Basic Troubleshooting

Using rig specific electrical and hydraulic schematics the following troubleshooting process can
be applied to multiple models of machines. The model mentioned herein is a PV 271, circa
serial number US004533 . Some information is also applicable to various ADS blasthole
models.

Reference documents:
Electrical Schematic # 2657663031
Hydraulic Schematic # 2657661290
Before continuing verify the following:

ƒ Is hydraulic tank sufficiently filled?

– If no, fill it with approved clean hydraulic oil.

ƒ Are batteries fully charged?

– If not, charge or replace batteries.
– Verify charging system is functional.

ƒ Is engine running correctly at rated rpm?

– If not, have engine performance corrected.

ƒ Are hydraulic filters bypassing?

– If so, change them with approved AC filters.

ƒ Are air filters clean?

– If not, replace with approved clean elements.
– Dump air cleaner dirt pans.

ƒ Verify all fluid levels are adequately filled.

ƒ Make sure Emergency stops are not actuated.

ƒ Verify battery power is available on wires #2 ,6, 7, 80, 82 (in drill mode).

ƒ Note: Ground or earth cable is always #5 (Black insulated cover)

Denison 5A Stroker

2 pin connector #57415002

Manual stroker
shaft. Turning this
shaft against servo
pressure will damage
the pump stroker.
First remove the
servo tube, cap off
ports. Then you can
stroke the pump
manually.
Important: Never
manually stroke the
pump with the
servo tube in place.
 TYPE 5A - CONTROL W/ CENTER DEAD BAND
Operational Tests
1. Stop the pump prime mover and remove the servo tube that connects the cover plate to the
control body (on older units, this is from the Port block H or G port to the control body). This
disconnects the servo pressure to the control. Cap the fittings. If possible, block the outlet
ports of the pump.

Note: Never attempt to operate control manually without first removing

servo pressure. Failure to do so will damage the control.

2. Assure no current is applied to the control. Restart the pump drive.

3. With the pump running, stroke the pump manually to about ½ stroke each direction using a
wrench on the flats of the control shaft to confirm manual control operation. The control
should spring return to center.

4. Adjust the unit to center with the mechanical centering adjustment on the control cover plate.
Pressure on each system port should be within 100 PSI of the other. Manually stroke the
pump each side of center and release. The pump must return to center from each side.

5. Turn the pump drive off and reconnect the servo tube removed in step 1. Restart the pump
drive. Adjust the null screw at the top of the force motor (near connector) until the pump is
at center. Slowly adjust the screw CW until the pump starts to build pressure. Note the
position of the slot on the screw at this time. Slowly adjust the screw CCW until pressure
builds the opposite side of center. Note the position of the screw. Turn the screw back CW to
the position directly between the two positions at which pressure starts to build and lock in
place.

6. Slowly apply + current to the valve. Note the value of current at which pressure starts to build
(e.g. + 40mA). Back off current and slowly apply - current to the valve. Note the value of
current at which pressure builds the opposite side of center (e.g. – 50mA) the sum of the
current magnitudes must be 50 to 120 mA (e.g. 40+50 = 90mA) and each reading must be
within 20mA of the other (e.g. 40 & 50 are within 10MA and therefore acceptable).

7. If the sum of current magnitudes is not within specification, the control must be rejected. If
the value on each side of center is not within specification, re-adjust the control until this
specification is met.

8. If the pump outlets were blocked, open them at this time. Apply + 350mA to the control. The
pump must go to full displacement flow . Remove the current and the pump must return to
zero volume. Apply -350mA and the unit must go to full displacement the opposite direction.
Remove current and the pump must return to zero. The max stops on the control may be
adjusted to the desired maximum volume.
 NULL ADJUSTMENT PROCEDURE FOR
DENISON 5A ELECTRIC INPUT CONTROLS

The purpose of this section of the document is to communicate a standard procedure for
nulling Denison 5A electric input controls. A pump nulling adjustment is usually required if
function drifting symptoms exist or if a pump input control is serviced or replaced. The
adjustment procedure applies to track and truck mounted machines with dual-side-of-center
(closed loop) pumps and truck mounted machines with single-side-of-center (open loop)
pumps.
Figure 1 shows a pump with a 5A electric input control. Parts of the input control that are
referenced in the following procedures are identified in the picture.

