9852 1979 01 Maintenance Instructions R

Atlas Copco ROC D5/D7/D9 Maintenance instructions

PM No. 9852 1979 01 2007-08

SAFETY INSTRUCTIONS Before starting, read all instructions carefully. Special attention must be paid to information alongside this symbol. Only use genuine Atlas Copco parts.

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© Copyright 2007, Atlas Copco Rock Drills AB, Sweden Any unauthorized unauthorized use or copying copying of the contents contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

Atlas Copco Rock Drills AB SE-70191 Örebro, Sweden

Safety

Safety Reference .......................................... ................................................................ ............................................ ............................................. ........................... .... 5

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Safety

4

Safety

Reference Note

Always read the information under Safety before starting to use the rig or starting maintenance work.

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Safety

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Maintenance instructions

Maintenance instructions 1. General ................................................................................................................... 11 General .................................................................................................................. 11 Safety ................................................................................................................ 11 Target group and objective ............................................................................... 11 Contact details .................................................................................................. 12 Signs for outsourced components ..................................................................... 15 Dismantling and assembly ................................................................................ 15 Scrapping .......................................................................................................... 16 Tightening torque in bolted joints..................................................................... 16 Welding............................................................................................................. 17 Points to be observed when welding:........................................................... 17 Electrode recommendations ......................................................................... 18 Fault finding...................................................................................................... 19 Battery ................................................................................................................... 20 Environmental considerations regarding batteries............................................ 20 Charging the battery.......................................................................................... 20 Proceed as follows (24V charger) ................................................................ 21 Proceed as follows (12V charger) ................................................................ 22 Starting with an auxiliary battery...................................................................... 22 Steel cables ............................................................................................................ 23 Scrapping guidelines for steel cables................................................................ 23 Wire break at cable attachment .................................................................... 24 Occurrence of strand breaks......................................................................... 24 Concentrations of wire breaks...................................................................... 24 Effects of heat .............................................................................................. 24 Occurrence of wire breaks due to operating time. ....................................... 24 Reduced elasticity ........................................................................................ 24 Decrease in cable diameter .......................................................................... 25 Certain number and type of wire breaks ...................................................... 25 Corrosion...................................................................................................... 26 Surface wear................................................................................................. 26 Deformation of the cable.............................................................................. 27 Wire displacement........................................................................................ 27 Strand displacement ..................................................................................... 28 Waviness ...................................................................................................... 28 Cracks........................................................................................................... 28 Kinks ............................................................................................................ 29 Flattening ..................................................................................................... 29 Local cable diameter decrease ..................................................................... 29 Local cable diameter increase ...................................................................... 29 Basket formation .......................................................................................... 30 Tensioning the crawler tracks ................................................................................ 30 Air conditioning..................................................................................................... 31 Safety ................................................................................................................ 31 Environmental issues when handling refrigerant ............................................. 32

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Maintenance instructions Changing air filter ............................................................................................. 32 Fault finding...................................................................................................... 33 No cooling.................................................................................................... 33 Poor cooling ................................................................................................. 33 Uneven cooling ............................................................................................ 33 Abnormal noise ............................................................................................ 34 2. Transport instructions ............................................................................................. 35 Hoisting ................................................................................................................. 35 Single-section boom version ............................................................................. 35 Folding boom version ....................................................................................... 37 Transport................................................................................................................ 39 Before loading the drill rig onto the transport vehicle. ..................................... 40 Once the drill rig is loaded onto the transport vehicle. ..................................... 40 Towing ................................................................................................................... 42 3. Drill system ............................................................................................................ 44 Adjusting the damper pressure .............................................................................. 44 Adjusting percussion pressure ............................................................................... 45 General .............................................................................................................. 45 Low percussion pressure ................................................................................... 47 High percussion pressure .................................................................................. 47 Adjusting drill feed pressure.................................................................................. 48 General .............................................................................................................. 48 Low drill feed pressure ..................................................................................... 49 High drill feed pressure..................................................................................... 50 Adjusting rotation speed ........................................................................................ 52 Setting rotation speed........................................................................................ 54 RPC-F system ........................................................................................................ 54 Adjusting........................................................................................................... 54 Pressure regulator adjustment................................................................................ 57 Anti-jamming protection ....................................................................................... 57 Air flow monitor B142 ..................................................................................... 58 Adjusting air flow switch.................................................................................. 58 Rotation pressure switch B134 ......................................................................... 59 Adjusting activation pressure............................................................................ 61 Setting lubrication to the rock drill........................................................................ 62 ECL collection....................................................................................................... 63 Locations........................................................................................................... 63 ECL collector pressure control valve................................................................ 63 Function ............................................................................................................ 64 4. Hydraulic systems .................................................................................................. 67 Environmental considerations when handling oil ................................................. 67 General................................................................................................................... 67 Repairing hydraulic components ........................................................................... 68 Replacement of hydraulic hoses ............................................................................ 68 Hydraulic workshops ............................................................................................. 68

