Atlas Copco PV-235 Series Blasthole Drill Safety, Operation and Maintenance Manual

Description

The Atlas Copco PV-235 Series Blasthole Drill Safety, Operation and Maintenance Manual is the complete instruction manual developed for the PV-235 Series crawler-mounted, hydraulic tophread drive, multi-pass rotary drilling rig. Published by Atlas Copco Drilling Solutions, LLC, this 878-page document covers every phase of PV-235 ownership — from pre-start safety inspections and operator controls through scheduled maintenance intervals, hydraulic and pneumatic system theory, and detailed troubleshooting procedures. Whether you run a PV-235 in production blasthole drilling or maintain one in the shop, this manual provides the manufacturer’s own procedures, specifications, and service data in a single downloadable PDF.

File Details

• Manual Type: Safety, Operation and Maintenance Instruction Manual
• Brand: Atlas Copco / Atlas Copco Drilling Solutions
• Model: PV-235 Series Blasthole Drill
• Covered Engines: Caterpillar C15, C18, C27; Cummins QSX15, QSK19
• Language: English
• Page Count: 878 pages
• File Format: PDF
• Publisher: Atlas Copco Drilling Solutions, LLC, Garland, Texas
• Copyright: © 2011
• Latest Revision: Revision 003, January 2012

Chapters Covered

• Section 1 — Introduction: Manual Revisions, Introduction, General Information, Drill Identification, Engine Identification, Instruction Manual Location, Drill Description
• Section 2 — Safety: Safety and Health, Safety Precautions and Guidelines, Regulations for Work Safety, Drill Applications, Electrical Safety on Drilling Machines, Protection against Shock, Safety Reminders, Qualify Your Personnel, General Guidelines, Equipment Safety Rules, Operation Safety, Maintenance Safety, Safety Decals and Nameplates
• Section 3 — Specifications: General Description, Drill Applications, Design Features, Environment Rate Factor Ranges, Operational Limitations, Standard Features, Main Frame, Leveling Jacks, Undercarriage and Propel System, Tower, Carousel and Drill Pipe Handling, Drill Pipe Change, Air Compressor, Engines, Cooling Package, Hydraulic System, Hydraulic Cylinders, Cooling System, Water Injection, Winch, Dust Collector, Operator’s Cab, Inclinometers, Operator’s Controls, Night Lighting, Dimensions and Weights, Drill Options
• Section 4 — Controls: Operating Controls and Instruments, Electrical Isolation Switches, SEOH (Standard Electric Over Hydraulic), RCS (Rig Control System)
• Section 5 — Operating: Operating Safety, SEOH (Standard Electric Over Hydraulic), RCS (Rig Control System), Common Equipment Between SEOH and RCS
• Section 6 — Maintenance: Maintenance Safety, Maintenance Schedule, Refill Capacities/Lubricants, Maintenance As Required, Maintenance (8-10 Hours), Maintenance (50 Hours or Weekly), Maintenance (100-150 Hours), Maintenance (250 Hours), Maintenance (500 Hours), Maintenance (1000 Hours), Maintenance (1500-2000 Hours), Maintenance (3000 Hours or 3 Years), Maintenance (5000 Hours), Maintenance (6000 Hours or 2 Years), Floating Cushion Sub, Torque Specifications
• Section 7 — Troubleshooting: Introduction, Hydraulic Symbols, Hydraulic System, Pneumatic System, EARS, PowerView (SEOH Drill), HNBR Hose/Victaulic Coupling Installation, Bean (FMC) Water Injection Pump, SEOH Relay Logic, Hydraulic Clutch, Engine Heater, Engine Oil Cleaning Centrifuge, Dust Collector, Lube Grease System
• Section 8 — Glossary: Glossary of Terms

Altogether, this manual gives the PV-235 technician a complete system-level reference — from the introductory drill description through safety, specifications, controls, operating procedures, maintenance schedules, and full troubleshooting sections covering hydraulics, pneumatics, EARS, PowerView, water injection, dust collection, and more.

