PV270 DTH Flow

Switch Replacement
Installation
For PDM and Non PDM Machines
Mark A Kramer, Technical Service
Engineer – Automation, February 2021
[email protected]
Table of Contents
Non-PDM Kit Installation

PDM Kit Installation

Power Kit Installation

Non PDM Kit
Installation
 Non PDM Kit Contents
Non PDM Complete Install
Component no Description Qnty
2659619452 MANIFOLD 1
2659609933 ELECTR.BOX 1
2658390626 CABLE,EXTN,4PIN 3
2659609953 CABLE 1
2659610440 CABLE 1
2658587480 CABLE 1
2659596591 CABLE M12-M/DS06-2S-8.5 1
2658636487 CABLE 1
2658552382 SOLENOID,COIL,24V 1
2695264941 TEE,MALE RUN,NPTF 1
2695303368 CONNECTOR,STRT THRD 1
2695219721 CONNECTOR,MALE,37 DEG. 1
2652240959 PLATE,TAPPED 4
2695378873 HOSE SUPPORT CLAMP (1.75) 3
2695301867 HOSE SUPPORT CLAMP (.913) 3
2695920187 CAPSCREW 4
2695919528 CAPSCREW 2
2695935029 WASHER FLAT 8
2695931564 NUT, HEX 2
2657609752 F04X012A--/A-- 1
N/A HOSE F08X10 J--/J-- 1
N/A HOSE F08X275 J--/J90 1
N/A HOSE F08X55 J--/J90 1
2657939639 M12-F-ST TO LDS (1,2,3,4) 5M 1
2657522047 BLOCK,FUSE TERMINAL 1
2650625946 CONNECTOR,CORD GRIP 1
2652241106 FUSE, 15A 1
2650249671 WIRE, 14AWG-WHITE (inches) 72
2657668600 TERMINAL, PIN 18AWG 2
2657471518 TERMINAL, PIN 16-14 AWG 2
2656780703 TIE, CABLE 20
© 2018 by Epiroc. All rights reserved.
2657691768 MARKERS,TERMINAL 1
Installing the Electrical Box and New DTH Valve
• Use the four Included Tapped Plates (2652240959) to mount
the electrical box on the available space between the top two
existing tapped plates and level gauge.
• Use the included hardware to install the box to the tapped
plates (4 cap screws 2695920187 and 4 flat washers
2695935029).
• Drill two 5/16” holes on the outside bottom wall of the tank to
mount the new DTH valve.
• Use the included hardware to install the DTH valve (2 cap
screws 2695919528, 4 flat washers 2695935029, and 2 nuts
2695931564).

© 2018 by Epiroc. All rights reserved.

DTH Manifold Assembly

The manifold has been pre built with

information provided by Technicians from the
Team in Penasquito. Make what ever
necessary adjustments are needed during
hose up and installation

© 2018 by Epiroc. All rights reserved. 6

DTH Oil Pump Modifications

• Disconnect the electrical connection to the

old flow switch.
• Tag and disconnect the supply line from the
flow switch. D515 X6a
Connection
• Remove the old flow switch from the pump.
• Remove the ORB to ORB fitting from the
pump.
• Install a new connector (2695303368) into
the pump.

© 2018 by Epiroc. All rights reserved. 7

Wiring the Pump and DTH Valve
• Disconnect and remove the RCS Cables from D515X6a and
D515X14a to the DTH Lube Pump and flow switch.
• Remove the 12 volt coil from the Lube Pump and install the 24
volt coil (2658552382).
• Install one Cable, Extn, 4 Pin 2658390626 to the DTH
Electrical Box Port 5
• Connect Cable 2658587480 to 2658390626 and connect it to
the Lube Pump.
• Install one Cable, Extn, 4 Pin 2658390626 to the DTH
Electrical Box Port 6
• Connect Cable 2659610440 to 2658390626 and connect it to
the 3/2 valve located on the DTH Valve.
• Install one Cable, Extn, 4 Pin 2658390626 to the DTH
Electrical Box Port 2
• Connect Cable 2659609953 to 2658390626 and connect it to
the Pressure Switch on the DTH Valve
© 2018 by Epiroc. All rights reserved. 8
Connection to Module D515

• Remove the RCS Cable from D515X6a.

• Remove the RCS Cable from D515X14a.
• Connect one 2658636487 Cable to
D515X6a and connect it to Port 3 on the
DTH Electrical Box.
• Connect one 2659596591 CABLE M12-
M/DS06-2S-8.5 to D515X14a and connect it
to Port 4 of the DTH Electrical Box.