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Maintenance instructions Filter ...................................................................................................................... 69 Return oil filter ................................................................................................. 69 General ......................................................................................................... 69 Changing the return oil filter........................................................................ 69 Breather filter .................................................................................................... 70 General ......................................................................................................... 70 Changing the breather filter ......................................................................... 71 Condensation in the hydraulic oil reservoir...................................................... 72 Draining condensation from the hydraulic oil tank ..................................... 72 5. Feeder ..................................................................................................................... 73 6000-series............................................................................................................. 73 Assembling the rock drill ...................................................................................... 73 Preparation ........................................................................................................ 73 Assembly .......................................................................................................... 73 Check after four hours ........................................................................................... 74 Haul and return ropes ............................................................................................ 75 Locations........................................................................................................... 75 Replacing the haul rope .................................................................................... 75 Adjusting haul and return ropes........................................................................ 76 Tension of return rope ........................................................................................... 76 Adjusting the cradle on the feed beam .................................................................. 76 Replacing the slide pieces in the holder ................................................................ 78 Replacing slide rails .............................................................................................. 78 Feed cylinder ......................................................................................................... 79 Dismantling the feed cylinder........................................................................... 79 Tension bushings for spacers ............................................................................ 80 Description ................................................................................................... 80 Dismantling .................................................................................................. 81 Assembly...................................................................................................... 81 Long-term storage............................................................................................. 81 6. Dust collector (DCT).............................................................................................. 82 Dust collector (DCT) ............................................................................................. 82 Setting the dust collector (DCT)............................................................................ 83 Preset times ....................................................................................................... 84 Setting the times ............................................................................................... 84 Filter test, dust collector (DCT)............................................................................. 84 Dust collector (DCT) filter change........................................................................ 85 7. Radiator .................................................................................................................. 86 Environmental issues when handling coolant ....................................................... 86 Coolant .................................................................................................................. 86 8. Diesel engine .......................................................................................................... 88 Safety..................................................................................................................... 88 Environmental issues when handling oil............................................................... 88 Oil for diesel engine .............................................................................................. 89

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Maintenance instructions Maintenance of components .................................................................................. 90 Air filter, service interval .................................................................................. 90 Cleaning or changing air filter .......................................................................... 91 Cleaning the main cartridge ......................................................................... 92 Checking air filter switches.......................................................................... 93 Fuel system ....................................................................................................... 93 Filter ............................................................................................................. 93 Prefilter......................................................................................................... 94 Fine filter ...................................................................................................... 95 Environmental issues when handling fuel ........................................................ 96 Draining the fuel tank ....................................................................................... 96 Belts .................................................................................................................. 97 Belts.............................................................................................................. 97 Tension gauge............................................................................................... 97 Changing the generator belt ......................................................................... 98 For further instructions, see separate instructions for the diesel engine......... 100 9. Oil and fuel ........................................................................................................... 101 Environmental issues when handling fuel ........................................................... 101 Filling fuel ........................................................................................................... 101 Environmental considerations when handling oil ............................................... 102 Compressor oil..................................................................................................... 102 Oil sampling ........................................................................................................ 104 Filling up with hydraulic oil ................................................................................ 104 Filling manually .............................................................................................. 104 Changing hydraulic oil ........................................................................................ 105 General ............................................................................................................ 105 Draining .......................................................................................................... 105 Lubricating oil ..................................................................................................... 105 For engine oil see section “Diesel engine” .......................................................... 107

