control X

system
Check the air cleaner service X

indicator
Check air compressor connections X

and ducts for leaks.
Empty dust cup. X
Clean the cooling fins (HOC, COC) X
Check the receiver separator tank X

compressor oil level.
Drain the water from the receiver X

tank.
Check the oil level on the Hydraulic X

Reservoir sight gauge.


8-10
50 - 250 500 1,000 - 5,000 6,000
(Daily)
150 2,000
Check the hydraulic oil return filter X

indicator.
Check the hydraulic oil drain filter X

restriction indicator.
Check the rotary head oil level. X
Grease the gearbox driveshaft X
Check the complete water injection X

pump, including oil level.
Check the dust collector dropout X

and suction hoses, rod seal, and
blower discharge.
Check the dust collector impulse air X

and filters.
Check battery electrolyte level. X
Make sure battery terminals are X

clean and tight.
Inspect the condition of the wire X

rope.
Inspect the pump drive gearbox for X

oil leaks. Clean the breather.
Check the pump drive gearbox oil X

level.
Check the undercarriage final drive X

mounting bolts.

for oil leaks.

oil level.
Check the track tension. Adjust as X

necessary.
Inspect the winch motor and winch. X
Tighten the winch mounting bolts. X
Change the initial oil in the water X

injection pump. Clean the magnetic
plug.
Change the initial main winch oil. X


8-10
50 - 250 500 1,000 - 5,000 6,000
(Daily)
150 2,000
Tighten the main winch mounting X

bolts.

mounting bolts.
Change the undercarriage X

planetary final drive initial oil.
Replace the compressor air cleaner X

primary and safety elements.
Inspect the Pro-Heat flame sensor X

lens and clean as necessary.
Change the hydraulic tank X

breather.
Perform a hydraulic oil analysis. X
Change the pump drive gearbox X

oil.
Clean and lubricate the feed cable X

and wire rope.
Grease the pulldown cable X

jackscrews.
Inspect the compressor air hose X

and re-tighten the clamp bolts.
Check the main winch oil level. X

bolts.
Check and clean the compressor X

oil strainer.
Change the compressor oil filters. X
Verify the rotary head oil filter is X

secured.
Check the oil level in the optional X

grease tank electric pump.
Change the cab fresh air filter. X
Change the A/C return air filter. X
Change the receiver tank X

compressor oil.
Perform compressor oil analysis. X


8-10
50 - 250 500 1,000 - 5,000 6,000
(Daily)
150 2,000
Change the return and drain X

hydraulic oil filters.
Change the pump drive gearbox X

oil.
Change the rotary head oil. X
Change the rotary head filter X

element.
Change the rotary head lube pump X

suction filter.
Change the main winch oil. X

bolts.
Check the tower cable tension. X
Change the receiver tank discharge X

hose and clamps.
Change the receiver separator X

elements.
Change the receiver tank X

compressor oil

mounting bolts.
Change the undercarriage X

planetary final drive oil.
Change the water injection pump X

oil. Clean the magnetic plug.
Change the oil in the optional X

grease tank electric pump.
Change the hydraulic oil. X
Replace NDE tank mounting X

hardware.

6.3 Refill Capacities/Lubricant
General Information
Lubrication is an essential part of preventive maintenance, affecting the useful life of the unit.
Periodic lubrication of the moving parts reduces to a minimum the possibility of the mechanical
failures.
Different lubricants are needed and some components in the unit require more frequent
lubrication than others. Therefore, it is important that the instructions regarding types and
frequency of the application be closely followed.
The lubrication chart shows those items requiring regular service and the interval at which they
should be performed. Details concerning the oil and other lubricants follow the lubrication
chart. A regular service program should be geared to the items listed under each interval.
These intervals are based on the average operating conditions. In the event of extremely
severe, dusty, or wet operating conditions, more frequent lubrication than specified may be
necessary.
• 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 the improved products. For more information, refer to component manufacturer’s
manual.
• All the oil levels are to be checked with the drill parked on a level surface and while
the oil is cold, unless otherwise specified.
• On plug type check points, the oil levels are to be at the bottom edge of the check
port.
• All the grease fittings are SAE standard unless otherwise indicated. Grease the non-
sealed fittings until the 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.
• Over lubrication on the non-sealed fittings will not harm the fittings or components,
but under-lubrication will lead to a shorter lifetime.
• The items not equipped with the grease fittings (linkages, pins, levers) should be
lubricated with oil once a week. Motor oil applied sparingly provides the necessary
lubrication and helps prevent the formation of rust. An anti-seize compound may be
used if rust has not formed. Otherwise, the component must be cleaned first.

• Grease fittings that are worn and do not hold the grease gun or those that have a
stuck check ball must be replaced.
To prevent the minor irregularities from developing into serious conditions, several other
services or checks are recommended for the same intervals as the periodic lubrication:
• Thoroughly wash all the fittings, caps, plugs, and the like with a non-flammable and
non-toxic cleaning solution before servicing to prevent dirt from entering while
• When draining the lubricants must be at the operating temperature.
• During the regular lubrication service, visually check the entire unit with regard to
capscrews, nuts, and bolts being properly secured.
• Spot check the several capscrews and the nuts for proper torque. If any are found
loose, a more thorough investigation must be made.
• If a defect is detected that requires special service, stop the drill operation until the
defect has been corrected. If necessary, contact Atlas Copco for assistance.
Atlas Copco Fluids

Table 6-3: Atlas Copco Fluids Chart
Fluid Temp Zone ISO Code

Hydraulic 180 Normal 18/16/13
Hydraulic 230 Extreme Arctic 16/13/11
Hydraulic 240 Arctic 16/13/11
Gearbox 110 Normal 18/16/13
Gearbox 210 Arctic 16/13/11
Compressor LP 150 Normal 15/14/10
Compressor HP 350 Normal 15/14/10
Compressor 200 Arctic 15/14/10
Grease 130 Normal
Grease 200 Arctic

Figure 6-1: Temperature Scale
The temperature scale shows the different ambient temperature zones.

Material Safety Data Sheets (MSDS), for each fluid can be found at:
www.atlascopco.com/msds
Lubrication Chart
Periodic lubrication requirements are listed in the following Lubrication Chart. These
requirements include lubricant checks and greasing designated areas of the drill.
Table 6-4: Lubrication Chart
Service
Description Service Remarks Quantity
Interval
10 hours Compressor oil Add as AC Compressor Fill to the middle of
or daily needed 150 oil, low the sight glass.
pressure
AC Compressor
350 oil, high
pressure
Hydraulic oil Add as AC Hydraulic 180 Fill to the full mark.
needed oil
Rotary head oil Add as AC Gearbox 110 oil Fill to the middle of
needed the sight glass.
Gearbox drive shaft Grease AC Grease 130 Five shots of grease
into each fitting.
John Bean water Add as SAE 30 non- Fill to the bottom of
injection pump needed detergent oil the plug hole.

Service
Interval
50 hours Pump drive gearbox Add as AC Gearbox 110 oil Fill to the level hole.
needed
Track planetary Check CAT Final Drive - Fill to the level hole.
gearbox Refer to OEM
manual.
AC Final Drive - AC
Gearbox 110
John Bean water Change SAE 30 Non- Fill to the bottom of
injection pump detergent oil plug hole
(1 qt or 0.95 L).
100 Main winch Change AC Gearbox 110 oil Fill to the level hole
Hours
150 Track planetary Change CAT Final Drive - 2.7 gal (10.2 L) per
Hours gearbox Refer to OEM final drive
manual.
AC Final Drive - AC
Gearbox 110
500 Hydraulic oil Hydraulic AC Hydraulic 180 150 gal (567 L)
Hours oil oil
analysis.
Pump drive gearbox Change AC Gearbox 110 oil 4.0 qt (3.79 L)
(used in position 2) initial
Pulldown cable Grease AC Grease 130 Fill unless the relief
jackscrews pops out.
Main winch Check AC Gearbox 110 oil Fill to the level hole.
Compressor oil Change AC Compressor Fill to the middle of
filters 150 oil, low the sight glass.
pressure
AC Compressor
350 oil, high
pressure
Grease tank electric Check SAE 10W30 motor Fill to the dot on the
pump (option) oil dipstick.

Service
Interval
1,000 Compressor oil Change AC Compressor Fill to the middle of
Hours 150 oil, low the sight glass.
pressure
AC Compressor
350 oil, high
pressure
Hydraulic oil filters Change AC Hydraulic 180 Full mark on the
(return and drain) oil hydraulic tank (all
cylinders retracted).
Pump drive gearbox Change AC Gearbox 110 oil 4.0 qt (3.79 L)
(used in position 2)
Rotary head oil Change AC Gearbox 110 oil 9 gal (34 L)
Rotary head filter Change AC Gearbox 110 oil Fill to the middle of
element the sight glass.
Rotary head lube Change AC Gearbox 110 oil Fill to the middle of
pump suction filter the sight glass.
Main winch 8,000 lb Change AC Gearbox 110 oil 4 pt (1.9 L)
hoist

Service
Interval
1,500- Track planetary Change CAT Final Drive - CAT 345 XL / 345
2,000 gearbox Refer to OEM SL Refer to OEM
Hours manual. manual,
AC Final Drive - AC ACGT 3400 EXT /
Gearbox 110 3400 STD 3.7 gal
(14 L) per final
drive.
Compressor oil Change AC Compressor Fill to the middle of
150 oil, low the sight glass - 38
pressure gal (143 L).
AC Compressor
350 oil, high
pressure
Compressor Change AC Compressor Fill to the middle of
discharge hose 150 oil, low the sight glass.
pressure
AC Compressor
350 oil, high
pressure
Receiver tank Change AC Compressor Fill to the middle of
element 150 oil, low the sight glass - 38
pressure gal (143 L).
AC Compressor
350 oil, high
pressure
John Bean water Change SAE 30 non- Fill to the bottom of
injection pump detergent oil the plug hole (1 qt
or 0.95 L).
Grease tank electric Change SAE 10W30 motor Fill to the dot on the
pump (option) oil dipstick (15 oz or
444 ml).
5,000 Hydraulic oil Change AC Hydraulic 180 150 gal (567 L)
Hours oil

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 make sure that the specified method of
checking for accurate fluid levels is used.
Table 6-5: Fluid Capacities
Approximate Capacities
Component Approximate Quantity
Systems
Hydraulic tank: AC Hydraulic 180 oil 150 gal (567 L)
Receiver tank oil: 38 gal (143 L)
AC Compressor 100 oil, low pressure
AC Compressor 350 oil, high pressure
Rotary head oil: AC Gearbox 110 oil 9 gal (34 L)
Pump drive gearbox: AC Gearbox 110 oil 4 qt (3.79 L) when used in position #2
Main winch: AC Gearbox 110 oil 4 pt (1.9 L)
Track final drive (CAT Final Drive: Refer to OEM manual. AC Final Drive: AC Gearbox
110)
345SL Final Drive Gearbox Refer to OEM manual
345XL Final Drive Gearbox
ACGT 3400 STD. Final Drive Gearbox 3.7 gal (14 L) per drive
ACGT 3400 EXT. Final Drive Gearbox
AC Hydraulic 180 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 make sure of proper system performance and life.
The drill left the factory filled with Atlas Copco (AC) Hydraulic 180 oil, unless otherwise
specified. Refer to Atlas Copco Fluids.
Hydraulic oil must conform to Parker Hydraulics Pump Division HF-O Standards (4-11-78).
Arctic temperature usage is AC Hydraulic 240 oil. Extreme Arctic temperature usage is AC
Hydraulic 230 oil.

Compressor Fluids
The drill is filled with AC Compressor 150 oil (low pressure) or AC Compressor 350 oil (high
pressure), unless otherwise specified. Refer to Atlas Copco Fluids.
Table 6-6: Compressor Fluids
Design Operating Pressure Ambient Temperature Specification

Low Pressure 100 to 300 psi -10 to 125 °F (-23 to 52 °C) AC Compressor 150 oil
(6.9 to 20.7 bar)
High Pressure 350 psi (24.13 -10 to 125 °F (-23 to 52 °C) AC Compressor 350 oil
bar)
Arctic temperature usage is AC Compressor 200 (Synthetic) oil.
Rotary Head Oil

Table 6-7: Rotary Head Oil
Model Quantity Type

PV-271 Approximately 36 qt (9 gal) (34 L) AC Gearbox 110 oil
PV-275
This gear lubricant is compounded to achieve high load carrying capacity and meet the
requirements of either API-GL-5 or SAE-J2360. Unless specified, AC Gearbox 110 oil may be
used for year-round service. Arctic temperature usage is AC Gearbox 210 oil. Refer to Atlas
Copco Fluids.
Pump Drive Oil

Table 6-8: Pump Drive Oil
Model Quantity Type

PV-271 4 qt (1.0 gal) (3.79 L) AC Gearbox 110 oil
PV-275
This gear lubricant is compounded to achieve high load carrying capacity and meet the
requirements of either API-GL-5 or SAE-J2360. Unless specified, AC Gearbox 110 - oil may
be used for year-round service. Arctic temperature usage is AC Gearbox 210 - oil. Refer to
Atlas Copco Fluids.

Winch Lubricant
Unless specified, AC Gearbox 110 oil may be used for year-round service. Arctic temperature
usage is AC Gearbox 210 oil. This gear lubricant is compounded to achieve high load carrying
capacity and meet the requirements of either API-GL-5 or SAE-J2360. Refer to Atlas Copco
Fluids.
Table 6-9: Winch Lubricant
Temperature Range Required Lubricant

-22 to 32 °F (-30 to 0 °C) AC Gearbox 210 oil
Final Drive Lubricating Oil
Normal Operating Conditions

Atlas Copco recommends using CAT Final Drive - refer to OEM manual, AC Final Drive - AC
Gearbox 110 oil for lubricating the final drives. Normal operating condition temperatures are
14 to 86 °F (-10 to +30 °C). Refer to Atlas Copco Fluids on page 6-10.
Arctic Operating Conditions

Atlas Copco recommends using CAT Final Drive - refer to OEM manual, AC Final Drive - AC
Gearbox 210 oil for lubricating the final drives. Arctic operating condition temperatures are -22
to 32 °F (-30 to +0 °C). Refer to Atlas Copco Fluids on page 6-10.
Water Injection Pump Lubricant

Table 6-10: Water Injection Pump Lubricant
Component Quantity Type

FMC John Bean 8 gpm 32 oz (946 ml) SAE 30 Non-detergent oil.
water injection pump (general service
temperature conditions.)
Grease System
The Central Automatic Lube System and general purpose grease systems use this type of
grease AC Grease 130 unless other wise stated. The equipment leaves the factory with the
following grease. Refer to Atlas Copco Fluids.

Normal Operating Conditions

Atlas Copco recommends using AC Grease 130. Normal operating condition temperatures are
14 to 86 °F (-10 to +30 °C). Refer to Atlas Copco Fluids.
Arctic Operating Conditions

Atlas Copco recommends using AC Grease 200. Arctic operating condition temperatures are
-22 to 32 °F (-30 to +0 °C). Refer to Atlas Copco Fluids.

6.4 Torque Values
Standard Torque Values
! CAUTION
Use only the proper tools (inch or metric) on hardware. Other tools may
not fit properly and may slip and cause injury.
Fasteners should be replaced with the same grade or higher. 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. Properly start thread engagement to prevent
the fastener from failing when tightening.
• The following pages list the recommended tightening torques for various size bolts.
Proper torque specifications should be used at all times.
• The head of Grade 5 is marked with three short lines. The head of a Grade 8 is
marked with six 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.
Figure 6-2: Standard Head Markings
1 Grade 5 capscrew head marking

2 Grade 8 capscrew head marking

Figure 6-3: Metric Head Markings
Recommended Torques in Foot-Pounds

This page lists the recommended tightening torques, in foot-pounds (ft/lb), for the various size
bolts and nuts that are used. Suggested assembly torque values are per engineering
specifications.
Table 6-11: Recommended Torques in ft/lb
SAE Grade 5 SAE Grade 8

Size
Dry Lube Dry Lube
1/4 - 20 NC 8 6 12 9
1/4 - 28 NF 10 7 14 10
5/16 - 18 NC 17 13 25 18
5/16 - 24 NF 19 14 25 20
3/8 - 16 NC 30 23 45 35
3/8 - 24 NF 35 25 50 35
7/16 - 14 NC 50 35 70 55
7/16 - 20 NF 55 40 80 60
1/2 - 13 NC 75 55 110 80
1/2 - 20 NF 90 65 120 90
9/16 - 12 NC 110 80 150 110

9/16 - 18 NF 120 90 170 130
5/8 - 11 NC 150 110 220 170

5/8 - 18 NF 180 130 240 180
3/4 - 10 NC 260 200 380 280

3/4 - 16 NF 300 220 420 320
7/8 - 9NC 430 320 600 460

7/8 - 14 NF 470 360 660 500
1 - 8 NC 640 480 900 680

1 - 12 NF 710 530 1,000 740
1-1/8 - 7 NC 800 600 1,280 960

1-1/8 -12 NF 880 660 1,440 1,080
1-1/4 - 7 NC 1,120 840 1,820 1,100

1-1/4 - 12 NF 1,240 920 2,000 1,500


Size
Dry Lube Dry Lube
1-3/8 - 6 NC 1,460 1,100 2,380 1,780
1-3/8 - 12NF 1,680 1,260 2,720 2,040
1-1/2 - 6 NC 1,940 1,460 3,160 2,360

1-1/2 - 12 NF 2,200 1,640 3,560 2,660
Recommended Torques in Newton-Meters

This page lists the recommended tightening torques, in Nm, for the various size bolts and nuts
that are used. Suggested assembly torque values are per engineering specifications.
Table 6-12: Recommended Torques in Nm

Size
Dry Lube Dry Lube
1/4 - 20 NC 11 8 16 12
1/4 - 28 NF 14 9 19 14
5/16 - 18 NC 23 18 34 24
5/16 - 24 NF 26 19 34 27
3/8 - 16 NC 41 31 61 47
3/8 - 24 NF 47 34 68 47
7/16 - 14 NC 68 47 95 75
7/16 - 20 NF 75 54 108 81
1/2 - 13 NC 102 75 149 108

1/2 - 20 NF 122 88 163 122
9/16 - 12 NC 149 108 203 149

9/16 - 18 NF 163 122 230 176
5/8 - 11 NC 203 149 298 230

5/8 - 18 NF 244 176 325 244
3/4 - 10 NC 353 271 515 380

3/4 - 16 NF 407 298 569 434
7/8 - 9NC 583 434 813 624

7/8 - 14 NF 637 488 895 678
1 - 8 NC 868 651 1,220 922

1 - 12 NF 963 719 1,356 1,003
1-1/8 - 7 NC 1,085 813 1,735 1,302

1-1/8 -12 NF 1,193 895 1,952 1,464
1-1/4 - 7 NC 1,519 1,139 2,468 1,491

1-1/4 - 12 NF 1,681 1,247 2,712 2,034


Size
Dry Lube Dry Lube
1-3/8 - 6 NC 1,979 1,491 3,227 2,413
1-3/8 - 12NF 2,278 1,708 3,688 2,766
1-1/2 - 6 NC 2,630 1,979 4,284 3,200

1-1/2 - 12 NF 2,983 2,224 4,827 3,606
Table 6-13: Recommended Torques in Metric Bolts in ft/lb
Class 12.9 (Socket

Class 8.8 Class 10.9
Head Cap Screw)
Size
Dry Lube Dry Lube Dry Lube
M6x1 8 6 11 8 13 9
M8x1.25 19 15 27 20 31 23
M8x1 21 16 29 22 — —
M10x1.5 39 29 53 40 62 47
M10x1.25 41 30 56 42 — —
M12x1.75 67 50 93 70 108 81
M12x1.25 73 55 101 76 — —
M14x2 107 80 148 111 173 130
M14x1.5 116 87 161 121 — —
M16x2 167 125 231 173 269 202
M16x1.5 177 133 245 184 — —
M20x2.5 325 244 450 337 525 394
M20x1.5 361 271 500 375 — —
M24x3 562 422 778 583 908 681
M24x2 612 459 846 635 — —
M30x3.5 1,117 838 1,545 1,159 1,804 1,353
M30x2 1,237 928 1,711 1,283 — —
M36x4 1,952 1,464 2,701 2,026 3,154 2,366
M36x2 2,187 1,640 3,025 2,269 — —
M42x4.5 3,123 2,342 4,320 3,240 — —
M42x2 3,513 2,635 4,860 3,645 — —
M48x5 4,684 3,513 6,479 4,860 — —

Class 12.9 (Socket

Head Cap Screw)
Size
M48x2 5,321 3,991 7,361 5,521 — —
Table 6-14: Recommended Torques in Metric Bolts in Nm
Class 12.9 (Socket

Head Cap Screw)
Size
M6x1 11 8 15 11 17 13
M8x1.25 26 20 37 27 42 32
M8x1 28 22 39 30 — —
M10x1.5 53 39 72 54 84 64
M10x1.25 56 41 76 60 — —
M12x1.75 91 68 126 95 146 110
M12x1.25 99 75 137 103 — —
M14x2 145 108 201 150 234 176
M14x1.5 157 118 218 164 — —
M16x2 226 169 313 235 365 274
M16x1.5 240 180 332 249 — —
M20x2.5 440 331 610 457 712 534
M20x1.5 489 267 678 508 — —
M24x3 762 572 1,055 780 1,231 923
M24x2 830 622 1,147 861 — —
M30x3.5 1,514 1,136 2,095 1,571 2,446 1,834
M30x2 1,677 1,258 2,320 1,740 — —
M36x4 2,647 1,985 3,662 2,747 4,276 3,208
M36x2 2,965 2,223 4,101 3,076 — —
M42x4.5 4,232 3,175 5,857 4,393 — —
M42x2 4,763 3,573 6,589 4,942 — —
M48x5 6,351 4,763 8,784 6,889 — —
M48x2 7,214 5,411 9,980 7,485 — —

6.5 Maintenance As Required
Service As Required
The preventive maintenance and service in this section requires attention on the need basis,
before, during, and after the drill operation shift. This is in addition to the 8 to 10 hour daily
routine maintenance procedures. Performance of this inspection can result in longer life and
maximum productivity from the drill.
Overpressure Control System Test
! WARNING
The overpressure control does not relieve the operator from the
responsibility of having control of the drill at all times. While the
overpressure control reduces the chance of a tip over, the operator must
see that he does not over feed the drill to this extent.
NOTICE
NOTICE
The operator must make sure the jacks are located on firm ground.
Nothing can prevent the drill from upsetting if the ground or shoring
under the jacks collapses.
Liability for tipping a unit over lies solely with the operator.
Overpressure Control System Test

Do not test the Overpressure Control System with a drill rod in the rotary head. Only test the
system with the rotary head against the lower tower stops.