© 2018 by Epiroc. All rights reserved. 9

Power the DTH Electrical Box
• Connect Cable 2657939639 with flying
leads to Port 1 of the DTH Electrical
Box.
• Route the Cable under the Lube Tank
and over to the Power Pack Box.
• Using an open port in the cable gland
run the cable up into the Power Pack
Box.
• *If there is no available port in the cable
gland, instead use open space in the
bottom of the box and drill a .89”
(22.5mm) hole and install the Cord Grip
2650625946, then run the cable up into
the power pack box.

© 2018 by Epiroc. All rights reserved. 10

Power the DTH Electrical Box
• Add one 2657522047, Fuse terminal block
in the available space inside the power pack
box.
• Install one 2652241106, 15 AMP fuse into
the fuse block.
• *It may be necessary to remove an unused
terminal block.
• Using the white wire (2650249671) and one
16-14AWG terminal pin (2657471518)
connect one end of the wire to an available
#6 (key switch power) terminal block
• Trim and connect the other end of the white
Unused and spare
wire with one 16-14AWG terminal pin terminals where fuse block
(2657471518) to the left side of the fuse cab be installed
terminal block.
© 2018 by Epiroc. All rights reserved. 11
Power the DTH Electrical Box
5
• Connect the Black (+) wire of cable
2657939639 with one 18AWG terminal
pin (2657668600) to the right side of the
fuse block terminal previously installed.
• Label this terminal DTH+.
• Connect the Blue (-) wire with one
18AWG terminal pin (2657668600) to DTH+
any available 5 inside the power pack
box.
• Label this terminal 5.
• Using the cable ties (2656780703)
secure all new wiring inside the power
pack box.

© 2018 by Epiroc. All rights reserved. 12

Hosing Up the DTH Valve
• Connect the F08X10 hose to the new JIC
connector that was installed into the pump.
• Connect the other end of the hose to the
Inlet of the DTH Valve.
• Attach the existing supply hose from the air
piping to the outlet of the DTH Valve.
* Note: A new hose is supplied if the existing
hose will not reach. In this case
attach one end of the new F08X275
hose to the outlet of the DTH valve
and the other end to the inlet of the
Main Air Piping on the Tower Support.

© 2018 by Epiroc. All rights reserved. 13

Hosing Up the DTH Valve

• Remove the vent from the top of the DTH

Tank.
• Install the ½“ NPT Run Tee (2695264941)
into the port that the vent was removed from
with the horizontal port facing the side of the
tank that the DTH Box was installed on.
• Install the vent into the top of the Tee.
• Install a new ½” NPT to JIC -8
(2695219721) fitting into the horizontal port.
• Connect the F08X55 hose from fitting
2695219721 on the Tee to the return on the
DTH Valve.

© 2018 by Epiroc. All rights reserved. 14

Prepare RCS for the New Coil

• Boot up RCS
• Log in under AC or SE Level.
• Save the parameters.
• Install the New RCS Program.
• Restart RCS.
• Install the parameters.
• Install the New DTH Micro parameters.

© 2018 by Epiroc. All rights reserved. 15

DTH Box Schematic

© 2018 by Epiroc. All rights reserved. 16

Timer Operation

• For this installation we are using the OFF Delay (R).

• Set the function to (R)
• Set the time limit to the desired amount
recommended is 3 to 5 seconds.

© 2018 by Epiroc. All rights reserved. 17

 PDM Kit
Installation
PDM Kit Contents
PDM Complete Install
Component no Description Qnty
2659619452 MANIFOLD 1
2659609933 ELECTR.BOX 1
2658390626 CABLE,EXTN,4PIN 3
2659609953 CABLE 1
2659610440 CABLE 1
2658587480 CABLE 1
2659596591 CABLE M12-M/DS06-2S-8.5 1
2658636487 CABLE 1
2658552382 SOLENOID,COIL,24V 1
2695264941 TEE,MALE RUN,NPTF 1
2695303368 CONNECTOR,STRT THRD 1
2695219721 CONNECTOR,MALE,37 DEG. 1
2652240959 PLATE,TAPPED 4
2695378873 HOSE SUPPORT CLAMP (1.75) 3
2695301867 HOSE SUPPORT CLAMP (.913) 3
2695920187 CAPSCREW 4
2695919528 CAPSCREW 2
2695935029 WASHER FLAT 8
2695931564 NUT, HEX 2
2657609752 F04X012A--/A-- 1
N/A HOSE F08X10 J--/J-- 1
N/A HOSE F08X275 J--/J90 1
N/A HOSE F08X55 J--/J90 1
2657939639 M12-F-ST TO LDS (1,2,3,4) 5M 1
2656780703 TIE, CABLE 20
© 2018 by Epiroc. All rights reserved.
Installing the Electrical Box and New DTH Valve
• Use the four Included Tapped Plates (2652240959) to mount
the electrical box on the available space between the top two
existing tapped plates and level gauge.
• Use the included hardware to install the box to the tapped
plates (4 cap screws 2695920187 and 4 flat washers
2695935029).
• Drill two 5/16” holes on the outside bottom wall of the tank to
mount the new DTH valve.
• Use the included hardware to install the DTH valve (2 cap
screws 2695919528, 4 flat washers 2695935029, and 2 nuts
2695931564).