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Maintenance instructions 1. General

1. General General Safety When maintenance work is carried out on the rig, observe the following points: • Never perform service or maintenance work while the rig is running • To prevent personal injury during service and maintenance work, all components that can be brought into motion or fall down must be thoroughly secured. • Ensure that the hydraulic and pneumatic systems are depressurised before starting work on them. • All controls must be deactivated during service and maintenance. • When changing hydraulic hoses, ensure they are replaced with hydraulic hoses fitted with the correct crimp couplings of correct quality and dimension. All pressurised hydraulic hoses have crimped couplings and should therefore be purchased ready made from Atlas Copco. Quality classes and hose dimensions are specified in the spare parts catalogue. Ensure also that all hose connections are clean, undamaged and securely tightened.

Target group and objective Note

This chapter (General) contains general recommendations for maintenance of the drill rig and its peripheral equipment. This means that certain sections may not be fully adapted to individual components. The maintenance instructions are intended for mechanics and personnel in maintenance and service. The user should have undergone Atlas Copco's training courses for the equipment concerned. The objective of these maintenance instructions is to detect and rectify faults at an early stage so that breakdowns, costly secondary damage and accidents can be prevented. Regular maintenance is a precondition for planning necessa ry interruptions in operation such as reconditioning and repairs. This allows maintenance to be carried out when most suitable with regard to production instead of causing complete breakdown.

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Contact details Table: Addresses, telephone numbers and fax numbers to Atlas Copco companies Country

Address

Phone and fax number

Argentina

Juncal 2869 B1640GRE Martinez

Phone: +54 - (0)11 - 47 17 22 00 Fax: +54 - (0)11 - 47 17 09 88

Buenos Aires Australia

P O Box 6134 Delivery Centre Blacktown NSW 2148

Phone: +61 - (0)2 - 9621 9700 Fax: +61 - (0)2 - 9621 9813

Austria

Postfach 108 A-1111 Vienna

Phone: +43 - (0)1 -76 01 20 Fax: +43 - (0)1 - 769 56 72

Bolivia

P.O. Box 290 Santa Cruz de la Sierra

Phone: +591 - (0)3 - 343 68 68 Fax: +591 - 0(3) - 343 69 69

Brazil

P O Box 12737 Sao Paulo, SP 04744-970

Phone: +55 - (0)11 - 247 88 00 Fax: +55 - (0)11 - 55242347

Bulgaria

14, Vasil Levski Str., fl. 2 North Industrial Area Kazichane Sofia 1532

Phone: +55 - (0) - 29 76 30 98 Fax: +55 - (0) - 29 76 30 90

Canada

200 Mumford Road Walden Industrial Park

Phone: +1 - 705 - 673 67 11 Fax: +1 - 705 - 692 31 01

Lively, Ontario P3Y 1L2 Chile

Panamericana Norte 5001 - Conchali Santiago, Chile 6553935 Conchali

Phone: +56 - (0)2 - 442 3600 Fax: +56 -(0)2 - 623 44 60

China 1

No. 1, Heng Da Road Nanjing Economic & Technological Development Zone Nanjing

Phone: +86 - 25 - 85 75 76 00 Fax: +86 - 25 - 85 75 75 30

Postal code 210038 China 2

No. 12, Kun Ming Hu Street Shenyang Economic & Technological Development Zone CN-Shenyang 110027

Phone: +86 - 24 - 25 81 17 19 Fax: +86 - 24 - 25 81 18 67

CMT International

S-105 23 Stockholm

Phone: +46 - (0)8 - 743 80 00 Fax: +46 - (0)8 - 702 21 29

Colombia

A.A. 95310 Santafé de Bogotá, D.C.