1. Level the drill with the tracks 1 to 2 inches (25.4 to 50.8 mm) off of the ground.
The drill weight must be fully supported by the leveling jacks.
2. Raise the tower and pin tower in the vertical position.
4. Slowly increase pulldown pressure to 2,500 psi (172.37 bar).
5. Slowly lift the cab side leveling jack off the ground. Feed pressure must vent
immediately and drops below 500 psi (34.47 bar), when the jack pad is lifted.
6. If feed pressure does not vent below 500 psi (34.47 bar), reduce system
pressure with the feed controls, level the drill and contact the supervisor
immediately for system repairs.
7. Repeat steps 4 and 5, this time raising the dust collector side jack slightly. If
pressure vents below 500 psi (34.47 bar) when the jack pad is lifted slightly off
the ground, the system is working.
8. If it does not vent pulldown pressure, shut off the drill immediately and report
any problems encountered to the supervisor.
Air Cleaners
The following are detailed instructions for performing routine maintenance procedures on
compressor air cleaner.
Figure 6-4: Compressor Air Cleaner

! WARNING
Wear proper personal protective equipment while handling air cleaners

and elements. Airborne dust may be hazardous.
! CAUTION
Never service the air cleaner while the drill is running. Raw, unfiltered air
can cause compressor damage.
Air Cleaner Indicator
Figure 6-5: Air Cleaner Filter Restrictor Switch
1. When the air cleaner filter restrictor switch detects the compressor air filter is
dirty or plugged, an icon light will come on at the bottom of the monitor screen.

Figure 6-6: Compressor Air Filter Indicator Icon
2. When this light comes on, the compressor air filter is indicating a plugged air
cleaner, service the air cleaner by cleaning or replace the air filter elements.
3. After servicing the air filter element(s), the icon light will go out on the monitor
screen.
Connections and Duct

Check air cleaner connections and duct for leaks before, during, and after every shift. Make
sure all connections between the compressor and air cleaner 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.

Figure 6-7: Empty Dust Cups
1 Gasket 4 Vacuator valve - normal

2 Cup clamp 5 Vacuator valve - inverted
3 Dust cup 6 Quick release dust cup
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 the compressor 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 160 °F (71 °C).

! 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.
Figure 6-8: Air Cleaner - Pre-Cleaner
1 Pre-cleaner 2 Rain guard
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
Figure 6-9: Air Cleaner Elements
1 Upper body assembly 5 Primary element

2 Clamp 6 Wing nut and washer
3 Safety element 7 Dust cover
4 Safety element restriction indicator and cotter pin
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.
When the air filter icon light comes on at the bottom of the monitor screen, 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
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
NOTICE
Make sure that the safety element wing nut is tight. Never attempt to clean
a safety element. 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:
Figure 6-10: Cleaning Primary Elements
1 Dry cleaning
2 Wet cleaning
a. To dry clean the element, carefully direct compressed air, not to exceed
100 psi (6.9 bar) at an angle onto the inside surface from no closer than 1
inch (25.4 mm) from the filter.
b. To wet clean the element, soak for 15 minutes in lukewarm water, not
exceeding 160 °F (71 °C), mixed with a commercially available detergent.
Rinse until water runs clear (40 psi [2.76 bar] maximum).
c. After the cleaning, the element must be thoroughly dry before using. Do not
use compressed air to dry the element.
7. Examine the new or newly cleaned primary element for torn or damaged pleats,
bent end covers, liners and gaskets.
8. Make sure 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 one year
duration.

c. Change safety element as indicated by the safety element restriction

indicator.
d. Change safety element if the air filter icon light comes on at the bottom of
the monitor screen after servicing the primary element.
10. Clean the inside of the air cleaner housing before removing the 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 make sure that no dusty air can enter.
16. Make sure all clamps are tight.
NOTICE
NOTICE
Never leave the air cleaner open longer than necessary.
After servicing the elements, the icon light will go out on the monitor screen when the element
is replaced in the air cleaner housing.
The two most common servicing problems are over servicing and improper servicing.
• 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.
• 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

Perform these service tips to keep the air cleaners working at their best to protect the
compressor.
• Let restriction levels be your guide. Use an air cleaner filter restrictor switch on each
air cleaner.
• Service the elements only when the restriction reaches the service level
recommended by the compressor or equipment manufacturer. It is only above that
point that air cleaner restriction begins to reduce performance levels.
• If the compressor performance is poor, but restriction is still within limits, do not
change the element. The air cleaner is probably not at fault.
• 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.
• Check to see that all connections are tight and leak free and that breakaway joints,
both intake and exhaust, are aligned and sealed.
• Make sure that the vacuator valve, on air cleaners so equipped, is not plugged. Make
sure the cup joint is sealing. This should take care of most of the air cleaner related
performance problems.
• When air restriction icon at the bottom of the monitor screen is on, remove the
primary element very carefully. Use a damp cloth to wipe out all excess dust in the
air cleaner.
• 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.
• A thorough cleaning with air or water is recommended in many cases. Be careful, too
much pressure can break the filter paper and destroy the element.
• Carefully check new or properly cleaned elements for damage before installing.
• Never attempt to clean a safety element. Change safety elements only after three
primary element changes or as indicated by a SafetySignal™ Service indicator.
• Make it a habit not to disturb the element until restriction again reaches the service
limit.
Cooling System (HOC and COC)

The cooling system must be checked daily as part of the 8-10 hour or daily routine
maintenance procedure.
Check the HOC and COC fins and housing for contaminants.
Check the HOC and COC for leaks.

Cleaning Cooler
1. Remove any leaves, rags or other debris from the cooler.

2. Clean the fins of any dust, oil or other contaminants that prevent the cooler from
cooling the HOC and COC fluids.
3. Wash cooler with a solution of soap and water. Do not use caustic solutions on
the cooler as they may degrade the fin material and cause a leak.
Check for Leaks
1. Look for signs of hydraulic oil or compressor oil on or under the hydraulic oil
cooler and the compressor oil cooler.
2. Inspect areas of concern more closely to determine if leaks exist.
3. If a leak is verified or adjustment is required, contact maintenance and take

corrective action.
Air Compressor
Compressor Air Hoses and Clamps
Figure 6-11: Hose Clamps
Dixon Boss clamp IC (Campbell) clamp
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.

Air Hose and Clamps (Dixon Boss Clamps)
! CAUTION
Refer to the Safety First manual for safety precautions when installing
clamps.
Refer to the Dixon Valve website for the proper way to select and install Dixon Boss clamps.
• Periodic clamping bolts re-tightening is necessary due to Cold-Flow present in all

rubber hoses. Tighten to recommended torque value listed on the Dixon Valve
website.
• 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.
Air Hose and Clamps (IC [Campbell] Clamps)

Refer to the IC (Campbell) Clamp Installation instructions shown in section 7- Troubleshooting
for the proper way to install IC (Campbell) clamps.
Periodic clamping bolts re-tightening is necessary due to Cold-Flow present in all rubber
hoses. Tighten to recommended torque value listed on IC (Campbell) Clamps chart in section
7- Troubleshooting.
Electric Motor
Refer to the WEG Operation and Maintenance Manual for maintenance schedule and
procedures.
Proheat (Option)
For drills with Proheat, inspect the flame sensor lens and clean as necessary during the 250
hour routine maintenance schedule or six months, whichever comes first.

Figure 6-12: Proheat Sensor Lens
1 Sight glass 3 Flame sensor lens

2 Air inlet screen
To maintain proper sensor readings, the flame sensor glass should be wiped clean. Remove
the fan end cover.
With the fan end removed, clean the sensor lens with water and a cloth. Glass should be clear.
Clean the sight glass with water and a cloth. Clean air inlet screen as needed.
Housekeeping
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 operator cab, decking, steps, and grab rails are
clean. Oil, grease, snow, ice, or mud in these areas can be slippery. Clean the
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, and the like with a nonflammable,
nontoxic cleaning solution before servicing to prevent dirt from entering while
NOTICE
NOTICE
Protect all electric components and control panels against entry of water
or steam when using high pressure cleaning methods. Cover the
hydraulic fill cap breathers.

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 the 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,
make sure they are properly torqued. Refer to Torque Values on page 6-19 for the required
torque for all bolt sizes and grades. Always replace self-locking nuts if they have been
loosened.
Dust Collector
In order to make sure 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.

Figure 6-13: Dust Collector
1 Blower assembly
2 Air inlet
3 Suction hose
4 Dust hood outlet
5 Dropout 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.
Filter Elements
Listen to the back-pulsing of the filter elements. There should be a sharp pulse of air every two
to three 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 (4.76 bar). 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.
Figure 6-14: Dust Collector Filter Elements

Rod Seal
Inspect the integrity of the rod seal attached to the drill. Also give attention to the dust curtains
surrounding the hole.
Figure 6-15: Rod Seal
Main Winch
! 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.
! WARNING
Cable clamps are not designed to hold rated winch loads. At least five
wraps of cable must remain on the drum at all times.
! CAUTION
Stay at least 10 feet (3 meters) away from cable while it is under tension.
Cable should be inspected whenever unwound and replaced when
broken strands are noted.

Periodic Inspection
The following jib hoist maintenance must be carried out as part of the 50 hour routine
maintenance schedule.
1. Inspect rigging, winch and hydraulic hoses at the beginning of each work shift.
Any defects should be corrected immediately.
2. Be certain that at least five 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.
Figure 6-16: Jib Hoist
5. Inspect gear teeth for excessive wear. Wear should not exceed 1/16 inch. Refer
to Feed Cable and Wire Rope for additional information on wire rope and wire
rope clamps.
Feed Cable and 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 and PV-275)

Preliminary Adjustments (Machine Running)
1. The upper tensioner relief valve is factory pre-set at 2,300 psi (158.58 bar).
Adjustment of a new or replacement part should not be required.

2. The sequence valve cartridge must be set at 500 psi (34.47 bar) inlet pressure
while its outlet is being directed to tank. Sequence valve is in port RSDC in the
manifold. To adjust:
A. Attach a 1,000 psi (68.95 bar) 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 unless the gauge reads 500 to 550 psi (34.47 to
37.92 bar).
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 (51.71 bar). To make this setting the fan speed must be set on high.
Cable Adjustment (Machine Running)
1. 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 unless 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 jack screws 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. Go to the M7 screen to release upper cable tension and activate the cable
tension adjustment and use paddles to control tension screws.
NOTE: Login in at SE level to access this screen.
4. 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
unless the cable sag (measured at the midpoint of the longest span) is 1.5 to
2.5 inches (38.1 to 63.5 mm) for the PV-275 or 2 to 3 inches (50.8 to 76.2 mm)
for the PV-271. Measurement is to be taken from the centerline of the front
tower tubing (that is, chord) to the centerline of the cables.
5. Use the NCS jack screw to tension the NCS lower cable unless 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.

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 broken wires in a wire rope lay length, or three
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 12 broken wires in a wire rope lay length, or four 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
criteria for determining wire rope replacement.
Figure 6-17: Wire Rope
1 Core 6 Start of lay length

2 Wire 7 Lay length
3 Center wire 8 End of lay length
4 Strand 9 One strand
5 Wire rope 10 One revolution
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 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.
Feed Cable Replacement

Refer to the parts manual for the specific rig serial number to make sure 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:
• Six randomly distributed broken wires are found in one lay

• The outside wires are worn more than one third (1/3) of their original diameter
• There is evidence of heat damage of any kind
• The wire rope is kinked or damaged.
Wire Rope
Winch ropes, including their anchorage and other load carrying components of the winch
system, for example sheave bearings, rope sheaves, and drill hooks must be checked at least
once a week.
Wire ropes must 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 must 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.
• Replace when four randomly distributed broken wires are found in one lay.
• Replace when wire rope shows wear of 1/3 of the original diameter of the outside
wire.
• Replace when evidence of any heat damage from any cause is found.
• Replace when any kinking or cracking occurs.
Wire Rope Installation
! WARNING
NEVER attempt to lift a load with less than five wraps of cable on the
drum. The cable clamp is not designed to hold the full load alone.

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.
Figure 6-18: Inserting Wire Rope
1 Insert large end first for 3/8” and 7/16” (10 mm and 11 mm) wire rope
2 Insert small end first for 1/2” and 9/16” (13 mm and 14 mm) wire rope
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. Anchor 3/8-inch and 7/16-inch (10 mm and 11 mm) wire rope by inserting the wedge
large end first. Anchor 1/2-inch and 9/16-inch (13 mm and 14 mm) 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 the winch cable to slip through your hands. Always use a
hand-over-hand technique.

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.
• Tracks that are too tight will put extra stress on both the undercarriage and the drive
train components, while wasting horsepower.
• 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. 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).
Figure 6-19: Track
1 Track pin 4 Track rollers

2 Idler 5 Length
3 Carrier roller 6 Sag
NOTICE
NOTICE
A sag must be present in the chain. On a length of 39.4 to 59.0 inches (1
to 1.5 meters), the sag must be 0.79 to 1.18 inches (2 to 3 cm). The correct
SAG (distance from the bottom of the straight edge to top of the track
shoe) is 3% to 4% of the distance between the top of the idler and the
carrier roller.

2. Place a straight edge on top of the shoe grousers between the front carrier
roller and the idler.
Figure 6-20: Shoe Grousers
1 Straight edge
2 Idler
3 First roller
4 Length
5 Sag
3. Measure the sag half-way between the carrier roller and the idler. Measure the
distance from the top edge of the shoe to the bottom of the straight edge.
4. The track requires adjustment when the track sag exceeds the following.
a. CAT Tracks: Adjust idler tension for a sag of 1 to 1.5 inches (25.4 to 38.1
mm).
b. AC Tracks: Adjust idler tension for a sag of 7/8 to 1.5 inches (22.2 to 38.1
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.
2. Inject AC Grease 130 with a high pressure grease gun, unless the required
track tension is obtained. Refer to Refill Capacities/Lubricants/Specifications,
for recommended grease requirements.
3. To reduce track tension, slightly unscrew the cover plug. The internal buffer
spring will relax and grease will be ejected.

Figure 6-21: Track
1 Grease port 2 Cover plug
4. To readjust, secure cover plug and inject grease at grease point unless correct
track tension is effected.
5. Repeat the same procedure for the other track drive.
! WARNING
Track components have the presence of stored energy. Read the Safety
Decal.

6.6 Lubrication and Filters
Compressor
The following compressor system maintenance must be carried out as part of the 500 hour
routine maintenance schedule.
! WARNING
Avoid contact with hot oil or components. Do not allow used compressor
oil to drain into the ground. Dispose of used compressor oil properly. Hot
compressor oil or components can burn.
Do not attempt to remove filler plug, drain valve, and fittings before
making sure all air pressure has been completely relieved from the
system. High pressure can cause severe injury or death.
Reinstalling 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 reinstalled
every 500 hours.

Figure 6-22: Compressor Oil Strainers
1 Oil pump 3 Compressor oil strainer

2 Compressor oil strainer
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. Reinstall the strainer element.
5. Replace and secure the cover.
Installing Compressor Oil Filters

The following compressor oil filter maintenance must be carried out as part of the 500 hour
routine maintenance schedule.
Figure 6-23: Compressor Oil Filters
1 High pressure compressor oil filter 2 Low pressure compressor oil filter

! WARNING
Avoid contact with hot compressor oil or components. Do not let used oil
drain into the ground. Dispose of properly. Hot compressor oil or
components can burn.
1. Level the drill.
2. Shut off the electric motor.
3. Lockout/tagout in accordance with site specific procedures.
4. Wipe all external dirt and oil from filter housing and head area to minimize
contamination from entering the system.
5. Place a container under the oil filter to collect any oil escaping during removal
and prevent any oil spill from contaminating the ground.
! CAUTION
Do not allow used oil to drain into the ground. Dispose of properly. Obey
all local standards and regulations for disposal of used oil filters and oil.
6. Use a oil filter strap wrench to remove the compressor oil filters.
7. Clean the sealing surface of the filter mounting base. Make sure that all of the
old oil filter gasket is all removed.
8. Apply clean oil to the new oil filter gasket.
9. Install the new oil filters. Tighten the oil filter unless the oil filter gasket contacts
the mounting base. Tighten the oil filter by hand according to the instructions
on the oil filter. Do not over tighten the oil filter. Most filters will have instructions
included.
NOTE: Low pressure compressors (110 psi [7.58 bar]) use AC

Compressor 150 oil.
NOTE: High Pressure compressors (350 psi [24.13 bar]) use AC

Compressor 350 oil.
10. Remove lockout/tagout and start the electric motor. Check for oil leaks. Run the
electric motor for one minute.

11. Stop the electric motor and check for oil leaks again. Check the compressor oil
level at the receiver tank. If low, add compressor oil to the middle of the receiver
tank sight glass. Re-check for leaks at operating temperature.
Checking 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:
3. The fluid must be in the center of the oil level sight glass.
4. If necessary, add fresh, clean synthetic oil (filtered through a 10 micron filter)
through the fill cap area to bring level to FULL.

Compressor 150 oil.
NOTE: High pressure compressors (350 psi [24.13 bar]) use AC

Compressor 350 oil.

Figure 6-24: Receiver Separator Tank
1 Separator cover
2 Type of oil decal
3 Oil filler cap
4 Drain valve
5 Oil level sight glass
6 High pressure warning decal
7 Receiver tank
8 Separator element
Changing Compressor Oil

Under normal operating conditions, the compressor oil must be changed every 1,000 hours as
part of a routine maintenance program.
! DANGER
DANGER
Do not attempt to remove any plugs or open 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. High pressure can cause severe injury or death.
! WARNING
Avoid contact with hot oil or components. Hot oil or components can
burn. Oil must be at normal operating temperature when draining.
1. Park the drill on a stable, level surface.

NOTE: 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 140 °F (60 °C) before draining oil.
4. Place a 38-gallon (144-liter) container with a capacity of at least under the

receiver tank drain or under the four compressor oil central drain points. Drill
Central Drain Point System (option) is located on the non-cab side, non-drilling
end of the drill.
Figure 6-25: Receiver Tank Drain
Figure 6-26: Drain Point System
1 Receiver tank 3 Compressor gearbox

2 COC 4 Compressor rotor housing

! WARNING
Make sure all air pressure has been completely relieved from the system
before removing filler plug, fittings, and opening the drain valve. High
pressure can cause severe injury or death.
5. Verify that no pressure is in the system by opening the service air valve and
checking the gauge. The gauge on the tank must read 0 psi.
Figure 6-27: Service Air Valve and Gauge
1 Service air valve

2 Service air gauge
! CAUTION
Do not allow used oil to drain into the ground. Dispose of properly.
6. Open the drain valve on the receiver tank or connect drain hoses to the Central
Drain Point System and allow the compressor oil to drain into a container.