What the PV-235 Manual Covers in Detail

Safety and Operator Protection

The Safety section (Section 2) runs from general safety and health statements through specific procedures for electrical power line safety, drilling safety, propel safety, maintenance safety, and handling of capacitors. It includes the full safety decal and nameplate list with part numbers and mounting locations, plus symbol identification tables used throughout the manual.

Specifications and Drill Systems

Section 3 documents the PV-235’s design features, main frame, leveling jacks, undercarriage and propel system, tower and carousel, drill pipe handling, air compressor, engine options, cooling package, hydraulic system, hydraulic cylinders, water injection, winch, dust collector, operator’s cab, and dimensions/weights. The standard rotary head is the 4SV-2-10, delivering 4,900 ft-lb at 0–190 RPM or 8,200 ft-lb at 0–110 RPM, with three optional direct-drive rotary heads also listed.

Controls: SEOH and RCS

Section 4 covers both the SEOH (Standard Electric Over Hydraulic) and RCS (Rig Control System) operator interfaces. The SEOH section includes joystick functions, center post gauges, dash switches, PowerView display, and circuit breaker assignments. The RCS section covers the touch-screen GUI, operator panel layout, mode/function buttons, and fault-finding on the display.

Operating Procedures

Section 5 walks through pre-start inspection, walk-around checks, starting and stopping the drill, leveling, tower raising and pinning, angle drilling, rod support, hoist operation, drill mode setup, rotary drilling procedure, rod changing, drill rod loading, shutdown procedures, and special conditions of use (cold, hot, muddy, dusty, high altitude). Both SEOH and RCS operation sequences are covered.

Maintenance Schedules

Section 6 is organized by maintenance interval — as-required, 8–10 hours (daily), 50 hours (weekly), 100–150 hours, 250 hours, 500 hours, 1,000 hours, 1,500–2,000 hours, 3,000 hours (or 3 years), 5,000 hours, and 6,000 hours (or 2 years). Each interval lists lubrication points, fluid checks, filter changes, torque values, and component-specific service procedures. Refill capacities and lubricant specifications are provided for engine oil, coolant, hydraulic oil, compressor oil, gearbox oil, and grease.

Troubleshooting and System Theory

Section 7 covers hydraulic symbols and system diagrams, the pneumatic/compressed air system, Electronic Air Regulation System (EARS) diagnostics with error codes, PowerView operation for SEOH drills, Victaulic coupling installation, Bean (FMC) water injection pump service, SEOH relay logic, hydraulic clutch troubleshooting (Twin Disc TDEC-050), engine heater diagnostics, engine oil cleaning centrifuge service, dust collector troubleshooting, and lube grease system maintenance.

Torque Specifications

Section 6.16 provides standard torque values for SAE Grade 5 and Grade 8 fasteners in both ft-lbs and Nm, plus metric bolt torque values for Class 8.8, 10.9, and 12.9 hardware. These tables cover the full range of bolt sizes used on the PV-235.

Who This Manual Is For

This PV-235 instruction manual is intended for drill operators, field service technicians, maintenance planners, and shop mechanics working on Atlas Copco PV-235 Series blasthole drills. It is equally useful for training new operators on the SEOH or RCS control systems and for experienced technicians who need to verify a torque value, fluid capacity, diagnostic code, or maintenance interval.

Get the Complete PV-235 Manual Today

This Atlas Copco PV-235 Series Blasthole Drill Safety, Operation and Maintenance Manual gives you the complete reference for keeping your blasthole drill running safely and efficiently. From the daily 8–10 hour checks to diagnosing EARS error codes or rebuilding the water injection pump, the manual’s 878 pages cover the procedures and specifications you need. Every section is organized by system and task, with step-by-step instructions, torque values, fluid capacities, wiring and hydraulic diagrams, and troubleshooting charts.

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