Figure 1 – 5A Electric input control with enclosed style mechanical null adjustment.
Nulling of these controls requires adjustment of the mechanical null adjust and the
electric null adjust shown in Figure 2. The adjustments must be done in the proper
order as described in the procedure.
Figure 2 - View of the coil end of the electric input control showing the location of the
screw with which the electric part of the null adjustment is made.

Tools needed: Two styles of electric input controls are used on Denison pumps. One control
has an “acorn nut” style mechanical null adjustment assembly. The other has an enclosed
style mechanical null adjustment assembly like that shown in Figure 1. Two 3/4” open end
wrenches and a small rod to fit through a 1/8” diameter hole are required to adjust the acorn
nut style mechanical adjustment. Adjustment of the enclosed style mechanical adjustment
requires a 3/4” open end wrench, a 3/16” Allen wrench, and a 1/4” Allen wrench. Both of these
controls have an electric null adjustment in addition to the mechanical null adjustment. The
electric part of the adjustment on both controls requires two 7/16” open end wrenches and a
3/32” Allen wrench.

Adjustment of electric input controls also requires the use of two -4 (1/4”) JIC capnuts.
PROCEDURE:
TRACK AND TRUCK MOUNTED MACHINES, CLOSED LOOP:
1. Track mounted machines should be in the propel mode with the machine raised on
jacks until the tracks clear the ground. Closed loop applications on truck mounted
machines are dedicated to the drill rotation circuit so the rotary head spindle will be
observed.
2. With the machine engine turned off, disconnect the electric wires from the 2 pin
connector on the pump input control.
3. Start the machine. If the track (rotation) is creeping, the pump null is out of adjustment.
4. With the machine engine turned off, remove the servo supply tube (see Figure 1) and
cap the 2 open ports with the -4 JIC capnuts.
5 .For acorn nut style adjustments, remove the acorn nut from the mechanical null adjust
screw using a 3/4” wrench, hold the null adjust screw with a rod inserted through the 1/8”
hole in the side of the screw (Figure 3), and then loosen the lock nut.

Figure 3. Acorn nut style null adjustment assembly with the acorn nut removed. Screw
can be turned with a rod inserted through the 1/8” diameter hole. The lock nut must be
loosened before the screw will turn. There are internal stops at each end position.
When resistance is felt do not continue to turn it, or force it. Internal parts will be
damaged.
Figure 4 - Enclosed style null adjustment assembly. The null adjust screw is behind
the plug in the end of the hex barrel. Remove the plug with a 3/16” Allen wrench. Then
hold the internal screw with a 1/4” Allen wrench and loosen the hex barrel with a 3/4”
wrench. The internal null adjust screw can then be turned.

If the adjustment is an enclosed type like the one shown in Figure 4, remove the plug from the
end of the 3/4” hex barrel using a 3/16” Allen wrench, insert a 1/4” Allen wrench into the end of
the barrel to hold the internal screw stem, and then loosen the 3/4” hex barrel.
6. Turn the null adjust screw in one direction until the track (rotation) starts creeping. Note the
position of the null adjust screw.
NOTE: The null adjust screw has a mechanical stop that limits its rotation in both directions.
Do not force the screw past its stops.
7. Turn the null adjust screw in the other direction until the track (rotation) starts creeping in
the other direction. Again note the position of the null adjust screw.
8. Position the null adjust screw halfway between the two positions found in steps 6 and 7 and
then lock the adjustment screw in place by tightening the lock nut (acorn nut style control) or
the 3/4” hex barrel (enclosed style control). The tracks (rotation) should not creep. Pump A
and B side pressures should now be equal (within 100 psi). This can be verified if desired by
measuring the pressures at the pump A and B ports.
9. Replace the acorn nut (acorn nut style control) or the barrel plug (enclosed style control). The
pump is now mechanically nulled.
10. With the machine engine off. Remove the -4 JIC capnuts from the input control and re-install
the servo supply tube. Re-start the engine.

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

Electric Null Adjustment:

11. The electric null adjust screw is an Allen screw located under the capnut shown in Figure 2.
Remove the capnut from the electric null adjust screw using two 7/16” open end wrenches. Hold
the internal Allen screw with a 3/32” Allen wrench and loosen the jam nut.

12. Turn the electric null adjust screw in one direction until the track (rotation) starts creeping. Note
the position of the null adjust screw.

13. Turn the electric null adjust screw in the other direction until the track (rotation) starts creeping in
the other direction. Again note the position of the null adjust screw.