Compressor 150 oil.
NOTE: High pressure compressors (350 psi [24.13 bar]) use AC

Compressor 350 oil.
7. Close the receiver tank drain valve or remove hoses from Central Drain Point
System. Refill the receiver tank through the oil filler cap or with the quick-fill
system. Fill to the middle of the receiver tank sight glass. Clean and replace the
oil filler cap.

Figure 6-28: Fast Fill System
1 Compressor oil fast fill connection
8. Remove lockout/tagout in accordance with site specific procedures.
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 accompany the air flow unless 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, make sure there is at least one
staple that shows through on both sides of the gasket and is not covered
with glue.

Figure 6-29: Separator Element
1 Outside cover 3 Staple

2 Gasket 4 Metal cover
NOTE: The staple connection acts as a bridge and allows the
static charge to drain off outside of the receiver tank.
Receiver Tank
The receiver tank separator filter element is an As Required maintenance item. Receiver tank
separator filter element varies according to each drill configuration. See the Preventative
Maintenance Schedule and filter kits located in the front of the Parts List for the drill.
Draining Water from Receiver Tank
! WARNING
High pressure can cause severe injury or death. Completely relieve

pressure before removing filler plug, drain valve, fittings or receiver
cover. There is a presence of stored energy.

Figure 6-30: Receiver Tank
1 Receiver tank 3,5 Drain valve

2 Oil filler cap 4 Oil level gauge
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 the drain valve.
3. Dispose of all accumulation in accordance with local regulations.
Receiver Separator Element

Maintenance on the receiver separator element should be performed as required. A change
of the receiver separator element is required when there is excessive oil carry over with the
compressed air.
! WARNING
Do not attempt to remove filler plug, drain valve, fittings, or receiver cover
before making sure all air pressure has been completely relieved from the
system. High pressure can cause severe injury or death.
! WARNING
burn.
1. Park the drill on a stable, level surface and shut off the electric motor. Allow
time for the drill to cool.

Figure 6-31: Receiver Tank
1 Vertical receiver tank

3 Receiver cover
4 Separator element
5 Oil fill plug
3. Remove the bolts that secure the receiver cover.
4. Lift the receiver cover with an approved rated hoist and lifting devices. Clean
the sealing surface of the receiver cover. Make sure that all of the old element
gasket is all removed.
5. Remove the separator element from the tank.
6. Discard the used element in accordance with local guidelines.
7. When installing the new element, make sure that the gasket is equipped with a
staple.
8. Re-attach the cover and tighten the bolts according to the following sequence.
NOTE: Vertical tank - torque bolts to 353 to 380 ft/lb dry (478 to 515 Nm).
Figure 6-32: Receiver Tank Cover Torque Sequence
4 bolt cover 8 bolt cover 12 bolt cover 16 bolt cover

9. Check the compressor oil fluid level:
a. The fluid must be in the center of the oil level sight glass.
b. If necessary, add fresh, clean synthetic oil (filtered through a 10-micron

filter) through the quick-fill or fill cap on receiver tank to bring level to FULL.
NOTE: Low Pressure compressors (110 psi [7.58 bar]) use AC

Compressor 150 oil.
NOTE: High Pressure compressors (350 psi [24.13 bar]) use AC

Compressor 350 oil.
10. After startup, check the drill for any leaks at operating temperatures.
Feed Cable and Wire Rope
Cable/Rope 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 lubricated about every 500 hours
with one of these lubricants or equivalent:
• Whitmore’s Wire Rope Lubricant (Whitmore Manufacturing Co.)

• Liquid-O-Ring 772 (Oil Center Research, Inc.)
• Texaco Crater A
The lubricant can be applied with either a spray or a brush and is recommended for protection
against corrosion. The above lubricants should penetrate to the wire rope core.
Whitmore’s Drag Rope Lubricant HF (Whitmore Manufacturing Co.) is recommended to
further protect the cable outer surface and sheave from wear.
For temperatures below 35 °F (2 °C), for Drag Rope Lubricant HF equivalent, use Whitmore’s
Envirolube (Whitmore Manufacturing Co.).
Hydraulic Tank
The hydraulic tank oil filter maintenance should be performed as required. See the
Preventative Maintenance Schedule and Filter Kits located in the front of the Parts List for the
drill.

Figure 6-33: Hydraulic Tank Oil Filters
1 Drain Filters (Drill end side 2 Return filters (Non-drill end

hydraulic tank side hydraulic tank)
Hydraulic Oil Filters

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.
Figure 6-34: Hydraulic Oil Filters
1 Drain filters
2 Return Filters
It is important to monitor the filter restriction indicator during the routine 8 to 10 hour walk-
around inspection by the operator. If the indicator window is red, then the filter elements
require replacement. If the window is green, the filters are satisfactory. When restriction
indicates that element servicing is required, perform the instructions shown in Maintenance

(1,000 hours). Under normal operating conditions, these filters are replaced at the regular
1,000 hour service interval.
If the drain filter(s) or return filter(s) fault icon illuminates on the monitor screen in the cab,
change the filter element(s). The filter fault icon(s) will appear at the bottom of the monitor
screens F1, F2, or F3 and (F4 GPS option).
1 Hydraulic drain filter #1

2 Hydraulic drain filter #2
3 Hydraulic return filter #1
4 Hydraulic return filter #2
The photo is an example of all hydraulic filter fault icons illuminated. When a fault icon
illuminates, touch on the fault icon and a fault message box will appear on the monitor. This
message will advise of the fault condition.
Figure 6-36: Fault Message Box

Replace Return/Drain Filters
! WARNING
Make sure all of the hydraulic pressure has been relieved from the system
before attempting to service the 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 4-gallon (15-liter) container under the oil filters to prevent any oil spill
from contaminating the ground.
3. Remove the bolt that secures the filters clamp to the hydraulic tank.
4. Carefully remove the four bolts that secure the retaining ring to the filter head.
Figure 6-37: Return/Drain Filters
1 In 6 Filter
2 Out 7 Spring
3 Bolts (typ.) 8 Plate
4 Retaining ring 9 Element
5 Filter clamp and bolt 10 O-ring
5. Remove elements from the filter housing.
6. Discard old elements in accordance with any local guidelines.
7. Clean the filter housing and filter head with an approved cleaning solvent.
8. Install the compression spring and the spring plate into the bottom of the
element before inserting element into the housing.

! CAUTION
Do not over torque bolts. Over torquing bolts will cause damage to the
housing and/or O-ring washer seal.
9. Attach the housing to the filter head and tighten the four bolts evenly and in
sequence.
10. Install filter clamp and tighten bolt.
11. Repeat the procedure unless all hydraulic filters are replaced.
12. Pressurize the hydraulic system and check for leaks.
Hydraulic Tank Breathers

The hydraulic tank breathers is an As Required maintenance item. See the Preventative
Maintenance Schedule and Filter Kits located in the front of the Parts List for the drill.
Figure 6-38: Hydraulic Tank Breathers
Follow the below procedure to replace the hydraulic tank breathers.

Figure 6-39: Hydraulic Tank Breathers
1. Thoroughly clean the area around the hydraulic tank breathers.
2. Remove the breathers.
3. Cover the breather ports to make sure that nothing can get into the tank
housing.
4. Install the new breathers.
NOTICE
NOTICE
Dirt in the hydraulic system will lead to premature component failure. A
clean, contaminant free system is extremely important to the proper
function of the machine. Take extra care when working around or on the
hydraulic system to make sure its complete cleanliness.
Hydraulic Reservoir
The hydraulic reservoir oil level must be checked daily as part of the 8 to 10 hour routine
maintenance procedure.
! WARNING
Disconnect hydraulic tank high voltage heater before draining or filling

system. Liquid explosion can cause severe injury.

! CAUTION
Do not fill hydraulic tank with cylinders extended. Retract all cylinders
and fill tank to indicated level. Excessive hydraulic oil can rupture
hydraulic tank and cause injury or property damage.
NOTICE
NOTICE
Take extra care when working around or on the hydraulic system to make
sure its complete cleanliness. When operating, the oil level must be
between the maximum and minimum levels.
NOTICE
NOTICE
Dirt in the hydraulic system will lead to premature component failure. A
clean, contaminant free system is extremely important for the drill to
function properly.
Checking Hydraulic Oil Level

Use this procedure to check the hydraulic oil level in the reservoir. If the hydraulic oil level is
low, add hydraulic oil.
1. Level the drill.
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.

Figure 6-40: Hydraulic Reservoir
1 Oil fill decal

4. Add hydraulic oil through the quick-fill as follows:
NOTICE
NOTICE
Do not use the quick-fill system to drain or remove fluid. Use the fittings
at the bottom of the hydraulic tank.
a. Level the drill.
b. The tower must be horizontal with the rotary head at the top of the tower
and all leveling jacks fully retracted.
c. Shut off the electric motor.
d. Make sure the breathers on top of the tank are clean and will allow the tank
to breathe.
e. Locate the proper port fitting in the quick-fill box for the hydraulic tank.
Remove cap and clean the fitting.

Figure 6-41: Quick Fill Station
1 Hydraulic oil connection
f. Locate the proper quick-fill hose. Clean the hose fitting and connect it to the
quick-fill fitting.
g. Add or refill with new oil AC Hydraulic 180 oil.
h. Verify that the low hydraulic oil level operator alarm turns off when the float
reaches the safe level at the bottom of the sight glass.
i. Verify the tank has not been over filled. Fluid should not be over the top of
the sight glass.
j. Verify the main valve under the tank is fully open.
Hydraulic Oil Analysis

Have a hydraulic oil analysis done as part of the 500 hour routine maintenance.
Let the oil analysis determine when to change the hydraulic oil. The hydraulic tank oil must be
replaced as part of the 5,000 hour routine maintenance.
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 exist:
• Viscosity increases by 16% or decreases by 10% (compared to new fluid)*

• Total Acid Number (TAN) increases by 2.5 or more (compared to new fluid)*
• Water content exceeds 0.1% (1,000 ppm)
• The fluid becomes contaminated with any other unfilterable contaminant.
* 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 especially if it corresponds to a viscosity
increase of over 16%, the fluid should be changed.

NOTE: High concentrations of soluble metals as indicated by a

spectrochemical analysis do not necessarily indicate a deterioration of
the fluid.
NOTE: 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.
Draining Hydraulic Reservoir With Central Drain Point System
! WARNING
Do not remove any plugs or open the drain valve before making sure all
air pressure has been relieved from the system.
! WARNING
Do not service the hydraulic system before making sure all the hydraulic
pressure has been relieved from the system.
! WARNING
1. Position drill on a 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.
6. Make sure the breathers on the top of the tank are clean and will allow the tank
to breathe.
7. Position a 175-gallon (662.4-liter) container under the central drain points to

collect used oil. Do not allow used oil to drain into the ground. Drill central drain
point system is located on cab side, non-drilling end.

NOTICE
NOTICE
Contain fluids during any inspection or when work is performed on this
component. Handle and dispose of fluids according to local regulations
and mandates.
Figure 6-42: Optional Drain System
1 Hydraulic oil
8. Close the tank main valve located under the tank.
Figure 6-43: Tank Main Valve
1 Hydraulic tank
(reference only)
2 Main valve handle

NOTICE
NOTICE
Do not use the quick-fill system to drain or remove fluid. Do not allow
used oil to drain into the ground. Dispose of properly. Obey all local
standards and regulations for disposal of used oil.
9. Connect drain hoses to each of the central drain points to drain oil. Allow the
hydraulic oil to drain into a suitable container.
10. After the hydraulic tank has stop draining, remove the drain hoses. Fill the
hydraulic tank with AC Hydraulic 180 oil through the quick fill port. See Refill
Capacities/Lubricants/ Specifications for details on hydraulic oil.
Filling Hydraulic Tank With Quick-Fill
1. Remove the cover cap on the hydraulic oil quick-fill and wipe the connection
clean. Clean the quick-fill hose connection and install the quick-fill hose.
Figure 6-44: Hydraulic Oil Connection
1 Hydraulic oil connection
2. Fill to the FULL mark on the hydraulic tank sight glass with AC Hydraulic 180
oil. After filling hydraulic tank remove the quick-fill hose from the connection
port. Removing the hose eliminates any chance of back pressure through the
quick-fill.
3. Verify that the low hydraulic oil level alarm turns off on RCS monitor when the
float reaches the safe level at the bottom of the sight glass.
4. Open the hydraulic tank main shut-off valve.
5. Start the drill and check the hydraulic oil level in hydraulic tank. Check for leaks
at filters and hydraulic tank.
6. Shut off the electric motor and re-check hydraulic tank fluid level.

7. Add AC Hydraulic 180 oil as needed through the quick-fill port. Fill to the FULL
mark on the hydraulic tank sight glass.
Figure 6-45: Hydraulic Tank
1 Hydraulic tank sight glass

2 Hydraulic tank level decal
Draining Hydraulic Reservoir Without Central Drain Point
1. Park the drill on a stable, level surface and shut off the electric motor. The tower
must be in the horizontal position and all jacks must be up. Allow time for the
hydraulic oil to cool.
2. Place a 175-gallon (662.4-liter) container under the hydraulic tank oil drain.
NOTICE
NOTICE
Do not allow used oil to drain into the ground. Dispose of properly. Obey
all local standards and regulations for disposal of used oil.
3. Close the hydraulic tank main shut-off valve.

Figure 6-46: Hydraulic Reservoir without Central Drain Point
1 Quick-fill connection under tank 3 Breathers

2 Main valve handle 4 Hydraulic tank main valve
4. Make sure the breathers on the top of the tank are clean and will allow the tank
to breathe.
5. Connect a drain hose to the quick connection under the tank to facilitate
draining the oil into the container.
6. Allow the hydraulic fluid to drain into an appropriate and approved container.
Obey all local standards and regulations for disposal of fluid.
NOTICE
NOTICE
and mandates.
7. When the tank is empty, disconnect the drain hose.
Refilling Hydraulic Reservoir

Refill the hydraulic tank through the quick-fill station. When using the quick-fill station, perform
the procedures below.
1. Level the drill.

! CAUTION
Do not add oil through the breather ports.
4. Make sure the breathers on top of the tank are clean and will allow the tank to
breathe.
Figure 6-47: Hydraulic Reservoir
1 Breathers 4 Quick-fill connection under tank

2 Hydraulic tank main valve 5 Fast fill station
3 Sight glass 6 Hydraulic oil connection
5. Close the main tank valve under the tank.
6. Locate the proper fitting on the quick-fill connection under tank for the hydraulic
oil and then connect the proper hose to the quick-fill station to the tank.
7. On the fast fill station located on cab side non-drill end, remove the quick-fill cap
and clean the fitting for the hydraulic oil fast-fill.
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.
8. Replace all hydraulic filters every time the hydraulic oil is changed.
9. Fill with new hydraulic oil. The tank holds approximately 157 gallons (594 liters)
of AC Hydraulic 180 oil. See Refill Capacities/Lubricants/ Specifications for
details on hydraulic oil.

10. Verify that the low hydraulic oil level alarm turns off on RCS monitor when the
float reaches the safe level at the bottom of the sight glass.
11. Verify the tank has not been over filled. Fluid should be to the FULL mark on
the sight glass.
12. Open the main tank valve under the tank.
13. Check the reservoir oil level by viewing the sight gauge.
14. Remove the quick-fill hose or fast fill hose.
15. Check for leaks at operating temperature.
Pump Drive Gearbox

It is recommended that the pump drive gearbox oil be changed as part of the 1,000 hour
routine maintenance schedule. Because the lubricant system is the heart of the unit, it is
especially important that the oil be kept clean.
! WARNING
Avoid contact with hot oil or components. Oil must be at normal

operating temperature when draining. Do not allow used oil to drain into
the ground. Dispose of properly. Hot oil or components can burn.
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.
Oil Leaks
Inspect the hydraulic pump drive gearbox for leaks as part of the 50 hour maintenance
schedule. Perform 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.

Checking 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.
! 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.
NOTICE
NOTICE
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.
Figure 6-48: Gearbox
1 Breather and fill plug 3 Oil level

2 Oil level dipstick 4 Magnetic drain plug
1. Move the drill to a level surface.
4. Clean around the oil level dipstick and fill plug before checking or adding oil.

5. Check the oil level within the gearbox. The oil should be at the full mark on the
oil dipstick.
6. If necessary, add AC Gearbox 110 gear oil and fill to the correct level. Always
use new oil and a clean container to dispense from. Do not overfill. This will
cause overheating. See Lubricant Specifications for the recommended
required oil specifications.
7. Check and clean the gearbox breather.
Changing Oil
Figure 6-49: Pump Drive Gearbox
1 Breather and fill plug 3 Oil level

2 Oil level dipstick 4 Magnetic drain plug
1. Move the drill to a stable, level surface.
4. Place a 4-quart (3.9-liter) container under the drain point. If drill is equipped with
a central drain system, connect to drain connection.

Figure 6-50: Drain System (Option)
1 Three hole gear box drain connection
5. Clean around the breather and fill plug and the drain plug areas.
6. Remove the drain plug and the breather.
7. Drain the oil while the pump drive is still warm.
8. 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.
9. Clean the magnetic drain plug before installing.
10. Refill the pump drive gearbox through the breather port with AC Gearbox 110
gear oil and fill to the correct level. Always use new oil and dispense oil from a
clean container. The gearbox requires approximately 4 quarts (3.9 liters) of oil.
Do not overfill. This will cause overheating. See Lubricant Specifications for the
required oil.
11. Clean the breather and install securely.
13. After startup, check the pump drive for any leaks at operating temperatures.

Rotary Head
! WARNING
Do not ride rotary head. Riding the rotary head can cause severe injury or
death.
Do not climb on the raised tower. Climbing a raised tower can cause
severe injury or death.
Make sure all locking pins are in the locked position. A falling tower can
cause severe injury or death.
Do not service the rotary head with the drill string in motion. Rotating
shafts or drill string can cause severe injury or death.
Checking Rotary Head Oil Level

Check the rotary head oil level daily. Perform this maintenance with the drill in the following
condition.
1. Level the drill.
2. With the tower vertical, bring the rotary head to the bottom of the tower.
3. Inspect the case for leaks.
4. Inspect the fluid level sight glass for damage.
5. Check the rotary head oil level. Oil must be showing in the middle of the sight
glass.
1 Rotary head oil fill plug

2 Rotary head oil sight glass
3 Lube pump
4 Rotary head oil lube filter

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 the area around the fill plug.
3. Remove the fill plug.
4. Add AC Gearbox 110 oil through the fill port unless the oil level is visible at the
middle of the sight glass.
5. Clean and install the fill plug.
Changing Rotary Head Oil
1 Rotary head oil fill plug

2 Rotary head oil sight glass
3 Suction pump lube filter
4 Lube pump
5 Oil drain
To change the lubricant in the rotary head, perform 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.
5. Make sure oil is warm before draining oil.
6. Place a 9-gallon (34-liter) container under the rotary head drain point.
7. Clean around the fill port area to prevent debris from entering during oil change.
NOTE: Make sure no contamination enters the fill ports.
8. Remove the drain plug and install a drain hose to the drain port.

NOTICE
NOTICE
Make sure fluids are contained during any inspection or maintenance on
this component. Handle and dispose of fluids according to local
regulations and mandates. Do not allow used oil to drain into the ground.
Dispose of properly. Obey all local standards and regulations for
disposal of used oil.
9. Remove the fill plug to allow air into tank during draining. Allow the oil to drain
into a container.
10. After the case is drained, close the drain valve, remove drain hose and install
drain cap.
11. After the case is drained, clean the drain plug and install. Torque to 60 ft/lb
(81 Nm).

2 Sight glass
3 Suction pump lube filter
4 Lube suction pump
5 Case drain
12. Remove the hose from the rotary head lube pump suction filter and plug.
13. Unscrew the suction filter from the bottom of the rotary head case.
14. Install the new suction filter and tighten.
15. Remove the plug from the hose and re-attach the hose to the rotary head lube
pump suction filter and tighten.
16. Using a strap wrench, remove the rotary head oil filter.
17. Install the new rotary head oil filter.
18. Refill the rotary head gearbox through the fill port with AC Gearbox 110 oil
unless the fluid is near the top of the fluid level sight glass. The rotary head
gearbox will hold approximately 9 gallons (34 liters) of gear oil.