Phone: +57 - 1 - 291 54 90 Fax: +57 - 1 - 430 6514

Czech Republic

Prumyslova 10 Praha 10, Post Code 102 00

Phone: +420 - (0)2 - 25 43 42 20 Fax: +420 - (0)2 - 25 43 42 22

Egypt

520 El-Obour Market Cairo

Phone: +20 - (0)2 - 610 20 57 Fax: +20 - (0)2 - 610 20 56

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Country

Address


Finland

Tuupakankuja 1

Phone: +358 - (0)9 - 296 64 42

SF-01740 Vantaa

Fax: +358 - (0)9 - 29 64 21 8

France

B.P. 67181 FR-95056 Cergy-Pontoise Cedex

Phone: +33 - (0)1 - 30 72 32 22 Fax: +33 - (0)1 - 30 72 32 49

Germany

Postfach 10 02 25

Phone: +49 - (0)201 - 217 70

D-46002 Essen

Fax: +49 - (0)201 - 217 74 54

P O B 10071

Phone: +233 - 21 77 45 12

Accra North

Fax: +233 - 21 77 61 47

Great Britain

P O Box 79 Hemel Hempstead Herts HP2 7HA

Phone: +44 - (0)1442 - 22 21 00 Fax: +44 - (0)1442 - 234467

Greece

93, Koropiou - Varis Avenue GR - 194 00 Koropi, Athens

Phone: +30 - (0)210 - 349 96 00 Fax: +30 - (0)1 - 345 47 83

Hong Kong

P O Box 1516 Shatin Central Post Office New Territories

Phone: +852 - 24 88 01 03 Fax: +852 - 24 88 98 63

India

Sveanagar Bombay Pune Road

Phone: +91- (0)20 -712 64 16 Fax: +91 - (0)20 - 712 65 87

Ghana

Dapodi Pune 411 012 Indonesia

P O Box 7021/JKS CCE Jakarta 12075

Phone: +62 - 780 10 08 Fax: +62 - 780 18 37

Iran

PO Box 13145-1311 Tehran 1345654551

Phone: +98 - 21 - 669 377 11 Fax: +98 - 21 - 669 273 14

Ireland

Kylemore Road Bluebell Dublin 12

Phone: +353 - (0)1 - 450 5978 Fax: +353 - (0)1 - 456 7686

Italy

Casella Postale 77

Phone: +39 - (0)2 - 61 79 91

IT-20092 Cinisello Balsamo MI

Fax: +39 - (0)2 - 66 01 32 99

Japan

Sumitomo Fudosan Shipa Bldg 4 llF 13-4 Shiba 2-chome Minato-ku Tokyo 105-0014

Phone: +81 - (0)3 - 57 65 78 90 Fax: +81 - (0)3 - 57653199

Kazakhstan

Kurmangaliev Str 8A 050010 ALMATY

Phone: +7 - (0)327 - 258 85 34 Fax: +7 - (0)327 - 258 85 35

Kenya

PO Box 400 90 Nairobi

Phone: +254 - (0)20 - 660 50 00 Fax: +254 - (0)20 - 82 54 72

Korea

C-P.O. Box 8354 Seoul

Phone: +82 - (0)2 - 21 89 40 00 Fax: +82 - (0)2 - 522 82 39

Malaysia

26 Jalan Anggerik Mokara 31/47 Kota Kemuning, Seksyen 31 40460 Shah Alam Selangor Darul Ehsan

Phone: +60 - (0)3 - 5123 88 88 Fax: +60 - (0)3 - 51 23 89 49

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Country

Address


Mexico

Apartado Postal Box 104

Phone: +52 - 5 - 626 06 00

Tlalnepantla Edo. De Mexico

Fax: +52 - 5 - 565 62 65

Morocco

P O Box 13 844 20 300 Casablanca

Phone: +212 - 2 - 600 040 Fax: +212 - 2 - 60 05 22

Mongolia

Building BP9, Tavan Erdene(MISHEEL) Center, 2nd Khoroo, Khan Uul District, Chinggis Avenue, Ulaanbaatar, Mongolia