© 2018 by Epiroc. All rights reserved.

DTH Manifold Assembly

The manifold has been pre built with

information provided by Technicians from the
Team in Penasquito. Make what ever
necessary adjustments are needed during
hose up and installation

© 2018 by Epiroc. All rights reserved. 21

DTH Oil Pump Modifications

• Disconnect the electrical connection to the

old flow switch.
• Tag and disconnect the supply line from the
flow switch. D515 X6a
Connection
• Remove the old flow switch from the pump.
• Remove the ORB to ORB fitting from the
pump.
• Install a new connector (2695303368) into
the pump.

© 2018 by Epiroc. All rights reserved. 22

Wiring the Pump and DTH Valve
• Disconnect and remove the RCS Cables from D515X6a and
D515X14a to the DTH Lube Pump and flow switch.
• Remove the 12 volt coil from the Lube Pump and install the 24
volt coil (2658552382).
• Install one Cable, Extn, 4 Pin 2658390626 to the DTH
Electrical Box Port 5
• Connect Cable 2658587480 to 2658390626 and connect it to
the Lube Pump.
• Install one Cable, Extn, 4 Pin 2658390626 to the DTH
Electrical Box Port 6
• Connect Cable 2659610440 to 2658390626 and connect it to
the 3/2 valve located on the DTH Valve.
• Install one Cable, Extn, 4 Pin 2658390626 to the DTH
Electrical Box Port 2
• Connect Cable 2659609953 to 2658390626 and connect it to
the Pressure Switch on the DTH Valve
© 2018 by Epiroc. All rights reserved. 23
Connection to Module D515

• Remove the RCS Cable from D515X6a.

• Remove the RCS Cable from D515X14a.
• Connect one 2658636487 Cable to
D515X6a and connect it to Port 3 on the
DTH Electrical Box.
• Connect one 2659596591 CABLE M12-
M/DS06-2S-8.5 to D515X14a and connect it
to Port 4 of the DTH Electrical Box.

© 2018 by Epiroc. All rights reserved. 24

Power the DTH Electrical Box

• Connect Cable 2657939639 with two pin

Deutsch connector to Port 1 of the DTH
Electrical Box.
• Route the Cable under the Lube Tank and
over to PDM2 located on the non cab side
drill end of the cooler.
• Use the existing straps to tie up the cable to
the other PDM Cables.
• Connect the two pin Deutsch connector to
Port B3 of the PDM Module.

© 2018 by Epiroc. All rights reserved. 25

Setting the B3 Port on PDM2
• Do the following steps with the key
switch on, but the engine not running.
Main Menu
• From the main menu of the PDM
module press the down arrow until you
come to the Advanced Features menu.

Advanced
Features
Menu

© 2018 by Epiroc. All rights reserved. 26

Setting the B3 Port on PDM2

• On the advanced features menu press the

circle button to enter the password input
feature.
• Follow the onscreen instructions to enter the
password for service level.
• Service level password is 1100 0000.
• Use the up and down arrows to filter thru the
numbers 0 thru 9.
• Use the square button to advance to the
next number in the sequence.
• Use the circle button to enter the password
once all numbers are entered.

© 2018 by Epiroc. All rights reserved. 27

Setting the B3 Port on PDM2

• If the password was entered successfully you

will enter the service level menu.
• Follow the onscreen instructions to navigate
the menu.
• Press up and down to change pages.
• Press circle to enter.
• Press square to select.
• Hold square to cancel.

© 2018 by Epiroc. All rights reserved. 28

Setting the B3 Port on PDM2

• Press the down arrow until you reach the B1

– B4 AMP Limits screen.
• Then press the circle button to edit the AMP
limits.

• Press the square button until the box next to

B3 is selected.
• The current AMP rating will be 0.0 AMP.

© 2018 by Epiroc. All rights reserved. 29

Setting the B3 Port on PDM2

• Use the up and down arrows to set the AMP

limit to 5.0 AMP.

• Once you have set the limit to 5.0 AMP,

press the circle button to save and exit
the AMP Limits editing menu.

© 2018 by Epiroc. All rights reserved. 30

Setting the B3 Port on PDM2

• Once you have exited the AMP editing menu

press the down arrow to reach the exit
screen of the Service Menus.

• At the Exit Menu, press down one

more time to exit to the main
menu.
• The AMP rating is now set and the
port is ready to power the DTH
Box.