19. Clean the plug, install the fill plug and tighten.
20. Remove the lockout/tagout in accordance with site specific procedures.
21. After startup, check the rotary head for any leaks while at operating
temperatures.
Rotary Head Oil Filter

The rotary head oil filter maintenance check must be carried out as part of the 500 hour routine
maintenance.
Check the rotary head filter. Make sure the filter is installed correctly.
Figure 6-54: Rotary Head Oil Filter
Gearbox Drive Shaft

The following grease procedures must be carried out as part of the 8 to 10 hour or daily routine
Greasing Gearbox Drive Shaft Universal Joints
! WARNING
Rotating shaft can cause severe injury or death. Do not operate with
guard removed.
1. Before greasing the gearbox driveshaft make sure the electric motor is shut off.
Remove the key, lockout/tagout the start switch.
2. Leave the guard in place.
3. Open the gearbox driveshaft cover doors to grease the fittings. Apply five shots
of AC Grease 130 to each grease fitting. If grease will not go into the fitting,

remove and replace the grease fitting. Wipe away excessive grease after
greasing all fittings and dispose of grease properly.
Figure 6-55: Grease Points
NOTE: If necessary line up access to the grease nipples by making sure

that all personnel are clear and momentarily press the starter button with
the key ON/OFF switch in the OFF position.
4. Remove the lockout/tagout from the start switch when conditions are safe to
start.
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 obeyed.
Check the complete undercarriage for over all conditions, fasteners, track shoes, seals, front
idler, tensioning system, carrier rollers, track links, bushing, and sprocket.
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/lb (569 Nm).

Figure 6-56: Drive Mounting Bolts
2. Repeat same procedure for the other track drive.
Checking 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
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.
Checking Oil Level

The following track final drive gearbox maintenance must be performed as part of the 50 hour
routine maintenance schedule. Perform the procedure below to check the fluid level and to add
fluid if level is low.
! WARNING
Avoid contact with hot oil or components. Do not allow used oil to drain
into the ground. Dispose of properly. Hot oil or components can burn. Oil
must be at normal operating temperature when draining.
NOTICE
NOTICE
Make sure fluids are contained during any inspection or when work is
performed on this component. Handle and dispose of fluids according to
local regulations and mandates.

1. Move the drill to a level surface and position the track final drive, with one port
at the 3 o’clock position and 12 o’clock position. Shut off the electric motor.
Figure 6-57: Track Final Drive
1 Fill port shown at 12 O’clock position

2 Check and full port shown at 3 O’clock position
2. Make 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 full/level plug and remove it.
4. The final drive lubricant should be lat the bottom of the check/full port. 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 to the final drive
components.
a. Add lubricant into the fill port unless the lubricant is up to the bottom of the
check/full port. Refer to Atlas Copco Fluids.
b. Clean the ports and plugs threads, then replace the plugs.
c. Repeat this procedure for the other track drive.
d. After all scheduled service is complete, remove lockout/tagout, start the

electric motor and move the tracks to check for leaks. Listen for any
unusual noises that might need attention.

Changing Initial Track Planetary Oil

The gear oil should be changed at every 1,500 hours of operation. This maintenance is
recommended as part of a lubrication and preventive maintenance schedule in order to help
provide maximum planetary gearbox life.
! WARNING
1. With the drill on a level surface, clock the track final drive with the full/level port
at the bottom or 6 o’clock position. Shut off the electric motor.
3. Make sure the oil is warm before draining but make sure that the planetary
housings are not too hot to touch. If they are hot, give them time to cool down
before proceeding.
4. Place a 3-gallon (11.4-liter) container under the track drive drain point.
5. Clean the area around the full/level plug and full plug.
6. Removed the fill and level plugs. Drain the oil from the final drive into the
container. Do not allow the used oil to drain into the ground. Dispose of
properly.
Figure 6-58: Track Fill Ports

2 Full / level port shown at 8 O’clock position

NOTICE
NOTICE
Make sure oils are contained during any inspection or when work is
performed on this component. Handle and dispose of oils according to
7. Clean and install the plugs hand tight.
8. Start the drill electric motor and slowly re-position the track final drive, with one
port at the 3 or 6 o’clock position and the other at 12 o’clock position. Do not
rotate the final drive more than 1/2 turn. Shut off the electric motor.
Figure 6-59: Track Fill Port Positions

2 Check and full port shown at 3 O’clock position
! CAUTION
Do not allow the excess oil to drain into the ground. Dispose of properly.
9. Refill the planetary final drive through the oil fill plug hole with 2.7 gallons (10.2
liters) per drive of oil unless the planetary is full. Allow the surplus oil to drain
out unless the oil level is up to the bottom of the level port.
10. Clean the ports and plugs threads, then install the plugs and tighten.
11. Repeat the same procedure for the other track drive.

12. After scheduled service is complete, check the planetary track drive for leaks
at operating temperatures. Listen for any unusual noises that might need
attention.
Grease Drum
Filling the central lubrication system fixed 55-gallon (208.20-liter) grease drum should be done
as required. The drills have an electric pump system. The type of grease required is AC
Grease 130. The drum automatically supplies grease to the grease injectors located
throughout the drill. Injectors supply grease to the various components on the drill.
Figure 6-60: Electric Pump
1 Electric grease pump 3 Grease level gauge

2 Timer control box 4 Grease drum
Use the gauge on top of the container to verify grease level.
Filling Grease Drum

On RCS drills the grease tank low fault indicator will come on when grease is low. An amber
icon fault indicator will come on at the bottom of the F1, F2, F3, and F4 monitor screens.

Figure 6-61: Grease Tank Low Fault Indicator
1. To fill the grease tank container when low, connect to the grease quick-fill port
located on the cab side non-drill end.
2. With a clean cloth, clean the fill port of dirt and debris.
3. Clean supply grease line of dirt and debris.
4. Attach supply grease line to grease quick-fill port. The normal type of grease
required is AC Grease 130.
5. Pump in grease unless the grease container is full.
Figure 6-62: Grease Quick-Fill Port
6. Monitor the F3 screen when filling grease tank. Watch the grease tank symbol
in the middle of the monitor screen for the percentage amount. Do not go over
90% when filling grease tank.
NOTE: Another monitoring method is viewing the grease tank level

gauge.

! CAUTION
Do not over fill the grease tank. Over filling the grease tank will cause
damage to the grease tank equipment and cause grease to vent onto the
ground.
Figure 6-63: Grease Tank Symbol
7. Remove the grease quick-fill supply line, clean connection port and install cap.
John Bean Water Injection Pump

Refer to the FMC Technologies Operation and Maintenance Manual for information and
instructions on maintaining the water injection pump.
Dynaset Water Injection Pump

Due to a small number of moving parts, in normal operating conditions the HPW-pump does
not require any other service, with the exception of replacing seals or water valves. The need
for these replacements depend on content of abrasives in the pumping fluid as well as
cleanliness of the hydraulic oil.
Continually check whether the fluid dropping from pump leakage detectors is increasing and
replace the seals to prevent intermixing of hydraulic oil and pumping fluid.
To enable easy surveillance, pump should be kept clean.
NOTE: When carrying out any service, disassembling or repair of HPW-

pump, absolute cleanliness must be maintained to make sure reliable and
trouble-free operation of the equipment.

Cab Air Filters

The following cab fresh air filter and A/C return air filter maintenance must be carried out as
part of the 500 hour routine maintenance.
Change the Pressurizer Air Filter

Use this procedure to change the pressurizer air filter.
1. Remove the cover on the pressurizer air filter housing.
2. Remove the air filter from the housing.
3. Dispose of the air filter according to local regulations and mandates.
4. Clean the inside of the cover and the housing with a clean, damp cloth.
5. Install the new air filter. Refer to Figure 6-64.
NOTE: The yellow arrows on the air filter show the three slot locations for
mating with the three ribs on the inside of the housing.
6. Align the air filter slots with the ribs in the housing, push the air filter all the way
into the housing.
NOTE: Installation in any other manner allows dirt to enter the ID of the
filter through the slots that are designed for clearance around the ribs, as
well as around the ribs themselves due to gaps forming.
7. Install the cover on the housing and latch the three clips properly to secure the
cover.

Figure 6-64: Pressurizer Air Filter
1 Cover
2 Housing
3 Air filter
4 Inside housing
5 Slots bottom of filter
Air Return Filter

Use the following procedure to change the air return filter.
1. Remove screws on both ends of the A/C air filter in the cab.
2. Pull the air filter out.
3. Dispose of the air filter according to local regulations and mandates.
4. Install the new air filter.
5. Install screws on both ends of the A/C air filter in the cab.

Figure 6-65: Air Conditioner Filter
1 Cab seat (reference only)

2 Air filter (return air)
3 Air conditioner under cab
Main Winch
Checking Oil Level

The gear oil level should be checked every 500 hours of operation.
! WARNING
winch.
! WARNING
Avoid contact with hot oil or components. Do not allow used oil to drain
into the ground. Dispose of properly. Hot oil or components can burn.
NOTICE
NOTICE
Make sure fluids are contained during any inspection or work is

Figure 6-66: Main Winch
1. Move the drill to a stable, level surface and lower the tower to the horizontal
position.
4. Remove the oil level plug to check the oil level
5. If necessary, add oil through the fill hole to bring the oil level with the bottom of
the fill/level hole.
6. Clean and reinstall the center port plug.

Table 6-15: Temperature and Lubricant

14 to 86 °F (-10 to 30 °C) AC Gearbox 110 oil

Changing Oil
The gear oil should be changed after the first 100 hours of operation, then at every 1,000
operating hours or six months, whichever occurs first. The gear oil level should be checked
every 500 operating hours or three months, whichever occurs first.
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 the winch is correct for the 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.
Figure 6-67: Main Winch
! WARNING
winch.
! 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
properly.

NOTICE
NOTICE
Make sure fluids are contained during any inspection or work is
Figure 6-68: Oil level and Vent Plug
1 Oil level plug 3 Vent plug (above drum centerline)

2 Oil drain opening (6 O’clock position)
Replace the lubricant using the following steps:
1. Remove the winch from the tower.
2. Position the drum drain port at 6 o’clock 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.
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 oil through the fill hole, unless 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.
7. Clean the center port plug and reinstall it.

Table 6-16: Temperature and Lubricant

14 to 86 °F (-10 to 30 °C) AC Gearbox 110 oil
8. Reinstall the winch and verify bolt torque. Use SAE grade 8 bolts.
Table 6-17: Thread Condition and Torque
Thread Condition Torque

Dry Thread 205 to 220 ft/lb (278 to 298 Nm)
Lubed Thread 158 to 170 ft/lb (214 to 231 Nm)
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.
Figure 6-69: Tensioner Motor and Coupling Grease Fitting
Use AC Grease 130 grease on the auto tensioner.
Grease Tank Electric Pump (Option)

The grease tank electric pump maintenance must be carried out as part of the 500 hour routine
maintenance.

Checking Electric Pump Oil Level
Figure 6-70: Electric Pump
1 Oil level dipstick

2 Breather
3 Grease tank level gauge
Pump oil level must be at the FULL mark on the dipstick.

Add oil as needed. Use SAE 10W30 motor oil.
Changing Electric Pump Oil

The grease tank electric pump maintenance must be carried out as part of the 2,000 hour
routine maintenance.
Figure 6-71: Grease Tank Electric Pump (Option)
1 Outlet pin nut

2 Oil level dipstick
NOTE: Use SAE 10W30 motor oil in all units used in an ambient
temperature between 150 to -40 °F (66 to -40 °C). For ambient
temperatures between 50 to -70 °F (10 to -57 °C), use Mobil Arrow HFA low
temperature oil.

3. Make sure electrical power has been removed to the pump.
4. Place an empty 1-quart (0.95-liter) container under the outlet pin nut.
5. Remove the outlet pin nut to drain used oil.
6. Remove the oil level dipstick.
7. Install outlet pin nut and tighten after used oil has drained. Do not allow the
used oil to drain into the ground. Dispose of properly.
8. Fill with new SAE 10W30 motor oil through the dipstick port.
9. Oil level should be at the dot on the dipstick (middle of the crankshaft) using
10W30 motor oil (approximately 15 oz). Do not over fill.
10. Install the oil level dipstick and tighten.
Replace the NDE Tank Hardware

The NDE tank hardware must be replaced after every 6,000 hours of operation. Use the
following procedure to remove and replace the NDE tank hardware.
NOTE: Refer to the parts book for your specific drill to order replacement
hardware for the NDE tank.
1. Remove the existing cotter pins, slotted nuts, bolts, and washers from the NDE
tank.
2. Insert the new bolts and washers.
3. Install the new flat washer and slotted nut onto the bolt.
4. Hand tighten the slotted nut until the slot and cotter pin hole FIRST align.
5. Install the cotter pin.

Figure 6-72: NDE Tank Hardware
1 Bolt
2 Washer
3 Cotter pin
4 Slotted nut
Figure 6-73: DE and Middle Tank Hardware
1 Bolt
2 Washer
3 Cotter pin
4 Slotted nut
Figure 6-74: Middle Tank Hardware
1 Bolt
2 Washer
3 Cotter pin
4 Slotted nut


Section 7 - Troubleshooting

PV-270E RCS4 Instruction Manual Section 7 - Troubleshooting
7.1 General Information
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 toed shoes/boots, gloves, respirator and ear
protection. Do not wear loose fitting clothing that can become caught on rotating components.
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.
Troubleshooting Information
Improper operation and maintenance is the most frequent cause of drill failures and problems.
Problems will be related to defects occurring in the following areas: electrical, operator
observed problems, pneumatic, and mechanical/hydraulic.
! WARNING
When carrying out troubleshooting procedures, it is important to strictly

observe the safety precautions and guidelines in Section 2 of this manual
and the Safety “First” Manual.

Section 7 - Troubleshooting PV-270E RCS4 Instruction Manual
7.2 Compressor With EARS
! WARNING
Read and understand Section 2 - Safety before operating or performing

any maintenance, service or repairs on the drill.
! WARNING
If not experienced with the drill controls and instruments, read and
understand Section 4 - Controls.
! WARNING
Unexpected drill motion or moving parts can cut or crush. Shut down
engine before working on the drill.
Pneumatic System
NOTE: When troubleshooting, refer to the appropriate schematic.
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 3-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.
The oil pump allows the operator to close the intake valve when no air is required.

Low Pressure compressors are those with discharge pressures of 100 to 150 psi (6.9 to 10.3
bar). A compressor is considered high pressure if the discharge pressure is 250 psi (17.2 bar)
or greater. All High Pressure compressors have discharge pressures of 350 psi (24.1 bar).
There are three systems on a rotary screw compressor:
• Lubrication System
• Separation System
• Regulation System
The systems are interrelated and each is critical to the operation of the air end.
Electronic Air Regulation System (EARS)
The following information is general for all Atlas Copco Drilling Solutions drills by using the
Electronic Air Regulation System (EARS). Due to differences in drill models, there will be
differences in electronic air regulation components used.
This information contains instructions for several Electronic Air Regulator systems used on
Atlas Copco Drilling Solutions drills. Therefore, refer to the parts book specific to the drill for
parts to the drill.
Figure 7-1: Electronic Air Regulation Components
1 Vacuum sensor 5 Vent valve (blowdown ball valve with actuator)

2 Inlet butterfly valve with actuator 6 Silencer
3 Pressure sensor 7 Compressor
4 Minimum pressure holding valve 8 Separator tank

Components
The Electronic Air Regulation System consists of 14 general components. Some of the
components are only required on some of the applications.
• Flow sensor
• Proportional Butterfly Valve and Actuator on the compressor inlet
• Pressure Sensor on the receiver tank
• Proportional Vent Valve and Actuator on the receiver tank
• Electronic Controller
• Flow Control Buttons (+ and -)
• Compressor ON/OFF Button
• Diagnostic Light (NCS Electrical Box)
• Hardware Interface Board
— Power Control Relay

— Diagnostics Port
— Fuse
— Sensor Power Conditioning Circuits
— Electrical Noise Suppression Circuits
• Interconnect System
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 pressure sensor.
Figure 7-2: Flow Sensor
1 Flow sensor

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 allowing no air to enter 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 fully open.
Figure 7-3: Proportional Butterfly Valve and Actuator
1 Proportional butterfly valve 2 Actuator
Pressure Sensor
The pressure sensor detects the pressure in the receiver tank and sends this information to
the electronic controller.
Figure 7-4: Pressure Sensor
1 Pressure sensor

Proportional Vent Valve and Actuator

The proportional vent valve and actuator can release air from the receiver tank. The Actuator
is controlled by the electronic controller MC2. The air is vented to atmosphere through an air
silencer. The proportional vent valve manually operated was previously called the blowdown
valve. The Actuator indicator will be horizontal when the valve is closed and vertical when the
valve is full open.
Receiver tank pressure gauge shows the pressure in the tank and should match the reading
on the RCS monitor screen in the cab.
Figure 7-5: Proportional Vent Valve and Actuator
1 Receiver tank pressure gauge 3 Actuator

2 Proportional vent valve 4 Indicator
Electronic Controller
The electronic controller monitors the flow and pressure inputs, operator inputs and motor
data. It controls the actuators so that the 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.

Figure 7-6: MC2 Electronic Controller
Air Regulation ON/OFF Button
NOTE: The Air Regulation ON/OFF button must be On to activate the Air
Flow Increase and Air Flow Decrease buttons.
Drill air control is activated by the Air Regulation ON/OFF button located on the right operator
panel. When it is on, drill air pressure will flow in the amount pre-set in the GUI program.
Air Flow Increase Button

Press the Air Flow Increase button to increase the air flow.
Air Flow Decrease Button

Press the Air Flow Decrease button to decrease the air flow.
Figure 7-7: Air Flow Regulation
1 Air regulation On/Off button

2 Air flow increase button
3 Air flow decrease button

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:
• 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.
• The diagnostic port allows a lap top computer equipped with the correct software to
monitor the system through a USB port.
• The fuse protects the system in the event of a wiring short.
• Sensor power conditioning circuits provide regulated power to the sensors and
operator inputs.
• Electrical noise suppression circuits prevent electrical noise from being generated by
the electric motors in the valve actuators.
Figure 7-8: Hardware Interface Board
1 Diagnostic port 3 Electronic noise 4 Fuse

2 Operator conditioning circuit suppression circuits 5 Power control relay
Interconnect System
The interconnect system includes cable 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.

Operation
Startup
During startup the controller commands the butterfly valve to close to prevent air entry into the
compressor and command the vent valve to open. This allows the motor to start with the least
possible load. After the motor speed reaches 700 rpm, the controller begins to regulate the
compressor.
Shut Down
When the key has been turned off and the motor is stopping, the butterfly valve closes and
bleeds down the pressure in the receiver tank through the vent valve. Normal system air leaks
will usually allow the pressure to drop fast enough during the early stages of the blow down
without the controller opening 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.
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:
• The flow control buttons (direct control).

• The compressor On/Off button (calls for minimum flow or command flow).
• The controller’s maximum pressure regulation system. When the maximum pressure
commanded (set in the EARS program) is reached, the controller overrides the flow
knob command and reduces the flow to lower the pressure in the receiver.
Maximum Pressure Regulation
The controller has two methods to control the maximum pressure in the receiver:
• Override the Air Flow Increase button and lower the commanded flow into the
compressor. When the maximum pressure is reached, the controller enters the
pressure control mode, overrides the Air Flow 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 Air Flow Increase button. If the pressure drops to a level
where commanded flow would be more than commanded by Air Flow Increase
button, the controller exits pressure control mode and returns control to the Air Flow
Increase button.
• Open the vent valve to let the air out of the receiver tank. The controller is
constantly attempting to regulate the receiver tank pressure by using a command
that is 15 psi (1.03 bar) above the Air Flow Increase button 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 Air
Regulation On/Off button (toggle) is in the OFF position.
Emergency Venting
If the maximum system pressure is exceeded, the controller commands the butterfly valve to
close and opens the vent valve. This allows quick system reaction to over pressure spikes.
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. This is
accomplished by monitoring the key switch and the J1939 CAN bus.
Electronic Air/Fan Diagnostics
EAR-EFR Diagnostics
The following 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
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 to the problem in the
minimum number of steps.
The questions are designed to be answered in sequence. Skipping a question will lead to an
incorrect diagnoses.
This procedure is designed to avoid rotating the compressor and engine where possible.