14. Position electric the null adjust screw halfway between the two positions found in steps 12 and
13 and then lock the adjustment screw in place by tightening the jam nut . Pump A and B side
pressures should now be equal (within 100 psi). This can be verified if desired by measuring the
pressures at the pump A and B ports.

15.Replace the capnut and reconnect the electric wires to the 2 pin connector. The pump null
adjustment is now complete.
How to manually stroke the Denison main pump with a 9A stroker:

Remove manual control access plug. Insert 3/16” Allen wrench into female socket within the access port. Use
wrench as lever to stroke the pump. Travel should be 19° both sides of center as shown below.

9A Stroker as mounted on pump.

Mid-Range and PV 270 drills built after June 2009 are been built with Denison
9A pump strokers.
The following pages give a description of the 9A stroker.

Never attempt to loosen or adjust the “Deadband” of the 9A stroker!

Do not loosen or adjust this

dead band joint!
Adjustment Procedure for 9A Controls on a Denison Main Pump

The 9A pump control is preset so that it is spring centered and it produces full displacement control both sides
of center (+/- 19°). Adjustments to the null and maximum volumes may be easily made in the field. The
Deadband adjustment is factory adjusted to give minimum backlash and should not be reset.

Procedure:
Insure that the machine is in a safe operating condition. Install Pressure gauges on each work port (AG and
BG). With the control installed and the pump running the adjustments are as follows:
Place the pump in a deadheaded condition, with both work ports blocked, if possible. If it is not possible to
physically block the ports, then block the load so it cannot move. Do not stroke the pump forward or reverse
Loosen the “Null” adjustment locknut and adjust the Null adjustment slightly, so that equal pressures (+/- 50
PSI) are attained on each of the work ports. (If unable to deadhead the pump, adjust for no motion on the
actuator). Lock the adjustment at this time. Apply 200 mA or more to one coil and release. The pump outlet
should go to compensator pressure then return to the null setting (+/- 100 PSI). Repeat by applying current to
the opposite coil.

Maximum Volume Adjustments:

Place the pump into a running condition (remove port or load blocks) and apply full current of 350 mA to one
coil. The maximum volume adjustment is on the side opposite the energized coil. Loosen the locknut and
adjust this to give the desired maximum flow or maximum actuator speed. Lock the setting with the locknut.
Repeat with the opposite coil energized.
Operational Checks:
Smoothly adjust the coil current from minimum (~ 150 mA) to maximum (~350 mA).
Note that the pump operates smoothly and continuously and that the actuator moves accordingly. Repeat
with current to the opposite side. Removal of current must result in the pump returning to center and the
actuator stopping.
If current is not available for setting the pumps, the control may be manually operated by removing the
Manual Control Access plug and using a 3/16” Allen wrench to stroke the pump. Centering and maximum
volume adjustments may be made by manually stroking the unit as described above, instead of electrically
stroking it.
Mechanical Null Adjustment-Blasthole Drill Method:
• Place drill on level ground and raise it off the tracks.
• By-pass tram interlock switches if applicable.
• Remove electrical connections to both coils.
• Select propel mode and check if either of the tracks are rotating.
• If no, there is no adjustment required.
• If yes, loosen the Null Adjustment Locknut on the appropriate pump and adjust the Null Adjustment
slightly clockwise and note if the track stops rotating, if yes tighten the Locknut.
• If no adjust the Null Adjustment counter clockwise until the track stops rotating. When this is achieved
tighten the locknut.
WARNING:
1. Do not over tighten Null Adjustment Locknut. This will distort the Null mechanism and will result in a
high ΔP (differential pressure) between ports A and B.
2. Remove tram interlock by-pass!
9A Stroker Inner Workings

2 Coils -# 57770240
Resistance - 41Ω
 Pump Controllers

The 5A and 9A pump strokers use different types of electrical controllers.

The 5A stroker has a single coil actuator. Energizing the stroker coil causes the pump
swash plate to change angles. Moving the pump control lever in one direction turns on a
positive current signal, energizing the pump stroker coil. This causes the swashplate to tilt
in one direction. Moving the lever to the opposite side of center reverses the electric
signals polarity. A negative current signal causes the swashplate to tilt the opposite
direction. Thus changing the pump flow from A port to B port, and visa versa.
The 9A stroker is a dual coil actuator. The pump controller has two outputs. One is A and
the other is B. Moving the lever in one direction energizes one coil on the 9A stroker. This
causes the pump swashplate to tilt one direction. Moving the lever the opposite side of
center energizes the opposite coil and causes the swashplate to tilt the opposite direction.
Neither output of a this pump controller is a negative current.
Thus the two controllers used for each type pump stroker are different and have different
part numbers. .
Propel controller adjustment

Main Pump Controller Settings – Propel Control shown.