Phone: +976 - (0)11 - 99 11 48 16 Fax: +976 - (0)11 - 11 31 26 13

Norway

P O Box 334

Phone: +47 - 64 - 86 03 00

N-1401 Ski

Fax: +47 - 64 - 86 03 30

Peru

Apartado 662 Lima 100

Phone: +51 - (0)1 - 224 86 80 Fax: +51 - (0)1 - 224 01 53

Philippines

P.O. Box 1373

Phone: +63 - (0)2 - 823 8178-80

1200 Makati City

Fax: +63 - (0)2 - 823 84 59

Poland

(Sales) ul. Katowicka 32 P-40-173 Katowice (Service) ul.Krzywa 3, 59-100 Polkowice

Sales Phone: +48 - (0)32 - 209 5774 Fax: +48 -(0)32 - 209 5776 Service Phone: +48 76 8474 935

Portugal

Apartado 14P-2790-953 Carnaxide

Phone: +351 - (0)1- 416 85 00 Fax: +351 - (0)1 - 418 0782 Service

Russia

27, Viatskaya Street, Building 14 127015 Moscow

Phone: +7 - 495 - 933 55 52 Fax: +7 - 495 - 933 55 58

Saudi Arabia

P O Box 7330 Jeddah 21462

Phone: +966 - (0)2 - 693 33 57 Fax: +966 - (0)2 - 693 28 92

Singapore

Jurong Point P O Box 438 Singapore 639456

Phone: +65 - 66 - 68 62 28 11 Fax: +65 - 66 - 68 63 60 98

South Africa

P O Box 14110 Witfield 1467

Phone: +27 - (0)11 - 821 90 00 Fax: +27 - (0)11 - 821 92 02

Spain

Apartado 24 E-28820 Coslada Madrid

Phone: +34 - (9)1 - 627 91 00 Fax: +34 - (9)1 - 627 9239

Sweden

S-10523 Stockholm

Phone: +46 - (0)8 - 743 92 30 Fax: +46 - (0)8 - 743 92 46

Switzerland

Büetigenstrasse 80

Phone: +41 - (0)32 - 374 15 00

CH-2557 Studen/Biel

Fax: +41 - (0)32 - 374 15 15

Taiwan

P O Box 14-45, Chungli Tao Yuen Hsien

Phone: +886 - (0)3 - 479 68 38 Fax: +886 - (0)3 - 479 68 20

Thailand

1696 New Petchburi Road

Phone: +66 - (0)2 - 652 90 06

Bangkapi Huay Kwang Bangkok 10320

Fax: +66 - (0)2 - 652 81 94

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Country

Address


Turkey

Istasyon Arkasi

Phone: +90 - (0)216 - 581 05 81

81700 Tuzla Istanbul

Fax: +90 - (0)216 - 581 05 82

USA

PO Box 1159 Commerce City CO 80022

Phone: +1 - 303 - 287 88 22 Fax: +1 - 303 - 217 2839

Venezuela

Apartado 76111 Caracas 1071

Phone: +58 - (0)212 - 256 23 11 Fax: +58 -(0)212 - 257 18 10

Vietnam

No. 42, Street 37, Thao Dien Ward, District 2, Ho Chi Minh City

Phone: +84 - (0)8 - 898 96 38 Fax: +84 - (0)8 - 898 96 37

Zambia

P O Box 11291 Chingola

Phone: +260 - (0)2 - 31 12 81 Fax: +260 - (0)2 - 31 38 77

Zimbabwe

P.O. Box CY 935 Causeway

Phone: +263 -(0)4 - 62 17 61-5 Fax: +263 - (0)4 - 62 17 94

Signs for outsourced components Signs are placed on the larger components of the drill rig. When ordering spare parts or making enquiries in regard to the drill rig, the type designation and serial number must always be stated. Type designations and serial numbers are specified in a separate document, MI (Machine Identification). Spare parts can always be ordered through Atlas Copco.