Table 7-1: EARS-EFR Diagnostic Procedure
1. Is the setup system in standard test condition? (See “Standard Test Conditions” on
page 18.)
Yes Is an error code flashing on the screen? (See Note 1)
Yes Refer to “Error Code Meanings and Diagnostic Information” on page 18.
No Go to the next step.
2. Does the error code display flash at controller power up?
Yes Go to step 16.
3. Are other controller outputs functioning? (T7=5V, T30=Battery V, T33=Gnd)
Yes Go to Step 8.
4. Does the controller have supply power at the interface board? (T32=Battery V, T33=Gnd)
Yes There are power wiring problems between the interface board and controller. Correct
the problem and restart.
5. Does the interface board have supply power? (T77=Battery V, T78=Gnd)
Yes Go to the next step.
No There is a problem with the wiring on the interface board. Correct the problem and
restart.
6. Does the interface board have power at the key switch input? (T76=Batter V, T78=Gnd)
No There is a problem with the wiring or operation of the key switch input. Correct and
restart.
7. Does the interface board have power at the clock supply terminal? (T31=Battery V, T78=Gnd)
Yes There is a problem with the interface board. Correct the problem and restart.
No The fuse is blown. (See Note 2) Replace the fuse and restart.
8. Is there any voltage at the diagnostic flash output? (T39<1.5 V, T38=Gnd)
No There is a short to ground in the power wires to flash, or there is a problem in the
connection between the controller and the interface board, or the controller is
damaged. Correct and restart.
9. Does the interface board Output System OK flash when the controller power comes on? (See
Note 2) (T39=Flash voltage above 8 V, T38=Gnd)

Yes There is a problem in the diagnostic flash output wiring between the interface board
and the flash or the flash is damaged. Correct the problem and restart.
10. Does the interface board lamp output go to zero volts five seconds after the key is turned off?
(T39=0 V, after five seconds T38=Gnd)
Yes The problem is a damaged or incorrectly programmed controller. Correct the

problem and restart.
11. Does the key switch input on the interface board go to OFF with the key switch? (T76=0, with
key off T78=Battery V, with key on T78=Gnd)
No There is a problem with the key switch wiring. Correct the problem and restart.
12. Is the pressure sensor input on the interface board indicating the receiver tank pressure is low
enough to allow the controller to shut off? (T51<0.525 V will allow controller to shut off, T8=Gnd)
No There is a problem with the pressure sensor input, or there is pressure in the
receiver tank. Correct and restart. (See Voltage Output for Vacuum Sensor T51
voltage.)
13. Does power sustain output from the controller go to zero volts five seconds after the key is
switched off? (T30=0 V, five seconds after key turned off T38=Gnd)
No There is a problem on the interface that allows power to remain on the controller.
Correct and restart.
14. Does the summed on/off inputs voltage go to zero when the key switch is off? (T5=0 V when
the key switch is turned off, T38=Gnd)
Yes There is a problem in the controller. Correct and restart.
15. Is the voltage at the auxiliary input the same, or very close to the same, as the voltage at the
summed on/off input terminals? (T5=T52, T38=Gnd)
Yes There is a problem with the compressor on/off input on T37 or the interface board is
damaged. The compressor on/off switch is connected between T36 and T37. They
should be isolated from all other voltages and grounds. Correct and restart.
No There is a problem with the auxiliary input on T52 or the interface board is damaged.
(See “Standard Test Conditions” on page 18.) T52 should be the same as T5.
16. Is the butterfly valve commanded closed? (T55=Battery V, T59=Gnd)
Yes Go to step 18.

17. Is the voltage at the auxiliary input the same or very close to the same as the voltage at the
summed on/off inputs terminal? (T5=T52, T38=Gnd)
Yes There is a problem in the actuator drive circuit. This could be a short in the actuator,
a problem in wiring between the controller and interface board, or a damaged
controller. Use the proper schematic to correct the problem.
No There is a problem with the auxiliary input on T52 or the interface board is damaged.
(See “Standard Test Conditions” on page 18.) T52 should be the same as T5.
18. Is the butterfly valve indicator knob horizontal with the long edge of the actuator? (closed
position)
No There is a problem in the actuator. (See “Actuator Diagnostics” on page 7-30)

Correct it and go to the next step.
19. Is the vent valve commanded closed? (T66=Battery V, T62=Gnd)
Yes Go to step 21.
20. Is the pressure sensor input on the interface indicating the receiver tank pressure is low enough
to allow the vent valve to open fully? (T51<0.525 V will allow the vent valve to be command open.
T8=Gnd)
Yes There is a problem in the actuator drive circuit. This could be a short in the actuator,
a problem in wiring between the controller and the interface board, or a damaged
controller. Use the schematic to correct the problem and restart.
No There is a problem with the pressure sensor input or there is pressure in the receiver
tank. Correct and restart. (See Voltage Output for Vacuum Sensor)
21. Is the vent valve indicator knob horizontal with the long edge of the actuator? (open position)
Yes Go to next step.
No There is a problem in the actuator. (See “Actuator Diagnostics” on page 7-30)

Correct and go to next step.
22. Is the vacuum sensor reading approximately correct for the altitude of the machine?
(T48=[Section Voltage Output for Pressure Sensor] voltage for present machine altitude. T8=Gnd)
No There is a problem with the vacuum sensor or vacuum sensor wiring. Use the
vacuum sensor diagnostics table to fix problem. Correct it.
23. Does the vacuum sensor voltage decrease quickly when the compressor is rotated for 10
seconds? (T48<2 V after 10 seconds of rotation, T8=Gnd)
No There is a problem with the vacuum sensor, vacuum sensor wiring, vacuum sensor
plumbing, or butterfly installation. Use the vacuum sensor diagnostics table to fix the
problem. Correct it and go to next step.

24. Is the pressure sensor reading approximately correct for an empty receiver tank?
(0.48 V< T51 < 0.52 V, T8=Gnd)
Yes Go to next step.
No There is a problem with the pressure sensor, pressure sensor wiring, pressure
sensor plumbing or there is pressure in the receiver tank. Use the pressure sensor
diagnostics table to correct the problem. Go to the next step.
25. Is the machine equipped with a transfer case?
No Go to step 27.
26. Is the auxiliary input ON when the transfer case is engaged? (See “Summed On/Off Inputs
Decode Table” on page 27. to decode voltage on T5. T8=Gnd)
No There is a problem with the transfer case switch or wiring. Correct it.
27. Is the machine equipped with a shaft speed sensor?
No Go to step 29.
28. Does the diagnostic light flash #8 error when the hydraulic fan is turning? There is no need to
engage the compressor for this check.
Yes There is a problem with the shaft speed sensor or the transmission is in the wrong
gear. Use the Magnetic Pickup Sensor Diagnostics Table to correct the problem. Go
to the next step.
29. Start the compressor turning at the idle speed that is normal for the machine. Observe the
following for 25 seconds and shut off the compressor.
• Vent valve operation
• Butterfly valve operation
• Receiver tank pressure
• Vent valve silencer air flow
Did the vent valve remain open for 20 seconds and then close?
Yes Go to step 31.
No Something is wrong with the vent valve actuator. Go to the next step.
30. Start the compressor turning at the idle speed that is normal for the machine. Wait 25 seconds.
Is the vent valve command closed? (T61=Battery V, T65=Gnd)
Yes There is a problem with the actuator. (See “Actuator Diagnostics Table” on
page 21.) Correct and restart. Go to step 29.
No There is a problem in the actuator drive circuit. This could be a short in the actuator,
a problem in wiring between the controller and the interface board, or a damaged
controller. Use the appropriate schematic to correct the problem. Restart. Go to step
29.

31. Did the butterfly valve remain closed for 20 seconds and then open a small amount?
Yes Go to step 33.
32. Something went wrong with the butterfly valve actuator. Start the compressor turning at the idle
speed that is normal for the machine. Wait 35 seconds. Is the butterfly valve command open?
(T61=Battery V, T65=Gnd)
Yes There is a problem with the actuator. (See “Actuator Diagnostics Table” on
page 21.) Correct and restart. Got to step 29.
No There is a problem in the actuator drive circuit, a problem in the wiring between the
controller and interface board or a damaged controller. Use the appropriate
schematic to correct the problem. Restart. Got to step 29.
33. Was there a large air flow out of the vent valve silencer before the butterfly valve opened?
Yes The butterfly valve or actuator has a mechanical problem. It is not fully closed when
the actuator is off. This could be a problem in the actuator cam adjustment or some
other form of damage or assembly error. Correct and restart. Go to step 29.
34. Was there air flow out of the vent valve silencer after the vent valve closed?
Yes The vent valve or actuator has a mechanical problem. It is not fully closed when the
actuator is off. This could be a problem in the actuator cam adjustment or some
other form of damage or assembly error. Correct and restart. Go to step 29.
35. Start the compressor turning at the idle speed that is normal for the machine. Observe the
following for 45 seconds and shut off the compressor.
• Vent valve silencer air flow
• Air flow at the bit
Did the pressure in the receiver tank increase and stabilize at the normal standby pressure for the
machine? (110 psi for high pressure machines, 50 psi for low pressure machines)
Yes Go to step 37.
36. Is the total observable air flow more or less than normal?
Yes There is a problem with the vacuum sensor accuracy or the butterfly valve is not
operating smoothly. Correct and restart. Go to step 35.
No There is a problem with the pressure sensor accuracy. The vent valve is not
operating smoothly or the minimum holding valve on the receiver is allowing flow at
a low pressure. Correct and restart. Go to step 35.
37. Start the compressor turning and increase the speed to full operating speed. Turn on the
compressor On/Off switch and observe the following:
• Total air flow out of the bit and vent
Did the total air flow increase?

Yes There is a problem with the flow potentiometer output or the potentiometer is not
turned all the way counterclockwise. Correct and restart. Repeat step 37.
38. Did the pressure increase?
Yes There is a problem with the maximum pressure potentiometer output or the
potentiometer is not turned all the way counterclockwise. Correct and restart. Go to
step 37.
39. The compressor should still be running at full operating speed with the compressor On/Off
switch set to On. Increase the maximum pressure potentiometer to full pressure (all the way
clockwise). Did the pressure increase to above the minimum holding valve pressure?
No There is a problem with the maximum pressure potentiometer output. Correct and
restart. Go to step 37.
40. The compressor should still be running at full operating speed with the compressor On/Off
switch set to On and the maximum pressure potentiometer to full pressure. Increase the flow
potentiometer to full flow (all the way clockwise). Did the flow increase to full?
Yes The fundamentals of the system are fully functional.
No There is a problem with the flow potentiometer output. Correct and restart. Go to
step 37.
Considerations
Having two people (a tester and a helper) is recommended.
The following test can be performed by using a volt/ohm meter on the interface board terminal
strips and observing the system behavior.
These tests are not intended to replace additional troubleshooting 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: The diagnostic lamp flashes 1 to 11 times with a pause at the end
of the cycle. The number of flashes is the error code.
NOTE: The system flashes for two seconds immediately after it is

powered up. This can be checked by turning off the key for six seconds
then back on.

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.
• The engine is not running.
• The key switch is on.
• Drill mode should be active.
• Receiver tank discharged.
• Compressor on/off button to off position.
• Flow or volume button to minimum (fully counterclockwise).
• The throttle valve should be open (if equipped).
NOTE: Codes #5 and #8 through #11 are not used on RCS PV-270 Series
drills.
Error Code Meanings and Diagnostic Information

Table 7-2: Diagnostic Error Codes with Possible Faults
Code Error Description

1 The vacuum sensor input has been below 1.05 VDC (2 psia) and above
0.5 VDC (0 psia) for more than five seconds.
Possible non-rotating compressor causes include
Partial short in vacuum sensor output signal wiring
Low vacuum sensor supply voltage
Damaged vacuum sensor
Damage controller
Additional causes in a rotating compressor
The butterfly valve is not opening and vacuum has remained low.
Interface board terminals for vacuum sensor
46 vacuum sensor supply (20 to 30 VDC)
47 vacuum sensor ground
48 vacuum sensor signal
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 VDC Possible causes include:
Disconnected or damaged vacuum sensor wiring
Shorted vacuum sensor wiring
Low vacuum sensor wiring
Damaged vacuum sensor
Damaged controller
Interface board terminals for vacuum sensor
46 Vacuum sensor supply (20 to 30 VDC)
47 Vacuum sensor ground
48 Vacuum sensor signal
3 The pressure sensor input has been below 0.25 VDC or greater than 4.75 VDC
Possible causes include:
Disconnected or damaged pressure sensor wiring
Shorted pressure sensor wiring
Low pressure sensor supply voltage
Damaged pressure sensor
Damaged controller
Interface board terminals for pressure sensor
49 Pressure sensor supply (20 to 30 VDC)
50 Pressure sensor ground
51 Pressure sensor signal (0.48 to 0.51 VDC)
4 The flow command missing
Possible causes include:
RCS boot-up not complete
J1939 CAN communication error
Damaged controller


5 Not Applicable
6 The controller is not receiving the data from the engine. (J1939) Possible
causes include:
Wiring problem in J1939 circuit
Missing or damaged terminating resistor
Damaged engine ECM
Damaged controller
Interface board terminals for J1939 Data from machine
34 data low (2 to 3 VDC)
35 data high (2 to 3 VDC)
7 The regulated 5 volt supply the controller provides to the interface board is
below 4.8 VDC or above 5.2 VDC.
(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 VDC)
8 ground from controller (ground)
8 Not Applicable
9 Not Applicable
10 Not Applicable
11 Not Applicable

Blown Fuse Checklist

1. Turn off the KEY input and verify the power to the controller is off.
Terminal 32 = Zero V
Terminal 78 = Ground
2. Use a multimeter 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.
NOTE: Terminals 8, 17, 33, N, 38, 47, 50, 53, 58, 64, 73, and 75 are also
ground and will always read 0 ohms.
Actuator Diagnostics Table

The actuator is composed of the following components:
• 24 VDC 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 six wires:
• Clockwise supply
• Counterclockwise ground
• Clockwise ground
• Counterclockwise supply
• Heater ground
• Heater supply
Using an Actuator Test Box
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 clockwise and counterclockwise switch to command the actuator and
observe the actuator response.
5. Set the speed switch to slow.

6. Use the clockwise and counterclockwise switch to command the actuator and
observe the actuator operation at slow speed.
Figure 7-9: Actuator Test Box
1 Connector
2 Fast/slow switch
3 CCW/OFF/CW switch
4 Connector
5 Actuator
Results
• 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.)
• The actuator should stop in the horizontal position after moving clockwise and in the
perpendicular position after moving counterclockwise.
• The actuator should move smoothly with a steady buzzing sound. (There should not
be any spots where the actuator loads up and slows down.)
Possible causes or actuator problems include:
• If the actuator operates backwards of the indications on the tester there are two
possible causes:
— The heater circuit is wired backwards. Diagnose and repair. This does not affect
operation of the system but should be corrected. Use the schematic and
connector pin diagrams to diagnose and correct.
— 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:

— The limit switch or limit switch cam have come loose. Diagnose and repair.
Remove the cover and correct the problem.
— 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.
— 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 counterclockwise the internal cams will need
to be adjusted.
Potentiometer Testing Using a Multimeter

1. Rotate the shaft to a position approximately half way between the mechanical
stops.
2. Measure the resistance between the three wires/terminals unless the pair with
the greatest resistance is found.
NOTE: The resistance should correspond with the resistance marked on the pot.
NOTE: 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/terminals is the wiper.
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 of rotation, the change in resistance could be reversed.
The resistance should change smoothly with no 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.

Voltage Output Tables

Table 7-3: Voltage Output for Vacuum Sensor
IA VDC PSIA VDC PSIA VDC PSIA VDC PSIA VDC

-1.00 0.22 2.50 1.19 6.00 2.16 9.50 3.12 13.00 4.09
-0.75 0.29 2.75 1.26 6.25 2.22 9.75 3.19 13.25 4.16
-0.50 0.36 3.00 1.33 6.50 2.29 10.00 3.26 13.50 4.22
-0.25 0.43 3.25 1.40 6.75 2.36 10.25 3.33 13.75 4.29
0.00 0.50 3.50 1.47 7.00 2.43 10.50 3.40 14.00 4.36
0.25 0.57 3.75 1.53 7.25 2.50 10.75 3.47 14.25 4.43
0.50 0.64 4.00 1.60 7.50 2.57 11.00 3.53 14.50 4.50
0.75 0.71 4.25 1.67 7.75 2.64 11.25 3.60 14.75 4.57
1.00 0.78 4.50 1.74 8.00 2.71 11.50 3.67 15.00 4.64
1.25 0.84 4.75 1.81 8.25 2.78 11.75 3.74 15.25 4.71
1.50 0.91 5.00 1.88 8.50 2.84 12.00 3.81 15.50 4.78
1.75 0.98 5.25 1.95 8.75 2.91 12.25 3.88 15.75 4.84
2.00 1.05 5.50 2.02 9.00 2.98 12.50 3.95 16.00 4.91
2.25 1.12 5.75 2.09 9.25 3.05 12.75 4.02 16.25 4.98

Table 7-4: Voltage Output for Pressure Sensor
PSI VDC PSI VDC PSI VDC PSI VDC PSI VDC
-20 0.39 120 1.14 260 1.89 400 2.63 540 3.38
-10 0.45 130 1.19 270 1.94 410 2.69 550 3.43
0 0.50 140 1.25 280 1.99 420 2.74 560 3.49
10 0.55 150 1.30 290 2.05 430 2.79 570 3.54
20 0.61 160 1.35 300 2.10 440 2.85 580 3.59
30 0.66 170 1.41 310 2.15 450 2.90 590 3.65
40 0.71 180 1.46 320 2.21 460 2.95 600 3.70
50 0.77 190 1.51 330 2.26 470 3.01 610 3.75
60 0.82 200 1.57 340 2.31 480 3.06 620 3.81
70 0.87 210 1.62 350 2.37 490 3.11 630 3.86
80 0.93 220 1.67 360 2.42 500 3.17 640 3.91
90 0.98 230 1.73 370 2.47 510 3.22 650 3.97
100 1.03 240 1.78 380 2.53 520 3.27 660 4.02
110 1.09 250 1.83 390 2.58 530 3.33 670 4.07

Table 7-5: Atmospheric Pressure and Vacuum Sensor Output
Elevation PSIA VDC Elevation PSIA VDC

0 14.70 4.56 9000 11.03 3.54
500 14.50 4.50 9500 10.82 3.49
1000 14.29 4.44 10000 10.62 3.43
1500 14.09 4.39 10500 10.41 3.37
2000 13.88 4.33 11000 10.21 3.32
2500 13.68 4.27 11500 10.00 3.26
3000 13.78 4.22 12000 9.80 3.20
3500 13.27 4.16 12500 9.60 3.15
4000 13.07 4.10 13000 9.39 3.09
4500 12.86 4.05 13500 9.19 3.03
5000 12.66 3.99 14000 8.98 2.98
5500 12.45 3.94 14500 8.78 2.92
6000 12.25 3.88 15000 8.58 2.87
6500 12.05 3.82 15500 8.37 2.81
7000 11.84 3.77 16000 8.17 2.75
7500 11.64 3.71 16500 7.96 2.70
8000 11.43 3.65 17000 7.76 2.64
8500 11.23 3.60 17500 7.55 2.58

Table 7-6: Temperature Sensor Voltage Output
Deg F VDC Deg F VDC Deg F VDC Deg F VDC

-40.00 0.50 50.00 1.55 140.00 2.61 230.00 3.66
-30.00 0.62 60.00 1.67 150.00 2.72 240.00 3.77
-20.00 0.73 70.00 1.79 160.00 2.84 250.00 3.89
-10.00 0.85 80.00 1.90 170.00 2.96 260.00 4.01
0.00 0.97 90.00 2.02 180.00 3.07 270.00 4.13
10.00 1.08 100.00 2.14 190.00 3.19 280.00 4.24
20.00 1.20 110.00 2.25 200.00 3.31 290.00 4.36
30.00 1.32 120.00 2.37 210.00 3.42 300.00 4.48
40.00 1.44 130.00 2.49 220.00 3.54 302.00 4.50
Summed On/Off Inputs Decode Table

The interface board adds the three on/off inputs together 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.