ƒ (Make sure the jack-up/or propel interlock devices are bypassed for the
following procedure.)
Note: Make sure the key is in the ON position, but engine is NOT running. Put
the rig in Propel mode.
– Remove the “B” wire from CS propel controller and connect an ammeter
between the controller “B” terminal and the open “B” wire. Connect the red lead
to B terminal, and the black lead to the open wire. Set meter to1 amp or less
scale. Move the lever. If no current is measured, verify propel interlocks are
disabled, and electric stroker coil and wiring are correct. Coil resistance s/b 41
ohm.
– 1. Pull the CS controller handle slightly on stroke (till the micro switches just
click). Adjust the threshold pot until the ammeter reads 150 milliamp (mA). If you
do not get a current reading, check the wiring.
– 2. Pull the CS controller handle fully on stroke and set the max-out pot to 350
mA. Return handle to center. Check mA reading in opposite direction. Should be
+/- 5 mA Repeat steps 1 and 2 for the DCS (left track) propel controller.
Feed And Rotation Controller

Main Pump Controller Setting – Feed and Rotation (Drill) Controls

Note: Put the rig in the drill mode, engine off, key-switch ON. If the machine is a HP
machine turn the holdback controller knob to the half way position. The rotary head
should be at the bottom of the tower.
1. Make sure the handle is in the center, off, position. Remove the B wire from the Feed
controller and measure the resistance between the open B wire and the controller A
terminal. Resistance should be 82 ohms, indicating that the controller is attached to the
pump electric stroker coil. If not, check the wiring.
2. Connect an ammeter between the controller B terminal and the open B wire (red lead
to B and black lead to the open wire).
3. Pull the Feed controller handle slightly on stroke (till micro switches just click). Adjust
the threshold pot until the ammeter reads 150 milliamp (mA)
4. Pull the Feed controller handle fully on stroke and set the Hi-Range pot to 350 mA.
5. Leave the controller handle fully stroked and hold down the button on top of the
controller. Set the Lo- Range pot to 198 mA. Return handle to center. Check all setting
in opposite direction, then reconnect the wire to the B terminal.
6. Repeat steps 1 through 5 for the Rotation controller.
Spool Valve Coils/Pulsar

There are two coils on each Spool valve section. To check the coil attached to the controller
“A” terminal, remove the wire from the “A” terminal and read the resistance between the
open wire and ground. The resistance should be about 65 ohms. The “B” side coil
resistance can be checked the same way.

Fema Coil:

The Pulldown FEMA coil resistance can be checked only if the carousel is in the stowed
(open) position. Remove the wires from the controller “A” and “B” terminals. Measure the
resistance between the two open wires. The resistance should be about 24 ohms.
Checking a proportional remote control output:
The remote controllers can be checked for proper output with a voltmeter. To check an RC
with a voltmeter follow the procedure below.
01. Check for 24 VDC input voltage. Read from terminal “+” to ground.
02. Check for good ground. Power off, read resistance from terminal”-” to
ground. Resistance should be zero.
03. Check the coil resistance for the particular circuit as explained in the
section above.
04. With the resistance known and the “A” and “B” wires connected back up,
the voltage from “A” to “-” or from “B” to “-” can be measured. The voltages
should be in the following ranges:
……… Apitech circuits: Variable 0 - 24 VDC w/65 Ohm coil
.......... FEMA circuit: Variable 0 - 12 VDC w/24 Ohm coil
........... Denison Circuits: Variable 0 - 10 VDC w/27 Ohm coil.

Checking a relay:

The easiest way to do a quick check on a relay is to listen to or feel the relay. If the relay is
being actuated by a switch signal, it will click when the connection is made. A more reliable
check requires the use of a voltmeter. Check the coil terminals. One coil terminal should be
grounded and one should receive a voltage signal when appropriate. If the relay is
switching, check the individual contact pairs next. Check the resistance across the contact
pairs (both open and closed) with the wires disconnected or the relay pulled from its socket.