Dismantling and assembly CAUTION • Exercise extreme caution when slinging and hoisting heavy objects • Can cause personal injury • Hoisting must take place at the centre of gravity • Only use slings which are intact and designed for the load they shall carry • Secure the slings in the lifting eyes, where available Before transporting in shafts or the like it may be necessary to fully or partially dismantle the drill rig. Observe the following when dismantling, lifting and assembling:

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• Before dismantling, hose the entire rig clean with water and/or detergent containing a grease solvent. • Observe the strictest cleanliness when dismantling hydraulic, compressed air and water flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes, or seal and protect them from dirt in some other suitable way. • Mark hoses, pipes and other connections, where this has not already been done, to make reassembly easier and prevent mix-ups. • Use properly secured lifting tackle of generous dimensions. Note

When the drill rig is scrapped, all materials that are harmful to the environment must be disposed of in a manner prescribed by the authorities.

Scrapping When the entire drill rig or part of the rig is to be scrapped, local regulations in force regarding handling, waste management, recycling and destruction must be followed. Collect and dispose of: • Rest oil and oil spill • Oil waste such as filters • Rest fuel and fuel spill • Rest grease and grease spill • Batteries • Discarded refrigerant, air conditioning • Chemicals such as flushing additives, other additives and coolants. • Metals, e.g. steel and aluminium (metals that are recyclable) • Plastics and rubber (often marked in various classifications for recycling) • Electrical components such as cables, electronics

Tightening torque in bolted joints. All joints are tightened to the torque required by Atlas Copco Standard K 4369 unless otherwise specifically stated. In such cases, this will be specified in the maintenance instructions of the module in question. Table: Atlas Copco Standard torques. Size

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Strength class

Torque in Nm.

Tolerance

M6

8.8

8

2

M8

8.8

20

5

M10

8.8

41

10

M12

8.8

73

18

±


Size

Strength class

Torque in Nm.

Tolerance

M14

8.8

115

25

M16

8.8

185

45

M20

8.8

355

85

M24

8.8

600

150

M12 x 1.25

10.9

135

6

M16 x 1.25

10.9

315

15

M18 x 1.25

10.9

460

20

M6

12.9

14

3

M8

12.9

34

8

M10

12.9

70

17

M12

12.9

120

30

M14

12.9

195

45

M16

12.9

315

75

M20

12.9

600

150

M24

12.9

1020

250

±

Welding • Applies to drill rigs equipped with one of the following engines: - CAT 3176 - CAT 3196 - CAT 6.6 - CAT 7 - CAT C9 - CAT C10 - CAT C11 - CAT C12 - CAT C13 - CAT C15 Note

It is important to consult Atlas Copco for approval of welding and choice of electrodes.

Points to be observed when welding: • Disconnect the cables from the generator, the battery and the engine's electronic module (A).

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A

Figure: • Grind off rust and paint from the area that is to be welded and carefully prepare the joint. • Weld in a dry area. • Connect the welding earth cable to a clean surface as close as possible to the welding area. Avoid welding close to bearings and bushes. If these cannot be removed, connect earth cables on both sides of the weld. • Alterations and reinforcements must not be made without previous consultation with Atlas Copco. • Do NOT weld hydraulic tanks, valve blocks, compressed air tanks or pressure lines. • Always keep a fire extinguisher for oil fires near at hand during all types of welding, cutting and grinding. Screen off the work area from flammable materials. • Always protect hoses, cables and electrical components. • Grind off spatter after welding. If possible, also grind the surface of the weld smooth and treat it with anti-corrosion paint.

Electrode recommendations Use only intact and clean electrodes that have been stored in a dry place. The generally recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the equivalent in accordance with the standard below:

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Table: Electrode recommendations ISO:

2560 E51 5B 120 20 H

SS:

14 3211 H10

DIN 1913:

E51 55 B10

AWS:

A/SFA 5.1 E 7018

The use of MIG welding equipment is perfectly acceptable. The generally recommended type of electrode is ESAB-OK Autorod 12.51 or the equivalent in accordance with the standard below: Table: MIG electrodes SS:

14 3403 3423

DIN 8559:

SG 2

AWS:

A/SFA 5.18: ER 70 S-6

If in any doubt, contact Atlas Copco for advice.