Table 7-7: Summed On/Off Inputs Decode
Voltage Range on Compressor

Key Switch Auxiliary On/Off
Terminal 5 On/Off Switch
0.000–0.557 OFF OFF OFF
0.558–1.323 ON OFF OFF
1.324–1.391 OFF OFF OFF
1.392–1.917 OFF OFF ON
1.918–1.964 OFF OFF OFF
1.965–2.321 ON OFF ON
2.322–2.351 OFF OFF OFF
2.352–2.623 OFF ON OFF
2.624–2.652 OFF OFF OFF
2.653–2.891 ON ON OFF
2.892–2.914 OFF OFF OFF
2.915–3.068 OFF ON ON
3.069–3.086 OFF OFF OFF
3.087–3.293 ON ON ON
BATTERY OFF OFF OFF
Figure 7-10: Male and Female Connectors

Male Connector
Female Connector

Figure 7-11: Male and Female Sensor Connectors

Male Connector
Female Connector
Figure 7-12: Female Control Connector

7.3 Hydraulic System
The PV-270 series is a hydraulically-driven production blasthole drill. Power to drive the
hydraulic system is supplied by a electric motor which drives a gearbox which in turn drives
three hydraulic pumps. These three pumps convert the 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 relatively simple and flexible drilling
system.
The hydraulic system consists of a 150-gallon (568-liter) hydraulic reservoir, hydraulic pumps
mounted on a pump drive gearbox and various hydraulic motors, valves, cylinders, pipes,
hoses, and filters. A hydraulic oil cooler assures cool oil temperatures to maximize system
efficiency and component life.
The three hydraulic pumps are mounted for convenient service access on a single pump drive
gear box driven off the electric motor through a drive shaft and coupling configuration.
The two main pumps supply hydraulic power to either drilling functions (drill feed and rotation)
or tram (propel) functions. The triple drive pump supplies oil for the auxiliary circuits. The
auxiliary circuits are the fan circuit, 7-spool, and 10- or 11-spool valve.
Figure 7-13: Hydraulic Pumps
1 Main pump 3 3-hole gearbox

2 Main pump 4 Triple pump

7.4 Propel System
Propel Circuit
The PV-270 Series is mounted on two crawler-type tracks, each track powered by a variable
displacement hydraulic motor, operating through a mechanical gearbox set to a final drive
which turns the drive sprocket. The hydraulic motors are piston type and bent axis design,
each driven by a pump located on a 3-hole single drive gearbox in a closed loop circuit.
The primary components of the propel circuit are the hydraulic pumps, propel motors, filters,
valves, and controls.
Main Pumps
NOTE: When troubleshooting the propel circuit, refer to the appropriate

schematics.
The main pumps are closed-loop, hydrostatic-transmission package pumps. 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 comes directly back from the system without first passing through the
system reservoir. Oil is used over and over again continuously. Hydrostatic transmission
means 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 the pump
unit contains not only the main pumping element but also the controls, valves and charge
pump needed for proper interface with the hydraulic system. The displacement of these pumps
can also be changed.

Figure 7-14: Main Pumps
The two main work ports are port A and port B. Either port can discharge oil depending on the
position of the pump displacement controls. Whichever port is not discharging oil is receiving
oil. For example, when oil is leaving A port practically the same amount of oil is being returned
to port B.
Two ports which are connected to ports A and B are AG and BG, respectively. These ports
provide a place to attach a pressure gauge.
A charge pump housed within the main pump package is driven off the main pump shaft. 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 port G. An external filter may be connected between
ports G and H to clean the oil before it is used in the system.
Oil present at pump port G is used for operating the main pump servo controls. A servo relief
valve limits maximum servo oil pressure. Any oil not used by the control system dumps over
the servo relief into the loop replenishment circuit. Replenishment, or makeup, oil is available
at port K. Port KG provides a suitable location for attachment of a gauge.
Replenishment oil can flow over the 200 psi charge relief valve to the pump case. As long as
pressure on the low pressure side of the loop does not exceed 200 psi (13.8 bar), the relief
valve will not open. Any excess oil which does dump over the relief mixes with leakage oil
already in the pump case and leaves the package pump through port D1 or D2.
Controls used with the main pump are proportional. Operator input is supplied electrically to
the pump stroker through a proportional electric controller. The electric input is converted to a
hydraulic input. Here it is amplified and the resulting output drives the pump swashplate
positioning system.
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 port A or port B to
5,000 psi (345 bar). If port VA is remotely relieved to a lower pressure, pump A port pressure
will be limited to the remote pressure instead of the higher internal setting. The same principle
governs the operation of port VB.

Propel Motors

schematics.
The propel motors are closed-loop, hydrostatic-transmission motors. Oil is supplied to the
basic motor through either port A or port B as shown below.
Supplying oil to port A will cause the motor to turn in one direction. After the oil is used to turn
the motor it leaves through port B. Oil supplied to port B will cause the motor to rotate in the
opposite direction and will leave through port A.
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.
Figure 7-15: Non-Cab Side Tram Motor
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.
Motor Brake

schematics.
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.

Figure 7-16: Non-Cab Side Motor Brake
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 makes sure 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 [34.5 bar]) 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

schematics.
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 seven test
ports that can be used for troubleshooting.
Figure 7-17: Diverter Valves
Non-cab side diverter valve Cab side diverter valve

The diverter valves 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 simplify the loop flushing circuit. These components acting together remove a small
portion of the total oil available in the transmission loop. Oil leaves the loop and carries with it
some of the heat and contamination which may be present in the system.
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 (10.3 bar). If the pressure in the low side of the loop drops below 150 psi
(10.3 bar), 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.
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.
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 port X 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.
Drill/Propel Control Valve

schematics.
The drill/propel control valve is a manifold and valve assembly that contains all the
components required to:
• Control diverter valve shifting from the Drill mode to Propel mode and vice versa
• Control propel brake operation
• Limit torque of the drill rotation circuit
• Limit drill feed force
The valve assembly consists of a steel manifold with four cartridge valves and an electrically-
operated, two-position, 4-way valve. The drill operator selects the mode of operation by
pressing the RCS mode selector button on the operator seat, left control panel. The drill/propel
valve is located below and between the diverter manifolds.
Figure 7-18: Drill/Propel Control Valve
Hydraulic pilot pressure is provided by the auxiliary circuit manifold to port P of the drill/ propel
control valve. When propel mode is selected, the coil on the DR/PR 4-way, solenoid-operated
valve is energized. Hydraulic oil travels from port P of the DR/PR control valve into #2 port of
pilot-operated, pressure reducing/relief valve out #1 port. Oil crossing this cartridge is reduced
to 500 psi (34.5 bar). Oil flows to the DR/PR solenoid 4-way valve, out through port B of DR/
PR control valve to port Y2 of DR/PR control valve and #3 port of the 3-way, solenoid-operated
directional valve. At the same time, the N.O. pilot-operated 2-way valves are piloted to the
closed position. When the trigger switch is depressed on the single propel joystick, the 3-way
solenoid valve shifts, allowing oil to flow from #3 port out #1 port through port BR1 of DR/PR

control valve to allow the 500 psi (34.5 bar) oil pressure to release the brakes at the tracks.
Before the tracks will move, the brake pressure transducer must read 400 psi, sending a signal
to the central computer to allow movement when the joystick is moved.
Within ports CP1 and CP2 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.
Hot Oil Shuttle

schematics.
There is one hot oil shuttle valve associated with each of the two main pumps. Ports 1 and 2
are connected through hoses to ports AG and BG of the main pump. Port T is connected to
the machines DRAIN manifold.
The hot oil shuttle valve is used in the loop flushing and replenishment circuit. Its primary
purposes are to flush and cool the closed loop. By working in conjunction with the 200 psi
replenishing relief found within the main pump, sufficient oil is stripped out of the loop to
accomplish adequate cooling and replenishing from the charge pump. Oil takes the path of
least resistance. The 50 psi pressure delta between the 200 psi replenishing relief in the pump,
and the shuttle relief, provides the and force needed to open the hot oil shuttle relief valve. The
shuttle piping is sized to allow adequate flow for cooling and flushing oil to escape from the
low pressure side of the closed loop. This is 6 to 7 gpm.
The charge pump, within the main pump is used to replenish the oil that is stripped out by the
shuttle relief and any leakage. This makes sure that the loop is continually flushed with cool,
clean oil, taking out hot oil and contamination within the loop. Ports 1 and 2 are connected to
the main pumps A and B ports, so that no matter which port is pressurized, the shuttle is
connected, and loop flushing is accomplished.
Loop Filling/Replenishment

schematics.
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, and 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 pump is collected in the pump case and returned to the main hydraulic
reservoir by way of the pump port D. Leakage oil, combined with hot oil shuttle flow also
returns to the system reservoir through the case drain manifold included in another circuit.

Loop Flushing Circuit

schematics.
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 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 when 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 can’t cause the main loop to run out of oil. The relief valve is set at
150 psi.
There is a one-loop flushing circuit for each main pump. The circuits work with their respective
pump whatever the mode of operation.
Circuit Operation

schematics.
There is a transmission system to drive each track. The main pump swash plate controls are
moved by an electrical input through a proportional electric controller. There is a controller for
each of the two main pumps corresponding to the left and right track drive systems.
When 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 counterclockwise 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

schematics.
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 when the propel circuit is energized.
These valves are shifted to connect P to A and B to T when the propel circuit is energized. The
propel circuit uses ports P and A on all four valves. The valves are all shifted by supplying oil
to ports X or Y. 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 control valve directs oil to the diverter valve ports Y and
drains ports X. 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 port X side.

7.5 Drill Feed and Rotation System
Drill Feed Circuit
The drill feed circuit uses the cab side pump and the pulldown cylinders in a closed loop circuit.
This pump is controlled by moving a proportional electric controller located on the operator
console in the operator 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, the cylinder rod moves up or down
correspondingly. The speed of cylinder travel is proportional to the amount of controller lever
movement.
Pumps
The main pumps used for the drill feed and rotation circuit are also used for the propel circuit.
Feed Circuit
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 when the Drill mode
is selected. This is done by supplying oil to port X and venting port Y on the diverter manifold.
Oil for this purpose is supplied by the fan circuit through the Drill/Propel Control Valve
Assembly.
In the Drill mode, the drill/propel control valve directs oil to the diverter manifold port X and
drains port Y. 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 cab side main pump compensator to the
pulldown gauge, the pressure control valve for feed force control, and the two-way valves for
overpressure control.
The feed pressure control valve is controlled from the machine 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 down force, at the desired level. The two-way valves
are capable of interrupting feed down pressure whenever they are actuated by either of the
drilling end jacks on the machine.
Feed Cylinders
The feed cylinders are double-acting, double-piston cylinders. Double acting means that the
cylinder can be powered down or powered up with the hydraulic system oil. The cylinder 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 in this cavity causes the rods to retract. The oil between the two
pistons now returns to the extend port.
Feed System Control Valve (Holding Valve)
The feed system control valve is a complete assembly that controls the flow of oil leaving and
entering the feed cylinders.
The feed control valve assembly contains an overcenter or holding circuit to hold back
pressure at ports CR, and another overcenter circuit to control oil flow from port PB. When oil
flows from port PR to ports CR, the check valve opens and the oil goes around the overcenter
valve. When oil is flowing from ports CR to port PR, the overcenter valve provides a flow
resistance. The overcenter valve resistance is influenced by the spring setting, the CR
pressure and 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.
Figure 7-19: Feed System Control Valve

The overcenter valve opening is influenced by its spring setting, and by the pressures at PR
and PB. The valve is set so that the pressure at PB alone is not sufficient to cause the valve
to open. Pressure applied at port PR will open the valve, however, since this pressure acts on
a larger area within the valve.
The feed system control valve assembly can be completely re-built in a few minutes without
disturbing the hydraulic piping by replacing its valve cartridges. It is not necessary to replace
the complete assembly.
The feed up pressure controls the rate at which the rotary head moves up the tower and is set
at 700 psi (48 bar). The feed down pressure controls the rate at which the rotary head moves
down the tower and is set at 2,000 psi (138 bar).
Overcenter Valve
The overcenter 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 attached to the pump, and a pilot port.
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
overcenter valve unless the pilot pressure is great enough to open the relief.
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 port P to ports T. When the plungers are pressed, however, the valves shift and free
flow is allowed.
There are two 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.
The two-way valves 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 off its tracks, the pipe nipples on the jack
cylinders are moved upward. This action moves the nipple away from the plunger on the 2-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 port A. This reduces all down pressure from the pump unless 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 starting the hole, or if the ground collapses under one of the
drilling end jacks.

Overpressure Control
The connections for the overpressure controls are part of the drill/propel control 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 collapses beneath the jacks
or for some other reason the drill is unsupported.
The ports labeled OP1 and OP2 are common to the feed pump port VA and are connected by
hoses to the overpressure control valves. These valves are mounted, one on each of the
drilling end leveling jacks. If for any reason the drill is unsupported by the leveling jack, the pipe
nipple will drop to gravity and compress the button as shown. This opens the path to the tank,
venting the feed pump compensator port VA.
Figure 7-20: Overpressure Control Valve
1 Leveling jack 2 Overpressure valve (2-way)
The overpressure control system should be tested daily to make sure it function properly. If
the system does not function properly, the drill should be shut down immediately. The drill
must remain shut down and not used unless the overpressure control system is repaired.
NOTICE
NOTICE
The operator is responsible for the safe operation of the drill.
Overpressure System Test

Do not test the overpressure control system with drill pipe or drill bit against the ground. Only
test the system with the rotary head against the lower tower stops.
1. With the tower in vertical position and pins in locked position.

2. Lower both drill-end jacks to the ground and load them enough to close the
overpressure control valves.
4. Slowly increase pulldown pressure to at least 2,500 psi.
5. Slowly lift the cab side drill end leveling jack off the ground. Feed pressure must
vent immediately, verify that the feed pressure drops below 500 psi. If pressure
vents immediately, proceed to step 6.
6. If feed pressure does not vent, reduce system pressure with the feed controls,
level the drill, and immediately contact the supervisor for system repairs.
7. Repeat steps, this time raising the dust collector side drill end jack. If pressure
vents when the jack pad is lifted slightly off the ground, the system is working.
8. If it does not vent pulldown pressure, shut down the drill immediately and report
any problems encountered to the supervisor.
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 3,400 psi on all PV-270 series drills. The main pump is
actuated by a proportional electric controller in the operator 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.
In extend mode, oil flow is supplied from cab side main pump at port B to port PA of cab side
Diverter Valve Assembly. Oil is directed through diverter valve out port DA to port PB of the
feed system control valve and out port CB1 and CB2 to the respected hydraulic cylinder.
In retract mode, oil flow is supplied from the cab side main pump at port A to port GB of the
cab side Diverter Valve Assembly. Oil directed through the diverter valve out port DB to port
PR of the feed system control valve and out ports CR1 and CR2 to the respected hydraulic
cylinder.
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 port D. 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 (10 bar)
and the flushing circuit allows no flow.
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 (6.9 bar). When the feed cylinders extend, 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
Rotation Circuit
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. The maximum torque output of the rotation circuit is 8,700 ft/lb
(11,800 Nm) gross at maximum displacement (0 to 105 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 main pump entering into the rotation motors. The
direction of rotation is controlled by the operator. If the rotation controller is pushed away from
the operator, the rotary head turns in the forward direction. If the rotation controller is pulled
towards the operator, the rotary head turns in reverse direction, or breakout direction.
The basic components of the rotation circuit are the 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 ports X. This shifts the four main diverter valves to the P to B and A to T positions.
Rotation Motors
The rotation motors are closed-loop, variable-displacement, hydrostatic-transmission motors.

Closed loop means that the reservoir is not included in the pump/motor circuit. Hydrostatic
transmission means that the motor is designed for use in a system in which power is
transmitted by the pressure of a fluid.

Figure 7-21: Rotation Motors
The servo receives oil to power its systems from the motor port. It also receives an input from
a mechanical arrangement of springs and pistons. The displacement of the motor can be set
at its maximum level or its minimum level by energizing port X or port Y, 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.
Figure 7-22: Rotation Motor Displacement Adjustment
1 Upper displacement screw assembly 3 Control spools

2 Spring 4 Lower adjustment screw assembly

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
clockwise to reduce displacement, increase rotation speed, or counterclockwise 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 unless 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. When replacing either
or both rotation motors, make sure 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 make sure the new
motor is configured the same way.
Rotation Motor Control Valve Assembly
The rotation motor control valve assembly that bolts to the top of one of the rotation motors.
The assembly contains a shuttle valve and a pressure reducing valve. The shuttle valve
receives oil from both sides of the motor into its two ends. If the pressure available at one end
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 [34.5 bar]).
The pressure reducing valve will open, close or even take oil in reverse to keep port REG
pressure at the value set by the spring adjustment. Any oil that the valve takes back from the
port REG, flows to the valve drain port where it can be passed back to the motor case.
Figure 7-23: Motor Control Valve

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 rotation motor
control valve. There is no charge pump within the motor, therefore the rotation 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 4,500 psi (310 bar). 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 (34.5 bar) and directs
reduced pressure oil to the motor 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 unless another screw adjustment is made.
The motor control valve must be replaced as a complete unit. There are no adjustments
required.
Rotation
The (DC) side main pump (rotation) is controlled by moving a proportional electric controller
located on the operator console in the operator 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).
Motor Displacement Control
Oil must be supplied to the motor ports H 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 port REG is supplied to ports H 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.
When selecting Drill mode, oil drains from the propel alarm and ports Y of the diverter valves.
This action also pressurizes ports X of the diverter valves and shifts them into the drill mode.

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 main pump to the rotation motors when the Drill mode is
selected. This is done by supplying oil to ports X and venting ports Y 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 control valve directs oil to the diverter manifold X ports and
drains ports Y. 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 main pump compensator to the
rotation gauge and, in some applications, a pressure control valve. With the drill off, the control
system defaults to the Drill mode. This is why the spring in the diverter is on the port X 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 which 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 port D. 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. 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 (2.1 bar) 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 (6.9 bar). 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.

7.6 Auxiliary Functions System
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 triple pump supplies two valve assemblies, a 7-spool valve and an 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 and the functions each section of each
valve assembly controls.
Triple Pump
The triple pump is located in the bottom position of the three-hole pump drive gearbox, below
the feed/rotation and propel main pumps. The triple pump is a three-section,
fixed-displacement, vane-type pump. The three pumping elements inside the housing have a
common inlet and three separate outlets with two going to a common manifold.

Figure 7-24: Triple Pump
1 Main pump (rotation and propel) 71.7 gpmt

2 Main pump (feed and propel) 71.7 gpmt
3 Triple pump 42.5/42.5/12.0 gpmt
Section 1 on each pump is designated as P1, section 2 of each pump is designated as P2, and
section 3 of each pump is designated as P3. The suction for the pump is designated as S.
The P1 and P3 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 triple pump suction comes through the suction manifold of the hydraulic reservoir and
enters the pump through a 2-inch 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 three sections of the
triple pump pick up oil from a suction pipe.
P1 and P3 Pump Circuit
The P1 and P3 section of the triple pump drives the cooler package fan motor. These sections
also supply pilot oil for use in propel functions, feed and rotation circuits, and the cable tension
circuit functions.
After P1 and P3 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 triple 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.

Cylinders
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 valve section is a dual overcenter valve circuit which effectively locks the cylinder. The
valves are preset at the factory to open at 4,000 psi (276 bar) relief pressure.
Motors
Both motors are fixed displacement. This means that speed may only be changed by changing
the motor supply flow.
Relief Valves
Relief valves are used in many locations in the auxiliary function circuit.
The adjustable length spring holds the valve spool in the closed position unless 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. Flow into the seat end of the valve pushes
the ball out of its seat to permit fluid flow. 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 port
P to port T. When the plunger is pressed 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.
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.
Pilot Check Valves
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.
An adjustable length spring holds the valve closed unless 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 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.

7-Spool Valve
Figure 7-25: 7-Spool Valve
1 7-spool valve
2 I/O module D511
3 11-spool valve
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.
Oil enters the inlet section and can exit the section through the parallel passageway or through
the unloader to section port T. 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
(13.8 bar) 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 (13.8 bar) higher than the pressure being called for by the valve
sections.
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 (13.8 bar).
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 to 220 psi (13.8 to 15.2 bar).
The 4-way valve sections of the 7-spool valve are all similar.

The components of the 4-way valve are the pressure compensator, the directional valve,
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
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 or 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 the amount of flow, is proportional to the positioning
pressure.
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 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 port T and returns to the return
manifold.
7-Spool Valve Sections
• Section 1 controls the hoist motor.

• Section 2 controls the tower raising cylinders.
• Section 3 controls the dust curtain cylinders.
• Section 4 controls the leveling jack cylinder on the drill-end cab side of the drill.
• Section 5 controls the rear leveling jack cylinder on the non-drilling end of the drill.
• Section 6 controls the leveling jack cylinder on the drill-end non-cab side of the drill.
• Section 7 controls the dust collector motor and the water injection motor. The return
oil from both motors does not return to valve port T. This allows water injection motor

to be controlled by port C2 and the dust collector motor to be controlled by port C1.
Return oil from both motors is routed back to the return manifold.
11-Spool Valve
The 11-spool valve operates like the 7-spool, but it does not have an inlet unloader or an 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 3,000 psi (207 bar).
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
• Section 1 controls the rod changer cylinders.