Open contacts read infinite resistance. Closed contacts read zero resistance. Make sure
the contacts are not welded together by switching the relay with 24 volts and repeating the
resistance check.
Checking a limit switch:
The easiest way to check the function of a limit switch is to rotate the arm and listen for the
click of the switch. A more reliable check requires the use of a voltmeter. Open up the
cover and check the resistance across the contact pairs (open and closed) with the wires
disconnected. Also make sure the contact pairs change from open to closed or closed to
open when the arm is switched back and forth.

Checking a diode:
To check a diode, remove it from the circuit. The diode is a uni-directional device (like a
check valve) so be sure to remember exactly which end was connected to which terminal so
that it can be put back in the same orientation. One end of the diode has a line printed
around it. The line is on the end that BLOCKS current flow. Set the voltmeter to read
resistance (ohms). Connect the red lead to the end with the line. Connect the black lead to
the end away from the line. The resistance indicated should be infinite (open circuit). Now
switch the meter leads black on line and red away from the line). Resistance should be
zero (closed circuit), If either test fails, the diode is no good.
Electrical Component Specs.
DC Electrical System- Expected Coil Resistance:
PCV (FEMA) VALVE
ƒ57309536
ƒCoil 24Ω -Not field serviceable.
Denison Main Pump Stroker Coil -
ƒ9A Stroker Complete 57731846
ƒSolenoid coil 57770240 (Replaceable -2 per pump)
ƒCoil resistance 41Ω
ƒ5A Stroker Complete-57480170
ƒCoil resistance- 27Ω
ƒCoil not field serviceable
ƒ1 Per pump
Spool Valve Coil (Pulsar) –
ƒ57394926- Replaceable 2 per valve section.
ƒCoil- 65Ω
Adjustable Potentiometer-(2 per machine)
ƒ57433781
ƒVariable 0-500Ω (used to control feed speed –decel, and/or feed force- “No
Bump” rod changer protection.
DPDT Relay -57394603
ƒCoil - 345Ω Not serviceable, replace relay
ƒUsed on DM45, DML, PV270, DMM3
Latching Relays- There are two common types
ƒ51818080
ƒUsed on PV271, PV 275
ƒ2 x coils
ƒC1- .5K Ω C2- .5KΩ
ƒ57352999 –
ƒUsed on DMM3
ƒOperate coil -resistance- 15.5Ω
ƒReset coil - resistance - 52Ω

See the machine sn specific schematics for circuit diagrams.

Hydraulic Specifications -From Schematic #57661290

Main pump compensator setting- 4500 psi / 310 Bar

Spool valve inlet unloader max relief – 3000 psi / 206 Bar
Hoist Work Port Relief 2000 psi / 138 Bar
Tower Raise work port reliefs Ext 2750 psi /190 Bar Ret. 3000 /206 PSI
Dust Collector Relief 3000 psi / 206 Bar
Water Injection relief 1000 psi / 69 Bar
Tower pinning 3000 psi / 206 Bar
Dust Curtain 3000psi / 206 Bar
DR/ PR Pulldown relief 3400 psi / 234 Bar
DR/PR Pilot pressure reducer 500 psi / 35 Bar
Motor Control Valve- Press Reducer 500 psi / 35 Bar
Cable tensioning pressure reducer 750 psi / 51 Bar
Cable tensioning sequence (in tower) 500 psi / 35 Bar
Cable tensioning counter balance valve (in tower) 1000 psi / 69 Bar
Symptom-Engine Running- Powerhead won’t go up.
ƒIs there oil in the hydraulic tank?
–Yes>. Shift to propel.
–No>- Fill tank .

ƒIn Propel mode does CS track function both directions?

–Yes>- Shift to Drill. .
–No>- Test CS pump manually.

ƒDoes CS pump work manually?

–Yes>- Investigate electrical system. Power at wire #82? Current output from controller? S/B 150-
350 mA.
–No>- Investigate pump- spline/ drive coupling / replace pump. Always replace the spline
coupling when changing a pump.

ƒDoes feed lever controller have 24 VDC at “+” terminal? Wire #82?
–Yes >–Test controller output.
–Remove wires form A and B terminals. Jumper DVM across A to B. Set meter to read mA.
–Controller current output should be 150 -350 mA. Lo Range 175 mA).
-Does controller output work?
- Yes > If current is read when circuit is jumpered across with the meter- circuit
bypassed, this indicates a good controller and an open circuit. i.e. There is broken
wire or open relay contact somewhere in the circuit. If all contacts are closed, and
resistance of the circuit is measured it should be 27Ω ±. If resistance is high,
- Investigate wiring and circuit and relays.