Fault finding Fault finding is a logical sequence of activities to locate a fault, thereby making it possible to rectify the fault as soon as possible. Always try to investigate the location of the fault in order to limit fault finding to a certain system or function.

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Battery Environmental considerations regarding batteries ENVIRONMENTAL DIRECTIONS

• Think of the environment! • Batteries contain acids and heavy metals. For this reason, expended batteries can be hazardous to the environment and to health. • Expended batteries must be sent for destruction in accordance with local regulations.

Charging the battery WARNING • Risk of fire and explosion • May cause serious personal injury and damage to property • Flammable hydrogen gas • Corrosive fluid • Avoid naked flames and sparks • Always detach the negative terminal first, and connect it last The battery is normally charged by the drill rig's generator. If the battery is fully discharged for some reason, it must be recharged using a battery charger. Follow the instructions carefully. Cell plugs should be unscrewed but left in the holes during charging.

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Explosive gas is formed in the battery during charging. A short circuit, naked flame or spark in the vicinity of the battery could cause a serious explosion. Ensure good ventilation. Always turn off the charge current before disconnecting the clips. If the density has not risen noticeably despite a number of hours of recharging, the battery is probable expended. Rapid charging, when carried out correctly, will not damage the battery. However, it should not be undertaken too often and is not recommended for old batteries. Repeated discharging for long periods, especially with low current such as leaving the lights on while the engine is stationary, will impair the service life of the battery. Discharging with high current is not normally harmful. The battery must be left to rest between start attempts, however. Since the drill rig's 24V electrical system is powered by two 12V batteries in series, the following points should be observed: • The batteries must have the same capacity (Ah). • The batteries must be the same age. This is because the charging current required to bring a battery up to a certain voltage changes with age. • The batteries must not be loaded unevenly. • Series coupling maintains the same capacity but increases the voltage (double). When 2 x 12V 60Ah batteries are connected in series, the voltage will be 24V but the capacity remains at 60Ah. • Ensure that the correct voltage is used before connecting a battery charger. Use a 24V charger when recharging both batteries and a 12V charger when charging each battery individually.

Proceed as follows (24V charger) Before charging

1. Inactivate battery switch S300. 2. Detach the cable between chassis earth and the negative cable on the battery G1B. 3. Connect the positive battery charger cable to the positive terminal on G1A. 4. Connect the negative charger cable to the negative terminal on G1B. 5. Start the battery charger. After charging

1. Turn off the battery charger 2. Detach the battery charger's negative lead from the negative terminal on G1B. 3. Detach the battery charger's positive lead from the positive terminal on G1A.

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4. Connect the cable between chassis earth and the negative terminal on G1B. 5. Activate battery switch S300.

Proceed as follows (12V charger) Before charging

1. Turn off the battery switch S300 2. Disconnect the jumper lead between the negative terminal on battery G1A and the positive terminal on battery G1B. 3. Connect the positive battery charger cable to the positive terminal on G1A. 4. Connect the batter charger's negative lead to the negative terminal on G1A. 5. Start the battery charger. 6. Once battery G1A is fully charged: Turn off the battery charger. 7. Detach the battery charger's negative lead from the negative terminal on G1A. 8. Detach the battery charger's positive lead from the positive terminal on G1A. 9. Detach the cable between chassis earth and the negative cable on the battery G1B. 10. Repeat steps 3 - 8 on G1B. After charging

1. Turn off the battery charger 2. Reconnect the jumper lead between the negative terminal on battery G1A and the positive terminal on battery G1B. 3. Connect the cable between chassis earth and the negative terminal on G1B. 4. Activate battery switch S300.

Starting with an auxiliary battery Note

Owing to the surge of current, the batteries could explode if a fully-charged battery is connected to a completely flat one. The connections to the drill rig's batteries must under no circumstances be broken during operation as this could lead to faults arising in the generator. For this reason, proceed as follows:

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1. Check that the auxiliary starting batteries (1) have the same voltage as the batteries on the chassis.