• Section 2 controls the breakout wrench swing cylinder.
• Section 3 supplies the breakout wrench clamp cylinder and rotate cylinder.
• Section 4 controls the sliding breakout cylinder.
• Section 5 supplies the rod support swing cylinder and clamp cylinder.
• Section 6 controls the tower pinning cylinders.
• Section 7 controls the tower angle drill cylinders.
• Section 8 controls the rod indexing cylinder (PV-271).
Section 8 controls the rod indexing motor (PV-275).
• Section 9 controls a cable tensioning motor.
• Section 10 controls the other cable tensioning motor.
• Section 11 (high pressure option) 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.
Circuit Operation
The P2 section of the triple pump supplies the flow requirements for the drill systems. Oil flow
from the pump is fed into the 7-spool valve. P2 circuit oil, when not used by the 7-spool valve,
is supplied to the 11-spool valve through the 7-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.

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.
Cooling Circuit/Cable Tensioners
The cooling circuit removes 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 and P3 sections of
the triple pump supply oil flow for the fan circuit and the cable tension cylinders circuit.
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 port P. From
here, the oil can flow to the fan motor.
When the electric motor is off and the main pump stops turning, the oil exiting the fan motors
regenerates through the 3-psi check valve 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 (5.2 bar). 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
This is a fixed displacement motor, which mean the speed may only be changed by changing
the motor supply flow.

Circuit Operation
The P1 and P3 section of the triple pump drives the fan motor for hydraulic and compressor
cooling. The oil provided from the triple pump 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 and is returned to
the drill return manifold.
Manifold System
The manifold systems provide connection points for all hoses that return oil from other
systems. The manifolds contain cartridge valves that regulate supercharge and drain
pressures, route oil through system filters and to the hydraulic tank, and provide connections
for filtered tank filling.
Figure 7-26: Manifold Systems
1 Supercharge suction manifold 2 Return drain manifold
Return Drain Manifold
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 20 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
back-pressure 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. The two sections are
separated by a barrier that contains two cartridge relief valves set at 100 psi (6.9 bar).
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
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 (2 bar) pressure
drop across the filter element.
Hydraulic Reservoir
The hydraulic reservoir is a 150 gallon (567.8 liter) 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 (13.8 bar) 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 (2 bar) 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
(13.8 bar).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 (2 bar) 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.
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 that can be acquired from
Atlas Copco Customer Center. 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 flow. To measure flow, you will need an additional flow transducer that is not
provided in the test kit.
The pressure transducer can be connected to a test port by unscrewing 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
NOTICE
and mandates.
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 four valve
cartridges are fitted. Each manifold has appropriate connection points for attaching two
diverter valves, seven 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 four 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 and
tracks off the ground, engine at idle and tracks turning, adjust the charge pressure setting to
150 psi (10.3 bar) 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 four 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 rebuilt by replacing the 4-valve cartridges and the
4-way 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 3,400 psi (234 bar).

Manifold Assemblies
The two manifold assemblies are the supercharge/suction manifold and the return/drain
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 two cartridge valves and the return/drain manifold
contains two 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-spool. It also contains the unloader valve for setting the maximum working pressure for all
spool valve functions on the 7-spool and the 11-spool valve assemblies. The unloader is
adjusted to 3,000 psi (207 bar) 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 in a new one.
There are seven 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 2,000 psi (138 bar) 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 3,000 psi (207 bar) 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 make 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.
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 in a new one.
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 two 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 3,000 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 (34.8 bar) 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
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 and must also be replaced. Remove the O-ring
with an O-ring pick. Insert the new O-ring into the coil cavity and make 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.

7.7 Clamp and Coupling Information
Dixon Clamps
For information regarding Dixon Clamp installation, refer to the Dixon Valve website.
Victaulic Couplings
For information regarding Victaulic Coupling installation, refer to the Victaulic website.
Figure 7-27: Victaulic Coupling
1 Victaulic rigid coupling

2 Hose restraint cable
3 HNBR air hose

IC Clamp Installation
IC (Campbell) clamps are 360° U-bolt interlocking clamps.
Figure 7-28: IC Clamp Installation
1. Insert fitting fully into hose.

2. Place cast part of clamp on top of hose so interlocking fingers fit into collar of
fitting.
3. Place ribbed steel liner under hose so it aligns with ribs in clamp casting.
4. Install U-bolts around steel liner and through clamp casting.
5. Tighten nuts on U-bolts evenly until steel liner is drawn up into clamp casting
on both sides and interlocking fingers engage collar of fitting.
6. Clamp assembly gives 360° of clamping pressure.
7. Clamps should be checked for tightness during use and re-tightened when
necessary.
Table 7-8: Clamp Size and Torque Value
Clamp Size Nut Torque # of U-bolts

1/2” 15 ft/lb (20.34 Nm) 1
3/4” 25 ft/lb (33.90 Nm) 1
1” 25 ft/lb (33.90 Nm) 2
1-1/4” 25 ft/lb (33.90 Nm) 2
1-1/2” 35 ft/lb (47.45 Nm) 2
2” 55 ft/lb (74.57 Nm) 2
2-1/2” 55 ft/lb (74.57 Nm) 2

Clamp Size Nut Torque # of U-bolts

3” 55 ft/lb (74.57 Nm) 3
4” 100 ft/lb (135.58 Nm) 3
6” 150 ft/lb (203.40 Nm) 3

7.8 Down-Hole-Drill Lubricator
The Down-Hole-Drill (DHD) lubricator (60-gallon system or 7-gallon system) is a sub system
of a rotary drill. The subsystem 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 (0.95 liter/hr) for air compressor capacity less than 600 cfm, 3 pints/
hr (1.4 liters/hr) for air compressor capacity over 600 cfm and up to 900 cfm, and 4 pints/hr
(1.89 liters/hr) for air compressor capacity greater than 900 cfm.
Timer
The timer cyclically delivers 12 volts to the pump coil and the indicator lamp circuits. The
electronic components housed in a NEMA 4 rated housing. The timer uses a 3-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 12 VDC
or 24 VDC 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 not 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 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 12 VDC and 24 VDC. To use the 12 VDC, one must
remove the protected terminal and switch with the 24 VDC terminal screw. The protected
terminal prevents against accidentally hooking up 24 VDC to the 12 VDC input.
Lube Injection Pump
The injector lube pump is a positive displacement, pneumatically driven device. The pump
uses three inputs (air, oil, and electricity) to deliver oil (0.375 in3/stroke) at pressures up to
2,000 psi (138 bar). The pump has two distinct sections: pneumatic and hydraulic.

• The pneumatic section uses the 12 VDC input to energize a coil and shift the
plunger. Once shifted, up to 400 psi (27.6 bar) air is delivered into the piston
chamber.
• The hydraulic section moves the oil from the reservoir through the discharge check
valve/flow switch into the pressurized air line.
General Operation
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.
The timer charges the coil for one second with 12 VDC. 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.
As air pressurizes the piston chamber it moves the piston. This motion of the piston forces oil
back into the inlet unless the piston covers the inlet. After the inlet is blocked, the piston will
force 0.44 in3 of oil out the discharge port, through the 1 psi check valve, and into the flow
switch.
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 keep the discharge line primed.
Flow Switch
The flow switch is a device which monitors the flow of rock drill oil into the discharge line. The
flow switch is connected to a light on the operator 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 poppet’s location.
General Operation
The poppet in the flow switch is normally in the closed position cutting off oil flow from the
pump oil discharge outlet and the 1 psi check valve.
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
flow out of the flow switch 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.

Diagnostics
This section assumes the drill uses the latest lubrication injection system produced. The
system uses the higher output pump, timer unit with 3-poled switch, flow switch, indicator light
and 60- or 7- gallon reservoirs. All diagnostics can be performed with:
• Multimeter
• 2,000 psi pressure gauge
• 400 psi relief valve
• 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

The following chart provides recommended oil types for various temperature ranges.
Table 7-9: Recommended Oil Type for Temperature Range
Less than 20 °F (-6.6 °C) Medium grade rock drill oil, 450 SUS at 100 °F (37.8 °C)
20 to 90 °F (-6.6 to 32 °C) Medium grade rock drill oil, 450 SUS at 100 °F (37.8 °C)
Above 90 °F (32 °C) Heavy grade rock drill oil, 750 SUS at 100 °F (37.8 °C)
Check the oil level in reservoir. Reservoir has a 1-inch stand on the oil outlet port.
Check the oil flow into pump. Shut off the oil flow into pump using the shutoff valve. Remove
the flow switch and check valve. Open the shutoff valve. Oil should flow freely at a rate of one
cup (8 ounce) per 15 minutes when the oil is at 50 °F (10 °C).
If the oil does not flow:
1. Check if the inlet piping is plugged. Back flush the inlet piping if necessary.
2. Check if the correct viscosity oil is being used. Change the oil if necessary.
3. Check if the pump piston is retracted, opening the inlet port

The pump piston not being retracted may be a result of:
• Broken piston return spring. Replace the spring if necessary.

• Grit in air piston chamber, causing piston to stick. Clean and reseal the pump as
necessary.
• Air valve leaking causing air pressure to displace piston. Replace the plunger and
plunger spring if necessary.
• Electronic timer holding system in the ON position. Replace the timer unit as
necessary.
Adequate Electrical Power To Pump Coil
1. Check that the unit is wired properly

2. Check that all connections are secure. Tighten or re-crimp connectors as
required.
3. Check if the timer is properly wired. All blasthole or track mounted rigs use 24
VDC, while some truck mounted rigs use 12 VDC. Verify proper voltage to
timer. Rewire as needed.
12 VDC means 12 volts nominal and actual voltage is between 9 VDC and 15
VDC. Also 24 VDC means 24 volts nominally and actual voltage may be
between 20 VDC and 30 VDC.
4. When the timer cycles one second ON, is 12 VDC present at the coil? Replace
timer if no output signal.
5. Can electrical current flow through the coil?
• Check the coil resistance. With both wires disconnected, coil resistance should
be approximately 12 ohms. If not, replace the coil.
• Check all connections for continuity.
Pressurized Air
Adequate Air Pressure
Tap into the air line and confirm that the lubrication pump line pressure is equal to the console
gauge.
Verify that air does not leak from the pump discharge port when the unit is off or during the off
cycle when the pump is operating. Air blow-by is a sign that the valve plunger has failed and
must be replaced.

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.
Low Back Pressure
Disconnect the discharge hose at the flow switch and pump oil into a measuring cup. The unit
should pump a 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 7-10: Timer Setting - Pump Output
Timer Setting Volume Period Cycles

2 pt (0.95 L)/hr 1 cup 15 minutes 38
3 pt (1.4 L)/hr 1 cup 10 minutes 57
4 pt (1.89 L)/hr 1 cup 7.5 minutes 76
If the volume is low and the number of cycles are correct, the pump has leakage and should
be resealed or replaced. 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:
• Out the discharge port. This is the desired effect.

• Out the intake port. This occurs when the clearance between piston and barrel
increases. Change out the pump.
• Out the breather. This occurs when discharge seals wear. Reseal the pump.
If the volume is low and the number of cycles is low, change out the timer.

Output Detection
The DHD indicator light on the console is a light-emitting diode (LED). 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. Make sure the unit is
wired correctly. Make sure the unit is adjusted properly.
Indicator Light Wiring Circuit
1. Use the schematic to trace all wires. The indicator circuit gets its power from
the 12 VDC out terminal on the timer unit.
2. Check for 12 VDC at the 12 VDC out terminal on the timer unit, during the ON
cycle.
3. Check for voltage at the indicator light. If 12 VDC is present, replace the LED.
4. Check all connections.
5. Check for 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 come on. If it
does, turn the reed adjusting setscrew counterclockwise unless the light stops
flashing.
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, turn the reed adjusting setscrew clockwise unless the light starts
coming on.
3. Connect a 400 psi relief valve to the discharge line. Make sure air pressure to
the 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, turn the
reed adjusting setscrew clockwise unless the light starts coming on.
4. As a check, block the discharge and verify the light does not come on.

DHD Lubricator Diagnostic Summary
Adequate Oil to the Pump
• Correct oil/viscosity
• Reservoir level adequate
• Inlet piping clear
• Pump piston retracted, opening inlet port
Adequate Electrical Power
• Wired properly and connections secure

• Proper voltage to the timer unit at correct terminal
• 12 VDC at 12 VDC out terminal when timer is on
• Coil resistance is 12 ohm
Adequate Air Supply
• Supply air is equal to console gauge

• Air is not leaking from pump air discharge port when timer is off
Output
• Against low back pressure, low output/proper cycles, reseal or replace the pump
• Against low back pressure, low output/low cycles, replace the timer
• Against 400 psi back pressure, low volume/proper cycles, reseal or replace the pump
• Against 400 psi back pressure, low volume/low cycles, replace the timer
Flow Indicator Light Wiring
• Wired properly and connections secure

• 12 VDC at 12 VDC out terminal of timer unit when cycled on
• 12 VDC at indicator light during ON cycle
Flow Switch Adjustment
1. Shut off the oil inlet. Light should not come on. Turn the setscrew
counterclockwise unless light stops flashing.
2. Open the inlet valve. Light should flash with pump cycle. Turn the setscrew
clockwise unless light starts flashing.

7.9 Bean (FMC) Water Injection Pump
For information regarding maintenance and troubleshooting of the Bean Water Injection Pump
refer to the FMC Technologies Operation and Maintenance Manual, A04/I04 Pump
Assemblies.
Figure 7-29: Bean Water Injection Pump

7.10 Centro-Matic Lube
For information regarding the maintenance and troubleshooting of the pump, refer to the
Lincoln Flowmaster™ 24 VDC Rotary Driven Electric Pump, Series A manual.
Operation
The electric grease pump is operated by the time controller. The timer closes the electric circuit
to the relay and energizes the grease pump motor. The grease pump motor operates for the
pre-set time allowed for a complete cycle.
The pump continues to operate until the lubricant pressure in the supply lines is sufficient to
operate the injectors. After the injectors operate, 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 relay, which shuts off 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.
Figure 7-30: Grease Tank Assembly
1 Electric pump motor

2 Pump housing
3 Electrical box assembly
4 Grease level gauge
5 Follower plate

Lube Injector System
! WARNING
Never exceed the maximum working pressure of the Lube Grease

system. Do not carry out any assembly or disassembly works when the
system is pressurized or pump/machine are in operation.
Adjustments are only permitted when supply line/injectors are

depressurized.
Operation of the drill with inactive or defective central lubrication system

will cause damages to the drill.
Excess lubrication or insufficient lubrication may result in drill damages.

Do not use contaminated lubricants.
Supply Lines
After the pump reservoir has been filled, turn the vent plug counter-clockwise one complete
turn and operate the pump until lubricant flows freely from the opening in the vent plug to expel
air pockets trapped between the pump and the supply line connection. Tighten vent plug.
Remove all plugs in the dead ends of the injector manifolds and supply lines. Operate the
pump until lubricant flows from any plug opening. Close the opening with a plug. Continue
operating the pump until the lubricant flows from another plug opening. Repeat this procedure
until all supply lines are primed and plug openings closed.
Feeder Lines
Fill each feed line with lubricant before connecting lines to outlet of injectors and bearing. This
will prevent having to cycle each injector for every inch of feed line between injector and
bearing.
Injectors
Check each individual injector for proper operation. After checking the injectors operation,
adjust them for the volume required for each individual bearing.
SL-1 Injectors (Single and Manifold Type)

For information regarding the maintenance and troubleshooting of the SL-1 injectors, refer to
the Lincoln Installation and Troubleshooting Manual.

7.11 Dust Collector
For information regarding the maintenance and troubleshooting of the dust collector, refer to
the Filter/Clone® Dust Control Systems Service Guide.
Figure 7-31: Dust Collector

Section 8 - Electrical

PV-270E RCS4 Instruction Manual Section 8 - Electrical
8.1 Introduction
! WARNING
If you are not experienced with the drill controls and instruments, read
and understand Section 4 - Operations.
Use the schematics prepared specifically for your drill. All PV-270E Series rotary drills are
custom designed per the specifications of each mine. The basic concepts are the same but
the operating parameters and performance value will vary between drills.
General Information
The following operational hints should be observed:
• Always perform safety checks prior to starting and using the drill.
• After starting the electric motor, wait until the hydraulic oil and the airend oil are up
to normal operating temperatures before operating the drill.
• Never allow uncontrolled movement of the tracks.
• Do not lubricate the drill while the electric motor is running.
• Always operate the drill at full power for normal drilling and propelling conditions.
• If 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 a risk of
overturning and when loading onto a transporter where there is a risk of overturning.
• Never propel or stop the drill on a slope or surface that is liable to collapse.
• Never stop the drill against a high wall that could collapse or cause a crushing risk.
• Always sound the horn before moving the drill in either direction to alert personnel
and allow sufficient time before putting the drill in motion.
• When hoist is not in use, stow hoist hook to the base of the machine.

Section 8 - Electrical PV-270E RCS4 Instruction Manual
General Instructions
Safety Instructions
All personnel involved with operation and maintenance should fully understand and follow the
safety standard and principles for the procedures they are performing.
Operators and maintenance personnel should:
• Avoid contact with energized circuits or rotating parts.

• Avoid bypassing or rendering inoperative any safeguards or protective devices.
• Avoid extended exposures in tight proximity to machinery with high noise levels.
• Use proper care and proper procedures when handling, lifting, installing, operating
and when maintaining the equipment.
• Obey consistently any specific instruction and proper documentation supplied when
they do such work.
NOTICE
NOTICE
Before initiating maintenance procedures, be sure that all power sources
are disconnected from the motor and accessories to avoid electric shock.
Power Supply System

The main power is (4,160 VAC or 6,000 VAC or 6,600 to 7,200 VAC 3-phase, 50 Hz or 60 Hz)
from the source (mine power distribution-Y/delta system) will be coming to medium voltage
electrical Box Disconnect / Cable Coupler. This will give the 6,000 VAC, 3-phase, 50 Hz or 60
Hz input power to the machine.
NOTE: The mine power distribution system must be equipped with a

ground fault pilot line connected to the high voltage coupler.
Disconnection of the coupler must open the upward contactor without
load.
Machines total maximum electrical power requirement is 572 kW which includes 522.2 kW
(700 hp for the main motor for the 1600 cfm compressor) plus 40 kVA for the distribution
transformer.
NOTE: The distribution transformer secondary (Y) neutral is isolated. All

the electrical panels including the ACCB box, starter panel, heaters, cab,
DC box supply are grounded to the machine which is connected to the
mine ground system through the SHD-GC mining cable.
The WEG electrical motor (700 hp/800 hp/900 hp, 6,000 VAC, 4 pole, 50 Hz or 60 Hz) is the
#TEFC enclosure and with IP56 protection. The electrical motor will run at 1,488 rpm (50 Hz)

and 1,785 rpm (60 Hz). It has an Ambient operating temperature range from -40 to +125 °F (-
40 to 52 °C). It can sustain a maximum of 158 °F (70 °C) rise in temperature. The motor is
rated for the 3,300 feet elevation and can be used up to 16,300 feet with 0.71 derating. It
contains total of eight NOS of #PT-100 RTDs (two NOS. per winding for 3-phases and one
each side of bearing) to monitor the motor and bearing temperatures. It has a space heater to
deal with low ambient temperatures.
Transformer and Power Distribution

The 3-phase incoming power from the Cable Coupler goes to the 3-phase, 40 – 80 kVA
distribution transformer and to the 700 hp MV motor starter controller as a parallel connection.
Distribution transformer is a delta-Y connection. Its secondary Y is a 3-phase 4-wire system
where the fourth wire, neutral, is isolated from the ground. The top half of the cabinet is
Nema 4 rated.
The distribution transformer has an additional winding for the 110 VAC (2 – 5 kVA rating) for
standardization purpose. This is in addition to 380/ 220 VAC (40 – 80 kVA) at the secondary
side.
This 40 – 80 kVA power is going to the ACCB Box which will contain 3-phase Main and power
distribution circuit breakers, Control contactors, 3 hp motor starter, 3 NOS of Ground Fault
Relays and 24 VDC, 1,500 watts DC power supplies. The DC power supply is for the
instrumentation and controls, interlocks and lighting needs. The 380 VAC, 3-phase power is
for all the heating loads and for the 3 hp air-conditioning compressor motor.