No > No output. change controller.

–No – Investigate wire #82 from DR/PR switch.
ƒIs the DR/PR switch contact “OX” (at wire #82) energized when in drill mode?
–Yes- Investigate wire #82 from switch to controller. Ck Ground.
–No-Investigate CB#3 and wire #80 to Dr/Pr switch.
- Check wiring circuit for continuity. Remove wires wire 79A to wire 61A Resistance sb 27Ω.
–Insure controller is grounded properly. (earth = Wire #5).
Ck relay 13 nc contact. SB open when coil is energized, closed when de-energized
ƒCk no bump circuitry.
ƒCk pump (9A coil resistance- s/b 41Ώ ,
Symptom-Engine Running- Powerhead won’t go up. (cont.)

– No – Investigate wire #82 from DR/PR switch.

ƒ Is wire switch contact and #82 energized at DR/ PR switch when in drill mode?
– Yes- Investigate wire #82 to controller
– No-Investigate CB#3 and wire #80 to Dr/Pr switch.

ƒ Is holdback N C two way valve in tower de-energized (closed) when feeding up?
– Yes- Check for stuck valve.
ƒ Plug R port on Regen or hose at two way valve inlet. Test feed up, if no affect
reconnect.
– No- It remains energized. Check wiring.
ƒ Wire #81 should be de-energized in neutral position and feed up direction.
ƒ If energized check cam/micro switch on controller for proper operation. Switch
must open in Neutral and remain open during feed up.
ƒ If N C valve is stuck open replace valve.

ƒ Are the feed cylinders bypassing internally?

– Yes. Repair or replace
– No- Check Feed Control Valve

NOTE: If feed upward is slow, the exhaust valves within the Feed control valve may be stuck shut.
This prevents the exhausting of excess oil from the base end of the feed cylinder, forcing the
pump to consume it.
Symptom- Powerhead won’t go down
ƒ Is there oil in the hydraulic tank?
– Yes >- Shift to Propel mode
ƒ Does the Propel function work?
– Yes >Troubleshoot hydraulic and electrical system.
– No> Troubleshoot pump.
– No > Fill tank .
ƒ Is the machine fully supported on the jacks? Inspect Over Pressure Control valves on DE jacks. OPC
valve buttons should be up (valves closed), hydraulic pipe must not be touching.
– Yes >- Troubleshoot electrically
– No >- Jack it up properly and retry.
ƒ In Propel does CS track function correctly in both directions?
– Yes>-Shift to Drill mode, troubleshoot electrical hydraulic feed controls.
– No >- Isolate the HOS valve. Plug and cap the “T” port of HOS and hose. Does pulldown return?
ƒ Yes – Replace HOS or investigate spool for sticking.
ƒ No –Reconnect valve and continue troubleshooting.
ƒ Does feed work when stroking CS pump manually?
– Yes>- Continue with Electrical Troubleshooting.
– No>- Replace pump. If splines are worn replace coupling also when changing pump.

Electrical Troubleshooting
ƒ Does wire #82 have 24 VDC at terminal “+” of feed lever controller
ƒ Yes >–Test controller output. (With powerhead low in tower, not in decel range).
– Check wiring circuit for continuity of wire #61 to “-” Earth (Key off, remove wire #61 from
“A” terminal to measure resistance. Should be 41ohm resistance.
– Insure proper earth. (Wire#2 at pump coils must connect to “-” Earth. i.e. to wire #5 in
PP box and operators console.
– Check relay 13 N O contact. (wires 61 to 60) Contact s/b open when coil is de-
energized, closed when coil is energized.
– Ck no bump circuitry.
– Ck pump (9A coil resistance- s/b 41ΩΏ ,
– Controller current Output (150 -350 mA, Lo Range 175 mA).
ƒ No >– Investigate wire #82 from DR/PR switch.
– Is wire #82 energized at DR/ PR in drill mode?
– Yes>-Investigate wire #82 to controller
– No>-Investigate CB#3 and wire #80 to Dr/Pr switch.
Symptom-Engine Running- Powerhead won’t go down
ƒ Still no down feed? Check pulldown force circuit.
– Do you have continuity of wire at terminal marked ”A “ on the rotary feed force controller to
earth? Remove wire from terminal “A” of the rotary pulldown force control.
ƒ Measure resistance from controller end of the wire to Earth. Resistance should be 24-27Ω
ƒ Is resistance OK
– Yes>- Check controller output. (0-500 mA)
– No>- Resistance is high?
– (PV 271) Retract or move the carousel to its fully stowed position.
– Ck no bump switch lever (activated by the carousel). If all is well, troubleshoot pulldown
force circuit and wiring (see rig specific electrical schematic).
ƒ Measure proportional pressure control valve coil resistance directly at the valve coil.
ƒ Resistance should be 24-27Ω. If more, change the valve.
ƒ If OK troubleshoot wires working back to LS7, and then all the way back to rotary pulldown
controller.
ƒ (Short cut: run a temporary unbroken jumper wire from the controllers “A” terminal to the
Fema directly.
Does the system work now?
Yes> find broken wires, loose connection etc in the circuit.