© 2018 by Epiroc. All rights reserved. 31

Hosing Up the DTH Valve
• Connect the F08X10 hose to the new JIC
connector that was installed into the pump.
• Connect the other end of the hose to the
Inlet of the DTH Valve.
• Attach the existing supply hose from the air
piping to the outlet of the DTH Valve.
* Note: A new hose is supplied if the existing
hose will not reach. In this case
attach one end of the new F08X275
hose to the outlet of the DTH valve
and the other end to the inlet of the
Main Air Piping on the Tower Support.

© 2018 by Epiroc. All rights reserved. 32

Hosing Up the DTH Valve

• Remove the vent from the top of the DTH

Tank.
• Install the ½“ NPT Run Tee (2695264941)
into the port that the vent was removed from
with the horizontal port facing the side of the
tank that the DTH Box was installed on.
• Install the vent into the top of the Tee.
• Install a new ½” NPT to JIC -8
(2695219721) fitting into the horizontal port.
• Connect the F08X55 hose from fitting
2695219721 on the Tee to the return on the
DTH Valve.

© 2018 by Epiroc. All rights reserved. 33

Prepare RCS for the New Coil

• Boot up RCS
• Log in under AC or SE Level.
• Save the parameters.
• Install the New RCS Program.
• Restart RCS.
• Install the parameters.
• Install the New DTH Micro parameters.

© 2018 by Epiroc. All rights reserved. 34

DTH Box Schematic

© 2018 by Epiroc. All rights reserved. 35

Timer Operation

• For this installation we are using the OFF Delay (R).

• Set the function to (R)
• Set the time limit to the desired amount
recommended is 3 to 5 seconds.

© 2018 by Epiroc. All rights reserved. 36

Non PDM Power
Kit Installation
Power Kit Contents

Non-PDM Power Kit

Component No Description Qnty
2657939639 M12-F-ST TO LDS (1,2,3,4) 5M 1
2658371075 CABLE, M12-M-4-ST TO LD (1,2) 1
2657522047 BLOCK,FUSE TERMINAL 1
2650625946 CONNECTOR,CORD GRIP 2
2652241106 FUSE, 15A 1
2650249671 WIRE, 14AWG-WHITE (inches) 72
2657668600 TERMINAL, PIN 18AWG 2
2657471518 TERMINAL, PIN 16-14 AWG 2
2656780703 TIE, CABLE 20
2657691768 MARKERS,TERMINAL 1

© 2018 by Epiroc. All rights reserved.

Power the DTH Electrical Box

• Remove the jumper wire installed from TB9

to TB3.
• Remove the jumper wire installed from TB7
to TB5.

Remove

• Check the port 1 wiring inside the DTH Box.

• Pin 1 (Brown) should go to TB1 (Terminal
Block 1)
• Pin 2 (White) should go to TB5.

© 2018 by Epiroc. All rights reserved. 39

Power the DTH Electrical Box
• If pins 1 and 2 are not available on the
connector installed into the box, remove the
bulkhead connector from the box.
• Enlarge the installation hole to .89”
(22.5mm) and install the included cord grip
(2650625946) with lock nut and seal.
• Insert cable 2658371075 into the cord grip
and connect pins 1 (brown) and 2 (white)
per the instruction in the previous slide.

© 2018 by Epiroc. All rights reserved. 40

Power the DTH Electrical Box
• Connect Cable 2657939639 with
flying leads to Port 1 of the DTH
Electrical Box.
• Route the Cable under the Lube
Tank and over to the Power Pack
Box.
• Using an open port in the cable
gland run the cable up into the
Power Pack Box.
• *If there is no available port in the
cable gland, instead use open
space in the bottom of the box and
drill a .89” (22.5mm) hole and
install the Cord Grip 2650625946,
then run the cable up into the
power pack box.
© 2018 by Epiroc. All rights reserved. 41
Power the DTH Electrical Box
• Add one 2657522047, Fuse terminal block
in the available space inside the power pack
box.
• Install one 2652241106, 15 AMP fuse into
the fuse block.
• *It may be necessary to remove an unused
terminal block.
• Using the white wire (2650249671) and one
16-14AWG terminal pin (2657471518)
connect one end of the wire to an available
#6 (key switch power) terminal block
• Trim and connect the other end of the white
wire with one 16-14AWG terminal pin Unused and spare
terminals where fuse block
(2657471518) to the left side of the fuse can be installed
terminal block.
© 2018 by Epiroc. All rights reserved. 42
Power the DTH Electrical Box
5
• Connect the Black (+) wire of cable
2657939639 with one 18AWG terminal
pin (2657668600) to the right side of the
fuse block terminal previously installed.
• Label this terminal DTH+.
• Connect the Blue (-) wire with one
18AWG terminal pin (2657668600) to DTH+
any available 5 inside the power pack
box.
• Label this terminal 5.
• Using the cable ties (2656780703)
secure all new wiring inside the power
pack box.

© 2018 by Epiroc. All rights reserved. 43

DTH Box Schematic

© 2018 by Epiroc. All rights reserved. 44

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