8.2 WEG Electric Motor
A number of nameplates are located on the motor frame. They contain information on the
motor rating, bearing grease, and motor starts. Each motor is designed for a specific mine so
these nameplates should be used as the final reference.
A key nameplate covers the motor ratings. The information provided covers rated voltage, full
load current, rated horsepower, service factor and etc. This information should be used as a
baseline to evaluate motor operation.
Figure 8-1: WEG Electric Motor

Motor Specifications
• The electric motor is designed to operate in a drilling machine in an open pit mining
environment which includes vibration, shock, a potential 15° degree tilt from the
drilling and propelling operation, temperature range of -40 to 125 °F (-40 to 51.6 °C).
These are the common requirements for the rotary drill industry.
• The electric motor is horizontal bi-directional, medium voltage, AC, continuous duty,
squirrel cage induction motor with double shaft end.
• TEFC enclosure, IP-56 protection, Class F insulation, Model HGF, Frame 6808, and
Mounting F-2.
Table 8-1: TEFC Enclosure
Item Information or Description

Working frequency 50 Hz or 60 Hz
Rated torque 2,471 lb/ft2
Locked rotor torque 120% (1.2 p.u.)
Locked rotor current 407 amp (6.5 p.u.)
Locked rotor time 15 second
Breakdown torque 250%
Moment of Inertia 460 lb/ft2
Max. allowable load inertia 9,000 lb/ft2 for 50 Hz
5,500 lb/ft2 for 60 Hz
Service factor 1.15
Duty cycle S1
Total weight 8,470 lb (3,842 kg)
Rotor weight 2,160 lbs (980 kg)
Output horse power 700 hp, 800 hp, or 900 hp, 4-pole
Rated speed 1,488 rpm at 50 Hz
1,789 rpm at 60 Hz
Service voltage range rated ±10% and frequency = rated ± 5%
Table 8-2: Electric Motor Temperature Range

Ambient temp. range -40 to +125 °F (-40 to +52 °C)


Temperature rise 176 °F (80 °C)
Outdoor application The motor is rated for the 3300 feet elevation and can be
used up to 16,300 feet with 0.71 derating.
Direct On Line (DOL) starting, direct coupling at the ends, noise level 88 dB (A), Vibration
Normal 0.15 in/s. Grounding Lug in the frame and in the terminal box. 115 VAC 180 watts
Space Heater, RTDs #PT-100, 02 per phase and 02 per bearing. Electrically insulated N.D.E.
bearing. D.E. bearing grounded. Bearing Life (L-10) to be increased to 100,000 hours. Winding
/ Brg Alarm Temp = 266 °F / 194 °F (130 °C / 90 °C) and shut down temp = 311 °F / 230 °F
(155 °C / 110 °C).
Increase insulation level to withstand an Isolated Neutral System. Starting time 1.5 seconds
for 50 Hz operation and 2.3 seconds for 60 Hz operation. Motor suitable for three cold starts
or two hot starts on the first hour.
The motor is designed, manufactured and name plated for 16 /starts / day over the life of the
motor. It meets or exceeds NEMA or IEC standards.
Efficiency % 94.8/95.5/95.8 and power factor 0.65/0.75/0.8 at output 50%/75%/100%.
Table 8-3: Altitude/Derated HP Example
Altitude (Ft) Derated HP Altitude (Ft) Derated HP Altitude (Ft) Derated HP

3,000 700 8,000 609 13,000 518
4,000 686 9,000 588 14,000 497
5,000 672 10,000 581 15,000 490
6,000 651 11,000 560 16,000 462
7,000 633 12,000 539 17,000 455
Maintenance and Troubleshooting

Refer to the WEG Installation and Maintenance Manual for maintenance schedules and
procedures. The manual also includes a list of abnormal situations and common failures.

8.3 Electrical Transformer
! WARNING
Personnel safety is very important when performing maintenance and

electrical testing where hazardous voltage may be encountered.
The electric transformer recommended interval for maintenance is 24 months or 8,500 hours
of operation, whichever occurs first.
Figure 8-2: Electric Transformer
Preventative maintenance of the transformer assembly must always be performed by qualified

personnel using proper equipment. Improper servicing can result in failure of the transformer.

Technical Features of Enclosed Transformer Assemblies

• Available dual voltage primary ratings.
• Available dual voltage secondary ratings: three phase of single phase.
• Voltage taps available within ±10% of primary rating.
• Voltage tap selector switch standard when provided with voltage taps.
• Standard primary BIL rating is 75 kV.
• Standard temperature rise is 149 °F (65 °C).
• Primary bushings are 110 kV BIL providing for altitude compensation as well as
tolerance for contamination.
• Upper section of enclosure containing live parts is dust-tight conforming to NEMA 4.
• Lower section of enclosure containing transformer body is ventilated for cooling.
• Full final testing performed to make sure integrity of finished product.
• Standard coolant / insulant is electrical grade mineral oil.
• Designed for minimal maintenance.
• Drop-out style enclosed fuse cutouts provided for transformer element protection.
• All transformer elements are wound with copper conductor using thermo-setting
epoxy kraft insulating paper
• Frequency tolerances ± 5%.
• Voltage tolerances ± 10%.
• Pressure relief device provided for tank ventilation on excess pressure.
• Drain valve provided for sampling and field maintenance.
• Designed for rugged, dependable service on rotary drilling apparatus.
• Fused porcelain cutouts for overload protection of transformer.
• 50 or 60 Hz operation.
• Ambient temperature operation typical -40 to +125 °F (-40 to 52 °C).
• Operation at altitudes up to typical 14,000 feet (4,567 m).
• Operable at up to 15-degree tilt.
Safety Features of Enclosed Transformer Assemblies

• All hazardous voltages are enclosed in the dust-tight upper section of the transformer
assembly.
• A viewing window is provided to allow for inspection of the voltage tap switch position
and fuse cutouts status without needing to open the enclosure.

• An electrical interlock switch is provided on all doors and/or panels that access areas
of the enclosure that contain hazardous voltages.
• The fused cutouts are of the enclosed type providing additional operator safety by
minimizing potential operator contact with hazardous voltages.
• The high voltage bushings of the transformer element are provided with insulating
covers to minimize potential contact with hazardous voltages.
• All primary voltage enclosed/guarded.
• Transformer element utilizes all copper windings.
Preventative Maintenance of Enclosed Transformer Assemblies
! WARNING
Personnel safety is very important when performing maintenance and

electrical testing where hazardous voltage may be encountered.
NOTICE
NOTICE
Preventive maintenance of the transformer assembly must always be
performed by qualified personnel using proper equipment. Improper
servicing can result in failure of the transformer.
Oil Immersed (Atlas Copco Type)

This recommended interval is for assemblies operating within 5% of nameplate kVA, 5% of
nameplate voltage, and 5% of nameplate frequency ratings. Assemblies that are often
operated more than 10% above nameplate kVA or voltage rating, or are often operated at less
than 90% of nameplate frequency rating should be serviced more often. The frequency of
servicing will depend on which nameplate parameters are exceeded and for what duration of
time. Unexpected operating events such as lighting strikes, prolonged operation of the
transformer assembly without adequate cooling, prolonged operation under single-phasing
conditions, or severe secondary faulting may also result in a need for more frequency
servicing. Atlas Copco customer center should be consulted for recommendations in any of
these special cases.
Preventative maintenance of these transformer assemblies should include three areas.
• General inspection and cleaning

• Oil testing
• Electrical testing
The following section outlines each of these areas and what should be done regarding them.

Preventative Maintenance Recommendations
General Inspection and Cleaning
1. Open the top door of the enclosure.

2. Remove the bolted lower front cover.
3. Check the gasket seals on the top section of the enclosure. Replace as
required.
NOTE: Small voids in the gaskets can be filled with Dow Corning #111
silicone sealer or equivalent.
4. Clean any dust from the top section of enclosure.

5. Clean the lower ventilated section of the enclosure.
6. Inspect the fuse cutout assemblies for dust or signs of arcing.
7. Clean the transformer bushings, fuse cutout assemblies, and plastic mounting
plates using Collite #237 insulator cleaner or equivalent and dry towels.
8. Inspect the transformer bushing gaskets and tap changer gaskets for leaks.
Repair as required.
9. Inspect the transformer tank for corrosion or leaks. Repair as required.
10. Open the transformer inspection cover, if so equipped, or the transformer main
lid.
11. Inspect the internal transformer connections at the transformer bushing to
make sure they are tight and that there is no evidence of arcing or corrosion.
12. Inspect the transformer core/coil assembly mounting bolts at the side of the
tank to make sure they are secure.
Oil Testing
1. Draw approximately one pint of transformer oil from tank while it is open into a
clean, dry container. Seal the container immediately after drawing sample.
2. Reinstall the inspection cover or transformer main lid and make sure that the
transformer is properly resealed. To do this, remove the pull-ring pressure relief
valve on the transformer tank and supply not more than 5 psi dry nitrogen or
dry breathing air into the tank. If properly sealed, the tank should retain this
pressure for a minimum of 15 minutes. If the transformer does not retain this
pressure tap the inspection cover or transformer main lid firmly around the
perimeter with a wooden mallet and tighten the clamping ring again. Retest
after tightening.

3. The oil sample should be sent to a laboratory equipped to test electrical

insulating oils. The tests that should be performed and the method used to test
are:
• Dielectric Strength (ASTM D-877)

• Interfacial Tension (ASTM D-971)
• Neutralization Number (ASTM D-924)
• Water Content (ASTM D-1533)
4. Acceptable results for these oil tests are:
• Dielectric Strength: Not less than 21 KV

• Interfacial Tension: Not less than 20 dynes/cm
• Neutralization Number: Not greater than 0.40 mgKoH/g
• Water Content: Not greater than 35 PPM
Electrical Testing
1. Disconnect cabling from high voltage and low voltage bushings.

2. Use a 500- or 1000-volt megger and take readings from the following:
• High voltage to low voltage

• High voltage to ground
• Low voltage to ground
3. Minimum acceptable results are as follows:
• High voltage to low voltage: 500 MΩ

• High voltage to ground: 500 MΩ
• Low voltage to ground: 100 MΩ
4. Using a low voltage ohmmeter, measure resistance between high voltage
bushing electrical connectors:
• Reading should be comparable (within 20% of each other) and less than 20Ω
between any two bushings.
5. Using a low voltage ohmmeter, measure resistance between low voltage
bushing electrical connectors:
• Reading between X1, X2, and X3 bushings should be comparable (within 20% of
each other) and should be less than 1Ω between any two bushings.
• Reading between X1 and X0, X2 and X0, and X3 and X0 should be comparable
(within 20% of each other) and should be less than 1Ω.

• If so equipped, reading should be taken between any other low voltage bushings
and results should be similar to readings listed above.
6. Other electrical testing can be performed depending on the test equipment
available. For specific recommendations of applicable tests, provide
information on the testing equipment to the Atlas Copco company
representative or follow the instructions of the test equipment manufacture. In
all cases, observe maximum test levels established for distribution
transformers.
Testing Information
Oil Testing for Preventative Maintenance

Basic oil screening tests are recommended on an annual basis for all transformers in a
distribution system. An annual testing program can detect problems occurring in a transformer
before the problem threatens continued operation. A significant deterioration of the oil signals
a need for maintenance. Increases in water content can indicate leaks in the transformer
where rain or condensation is entering. Tests such as interfacial tension and acidity can
indicate overheating or normal service-aging of the oil. Dielectric tests can reveal when an
insulating oil is becoming too weak to perform its job within a transformer. An important factor
to consider with oil testing is that on most station type transformers, taking an oil sample can
be done with no disruption of the system. During the sampling process, a physical inspection
can also be performed and notations made of leaks or faulty gauges that should be scheduled
for repair.
If the oil screening tests indicate problems with the transformer oil or the transformer itself,
outage can be scheduled for the repairs to be made. Attached are the basic oil screening tests
that we recommend along with an explanation of each test and what the test result can mean.
Evaluation of Transformer Oil Tests

Evaluation of transformer oil test results requires a working knowledge of the individual tests
and consideration of the specific application of the particular transformer. Some of the
variables include the age of the transformer, the voltages of the transformer, and how
important the transformer is to the distribution system in which it operates. The age of the
transformer is a factor because newer transformers generally have less oil and smaller
electrical clearances than older units of comparable kVA rating. A transformer operating at
34.5 kV will generate more stress on the insulation system than a transformer operating at
2.4 kV. The importance of the transformer to the distribution system is a determining factor in
how seriously marginal test results must be taken. Outlined below are some standard tests on
transformer insulating oil along with some widely accepted criteria for acceptance of continued
in-service use of the oil. This criteria is based on transformers with voltage ratings below 69 kV.
Dielectric Strength (ASTM D-877)

Dielectric strength should not be less than 25 kV for continued use. This is one of the oldest
tests performed on transformer oil. While dielectric strength alone does not reveal much
information about the condition of the oil, it is an excellent indicator of the need for additional

tests. The dielectric break down voltage of an insulating oil is important as a measure of ability
to withstand electrical stress without failure. The test consists of placing a sample of oil from
the transformer in a cup and raising the voltage applied across two flat electrodes at a
controlled rate until the voltage arcs through the oil across the electrodes. If a sample of oil
from a transformer has too low a dielectric strength, it can mean that a flashover could occur
between adjacent windings or between windings and ground if the transformer is subjected to
a high voltage spike resulting from lighting or switching on the distribution system.
Neutralization Number (ASTM D-974) (Acidity Test)

A neutralization number of less than 0.39 mg KOH/g is considered to be satisfactory for
continued in service use. This test measures the acid content of the oil and expresses the
result in milligrams of potassium hydroxide required to neutralize the acid in one gram of
insulating oil. The neutralization number is a measure of the deterioration of insulating oil
because the oil produces acids as it degrades. If left unchecked, these acids will attack the
windings and insulating materials in a transformer.
Interfacial Tension (ASTM D-971)

A minimum IFT number for continued use of an insulating oil is 20 dynes/cm. This is the force
required to pull a platinum ring through the interface of insulating oil floating on top of water.
Good clean insulating oil has a strong surface tension and will not easily mix with water. As
the oil deteriorates through normal aging and contamination with water, it loses some of this
strong surface tension. The IFT test measures this surface tension and provides a means of
detecting soluble contaminants and products of deterioration of the oil. At a point below 20
dynes/cm, insulating oil begins the process of sludging. Once this process has begun,
deposits will build up on the transformer windings and block cooling passages. This results in
higher operating temperatures which increases the rate of deterioration of the oil In other
words, a rapidly accelerating cycle of decay. Any oil with a low IFT is a sign of a problem and
should be further tested to determine if the problem is water or aging or both.
Water Content (ASTM D-1533)

Generally, the water content of an in-service insulating content of the insulating oil is high, it is
virtually certain that there is quite a bit of moisture in the paper insulation in the transformer
windings. The water content test usually correlates to the interfacial tension test since high
water content will lower the surface tension of the oil. High water content lowers the dielectric
strength of the oil, as well. If the water content is too high, it usually means that the insulating
paper in the transformer will be wet and the transformer will have to be dried as well a the oil.

8.4 Electrical Starter Controller
Electrical Starter Controller
Starter Controller
The starter controller is a Direct On Line (DOL) type. It is Culter-Hammer (Eaton Electrical)
make with Nema 4 enclosure suitable for outdoor application. This unit contains an isolation
switch, for the maintenance of the starter unit. It contains MV fuses, vacuum contactor, earth
fault sensing, current metering for each phase, phase voltage sensing through potential
transformers, and control supply of 120 VAC. It contains a GE Multilin 369 motor protection
relay unit with metering option. This option includes monitoring of 3-phase voltage, load, stator
and bearing temperature, current, power factor, frequency, kW, and kWh. It also contains a
space heater for the severe low temperature ambient conditions
Figure 8-3: Starter Housing
Starter Specification
Full voltage, non-reversing, medium voltage motor starter controller (ampgard) used to
operate a continuous duty squirrel cage induction motor.

Ambient temperature –40 to +125 °F (–40 to 51.67 °C). Operable altitude 16,404 feet
(5,000 m) with correct return spring assembly.
Provisions include the following:
• Connection for a 300 watt motor space heater to be energized when the contactor is
in the OPEN position.
• Remote mounted ammeter (from the secondary of the CT).
• Remote mounted elapsed time meter, energized when the contactor is in the
CLOSED position.
• Remote mounted start and stop push buttons through the Aux. contacts.
• Control circuit potential transformers (CPTS) rated to 4,160 – 7,200 / 120 VAC with
VA ratings 1,000 VA and 500 VA.
• Controller cabinet space heater and thermostat.
Other features include:
• Controller serviceability from the front.

• Easy accessibility of all terminal blocks.
• All the wiring and devices be labeled for easy identification.

8.5 Electrical Soft Starter
Refer to the MVC Plus User Manual, Medium Voltage Solid State Starter 2.3 – 7.2kV for
specifications and all information regarding the programming and operation of the electrical
soft starter.

8.6 369 Motor Management Relay
Refer to the 369 Motor Management Relays Instruction Manual for additional information and
procedures.
For the motor protection 369 MPR has trip set points which include the following:
• Short circuit
• Mechanical jam
• Current unbalance
• Ground fault
• Winding temperatures Hi, Hi-Hi
• Bearing temperature Hi
• Under voltage
• Over voltage
• Phase reversal
• Under and over frequency
NOTE: Refer to the 369 Motor Management Relay Instruction manual for
set point specifications.

Glossary
DRILLING SOLUTIONS GL-1

PV-270E RCS4 Instruction Manual Glossary
~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
GL-2 DRILLING SOLUTIONS

Glossary PV-270E RCS4 Instruction Manual
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.

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.

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 drill’s controls. Also called the Operator’s 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.

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

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.

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.

~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.

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.

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.

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.

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 drill’s
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
The 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.

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.

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.

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 and C)
Steel casing using a coupling between each section of pipe. Thread style is right hand,
fine thread.

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

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.

Committed to
sustainable productivity.
Copyright © 2015 Atlas Copco Drilling Solutions, LLC
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

Pv-270e Instruction Manual July 2015 PDF

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Pv-270e Instruction Manual July 2015 PDF

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Atlas Copco Drilling Solutions

Instruction Manual Original Instructions

Read the instruction manual before operating this equipment.

SECTION 1 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION 2 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

SECTION 3 - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

SECTION 4 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Rig Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

SECTION 5 - OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

SECTION 7 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

DRILLING SOLUTIONS July 2015 1-1

Figure 1-1: PV-271E

1-2 July 2015 DRILLING SOLUTIONS

NOTE: This manual is accompanied with an electric motor instruction

DRILLING SOLUTIONS July 2015 1-3

• FMC Technologies Operation and Maintenance Manual, A04/I04 Pump Assemblies

Figure 1-2: Manual Location

1 Safety manual and container

Receiving the Drill

1-4 July 2015 DRILLING SOLUTIONS

Figure 1-3: Drill Identification

1 Standard drill identification plate

Figure 1-4: Electric Motor Identification

1 WEG electric motor

DRILLING SOLUTIONS July 2015 1-5

Drill Information Record

1-6 July 2015 DRILLING SOLUTIONS

DRILLING SOLUTIONS July 2015 1-7

1-8 July 2015 DRILLING SOLUTIONS

Identification of Major Components

Figure 1-5: View of PV-270E Drill

DRILLING SOLUTIONS July 2015 1-9

Personnel life may be in danger if the following is not complied with. DO

• WEG Electric motors:

1-10 July 2015 DRILLING SOLUTIONS

DRILLING SOLUTIONS July 2015 1-11

Figure 1-6: Rotary Head

1 Motor 3 Lube pump

1-12 July 2015 DRILLING SOLUTIONS

Figure 1-7: Feed System

1 Crown tensioner cylinder 2 Base tensioner motor

Drill Rod Handling

DRILLING SOLUTIONS July 2015 1-13

Drill Rod Change

1-14 July 2015 DRILLING SOLUTIONS

Figure 1-8: PV-275 Tower with Four-Rod Carousel

1 Rotary head (not shown) 4 Wrench assembly

DRILLING SOLUTIONS July 2015 1-15

Figure 1-9: PV-271 Tower with Two-Rod Carousel

1 Rod changer and carousel 3 Breakout fork

1-16 July 2015 DRILLING SOLUTIONS

An air inlet cleaner is standard for the air compressor intake.

Figure 1-10: Air Compressors

1 HP1450 Airend 3 XL2600 Airend

DRILLING SOLUTIONS July 2015 1-17

Figure 1-11: Cooling Package

Water Injection System Option

1-18 July 2015 DRILLING SOLUTIONS

Dust Decking Misting System Option