ƒ Is Carousel fully open?

– Yes. Check LS7 on side of tower.
ƒ Does the actuator arm of LS7 contact its actuator ramp on the carousel?
– Yes>-Is LS7 N O contact being held closed?
– No >- Adjust actuator and lever arm. Insure proper functioning of the switch contacts.
– No- Open carousel, verify as recommended above.

– Isolate the DR/PR valve by:

ƒ Removing the VA line at the CS main pump. Cap and plug the port and hose.
ƒ Try feed down.
ƒ Important: While VA port is capped do not allow powerhead to contact lower stops or
the bit to contact the ground!
ƒ Does pulldown return?
– Yes>-Troubleshoot DR/PR feed relief valve. It could be bypassing. Back it out and try to
readjust to proper setting.
– Do not exceed 4500 psi (DML) in pulldown. (3500 psi if 35’ tower)
– Do not exceed 3000 psi (DM45) in pulldown.
– Do not exceed 3400 psi (PV271) in pulldown.
Symptom-Propel Mode-Tracks Won’t Move

Electrical Troubleshooting
-Are Propel controllers energized when in Propel mode?
(Look for 24VDC at “+“ terminals and wire from Drill/Propel switch?
Yes>- Verify Propel controller outputs. Set Digital Volt Meter (DVM) to measure milliamps.
Settings are :
Threshold 150mA
Max out 350 mA.

If there is no current output - check continuity of circuits.

- Is DR/PR valve coil energized in Propel mode?

Yes>- Press manual override button on DR/PR valve. Do tracks now move while override
button is pressed and controller levers actuated?

Y>- Change DR/PR valve coil or 4 way valve assy.

N>Check pilot/brake release pressure at “P” port of DR/PR valve.
Is pilot it 500 psi?
Y>- Trouble shoot electrical controller system further.
N>- Troubleshoot pilot pressure supply from double pump to
DR/PR “P” port.
No>Verify 24 VDC power from Drill/Propel selector switch on the operators console, to
DR/PR coil at Drill /Propel valve.
-Verify 24VDC power at the wire 70A at Drill/Propel switch and at R5 and R6
(Wire #70A for both DML and PV271)

Is there power to Relays 5 and 6 coils? (Relays are located in the console
behind ignition key panel?)

Y>
Are relay 5 and 6 coils grounded and functioning properly?
N> Verify continuity of wire #70A from switch to DR/PR to relays.
-Troubleshoot power to R5 and R6 coils at wire #70B.
(See coil resistances listed on page #13)
- Investigate power to wire #80 from key switch to Drill/Propel
switch.
Symptom- Propel Mode- One track will not move in one
direction.
Troubleshoot the electrical system first.
(See electrical troubleshooting steps above).

Remember the hydraulic components used on a drill are very costly. The main pumps
provide flow and compensator pressure control for both DRILL and PROPEL modes. If
one mode functions well and the other mode does not, the problem is not the pump. It
is the external controls. The technicians job is to troubleshoot, identify, and isolate the
problematic component or components before replacing any. Do not just change parts.
Identify the problem first! To do this correctly first define and understand the
component relationships.

Hydraulic tests:
Does machine function correctly in “Drill” mode?
Yes> Troubleshoot Propel circuits.
-Swap the positions of the two way valve cartridges in the DR/PR valve.
Does the problem move to opposite track?
Yes> Replace two way cartridges.
No> Stoke pump manually. (See page 7of this document for the location of the pumps manual actuator)
Do Drill and Propel systems work manually?
Y> Investigate electrical system.
-FYI Pump coils circuit resistance s/b 41Ω. (Powerhead not in decel range of tower)
N>- Investigate Hot oil shuttle valve.
-Plug off Hot oil shuttle tank ports (See rig specific hyd. schematic for port locations).
With HOS “T” port plugged, does propel power return?
-Yes> Change HOS valve and adjust flow.
(Correct HOS flow S/B 4 GPM. HOS relief pressure 150 psi aprx)
- No>-Reconnect HOS.
Plug VA port on pump. Does power return to both tracks?
Yes> Investigate the pump control circuits further.
No>- The problem is internal of the pump compensator control valve.
Change pump.
Feed System Control Valve (Regen Valve)

HP 57448144
LP 57448136
Symptom- Drill Mode - Powerhead drifts down with controls in
neutral.
1. Does the powerhead creep with engine off?
Y> Skip null adjustment step.
N> Continue to Pump Null Adjustment step.
Pump Null Adjustment.
Does the CS track also “creep” while in propel mode ?
Y> Adjust pump null. See Operations and Maintenance manual.
N> Go back to Drill mode.
In Drill mode, move the powerhead to the top of the tower.
Move the feed control lever 1/4th stroke in the down direction. Turn the force control
on slightly, just enough to make the head begin to move downward. Note the
Pulldown pressure when the head begins to move.
Does it take less than 6-700 psi on the pulldown gauge to make the powerhead begin to move
down?
Y> Place feed lever in neutral, turn up holdback on full. (HP drills)
Readjust the sequence valve cartridge setting to increase the pressure required to
move the power head downward. (the only accessible adjustable
cartridge on the Regen valve. See page 21)
To make the adjustment:
Again as described above, while the powerhead is moving slowly downward, turn in
(CW) on the sequence valve setting until 700 psi is reached. Put lever in neutral. Look
for creeping. If creep is gone, you are finished. Note: Use of heavy wall drill pipe may
require a slightly higher pressure setting to hold the load while in neutral.
Note: Sequence valve adjustment is only visible on the pulldown pressure gauge.
Is creep still present after adjustment of sequence valve?
Y>Go to “R” port test. (HP machine sonly)
N> You are finished.
“R” port test
Move the head to the bottom stops. Stop the engine. Allow the system to neutralize
and then relieve all hydraulic feed pressure. After making preparations to manage
and control oil leakage, remove the hose from the “R” port on the Regen valve and
cap the port and plug the hose.
Start the machine and retest as described above.
Is creep still present after isolating the Holdback system?
Y> Continue to replacement of sequence valve.
N> Trouble shoot holdback solenoid valve.
Is creep still present after adjustment of sequence valve?
Y> Move powerhead to its bottom stops. Stop the engine. Allow the system to
neutralize and then relieve all hydraulic feed pressure. After making preparations
to manage and control oil leakage, remove the Sequence valve cartridge.
Inspect its orings and seals. If any signs of cuts, tears, damage, or parts missing.
Replace the cartridge and adjust as described above. Final pressure setting
should be just high enough to stop powerhead creep while in neutral. No higher
setting is needed.
N> You are finished.
Is creep still present after placement and adjustment of sequence valve?
Y> Go to leak checks.
N> You are finished.

Note: the sequence valve for a LP machine is not the same part number as that of a HP machine.
Order parts only from the specific machines parts book.

Feed Cylinder Leak Check

Lay the tower down and vent the feed control valve assembly. (Regen valve). Disconnect the
feed cylinder rod-end hoses at the feed control valve assembly and cap off the open fittings on
the valve. Plug one of the cylinder hoses and leave the other one open. Slowly raise the tower
and watch for feed system drift.

Does the head drift?

Y> The plugged cylinder is leaking internally. Repair or replace.
N> Lay the tower down and vent the feed control valve assembly. Move the
hose plug from the previous cylinder rod-end hose to the other cylinder rod-
end hose. Leave the previous hose open. Raise the tower and watch for feed
system drift.
Does the head drift?
Y> The plugged cylinder is leaking internally. Repair or replace.
N> The Sequence, isolation plug or counterbalance valve is leaking. Vent the
feed control valve assembly. Remove each of the se valve cartridges and
check the o-ring seals. Repair or replace any damaged o-rings. (Some
cutting or fraying of the backup rings is normal and will not cause leakage.) If
the head still drifts, replace all three cartridges and readjust the sequence
valve according to the adjustment procedure. The cartridges removed can
be re-inserted one at a time, into the assembly to identify the actual failed
cartridge.
We are committed to your
superior productivity through
interaction and innovation.
39