1

1250 0064 41

Figure: Starting assistance 1 2

Auxiliary batteries Drill rig batteries

2. First connect the positive terminal of the auxiliary battery to the positive terminal of the chassis battery (2). 3. Then connect the negative terminal of the auxiliary battery (1) to earth on the chassis (not to the chassis battery's negative terminal). 4. Once the engine has started, first remove the starter cable between the chassis and the negative terminal on the auxiliary battery (1). 5. Then remove the cable between the positive terminals of the batteries.

Steel cables Scrapping guidelines for steel cables Steel cables should be scrapped when they display any of the following: • Wire break at attachment • Occurrence of strand breaks • Concentrations of wire breaks • Effects of heat • Occurrence of wire breaks due to operating time. • Reduced elasticity • Decreased cable diameter

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• Certain number and type of wire breaks • Corrosion • Surface wear • Deformation of the cable • Permanent elongation of the cable

Wire break at cable attachment Broken wires at cable ends indicate that they have been heavily loaded and can be caused by faulty end attachments. Shorten the cable and reattach it. However, the remaining cable length must be sufficient.

Occurrence of strand breaks If there are strand breaks, the cable must be scrapped

Concentrations of wire breaks If there are concentrations of cable breaks, the cable must be scrapped. If such concentrations occur within a length less than 60 cm or on an individual strand, the cable must be scrapped. If this is the case, the cable must be scrapped even if the number of wire breaks is less than the maximum specified in the table.

Effects of heat Cables exposed to extreme heat must be scrapped. The effects of heat can be established through annealing colour.

Occurrence of wire breaks due to operating time. Wire breaks occur first after a certain operating time depending on operating conditions and subsequently occur more frequently. If this is the case, the number of wire breaks in relation to the operating time should be determined and documented. This can then be used to estimate the future increase in wire breaks and the foreseea ble time point for scrapping.

Reduced elasticity Under certain conditions, the cable loses its elasticity.

24


Reduced elasticity is difficult to detect. If in doubt, consult a specialist. If the cable has lost elasticity, the following characteristics usually appear: • Decrease in cable diameter • Elongation of the cable • No gap between individual wires and between the strands. This is caused by its components being pressed together. • Fine, brown dust inside the strands. • Even if there are no visible wire breaks, the cable is noticeably stiffer. • The cable's diameter decreases more quickly than during normal wear of the individual cable wires. Reduced elasticity can lead to sudden cable breaks during heavy loads. The cable should be scrapped.

Decrease in cable diameter Decrease in cable diameter through material fatigue in the cable can have the following causes: • Inner surface wear and surface wear nicks • Inner surface wear through friction between the strands and wires in the cable • Fatigue of plastic core • Break in steel core • Break in inner layer in multi-strand cable If the cable's diameter decreases more than 10% in relation to the nominal diameter of the cable, it must be scrapped. It should then be scrapped even if no wire breaks have been detected.

Certain number and type of wire breaks The cable drums are designed in such a way that the cables do not have an unlimited service life. Wire breaks can therefore occur during operation. On 6 and 8-strand cables, wire breaks are primarily superficial. The cables should be scrapped if the number of wire breaks specified in the table have been detected

25


Table: Number of load-bearing

Number of visible wire breaks 2 that require wires in the outer strand 1 scrapping Machine groups M1 and M2 Cross lay

Equal lay

Over a length of

Over a length of

6d

30d

6d

30d

201 - 220

9

18

4

9

221 - 240

10

19

5

10

n

d = Cable diameter 1

= Filler wire is not considered load-bearing.

In cables with several layers of strands, only the outer, visible layer is considered. In cables with steel cores, the core is regarded as an inner strand and is not included. 2

= In the event of a wire break, two ends can be visible.

Corrosion Corrosion is especially problematic in marine environments and in areas where the air is polluted by industrial emissions. Corrosion can reduce operational strength through rust spots and static tensile strength through a reduction in the cross section of the metallic cable. Severe corrosion can reduce elasticity. Outer corrosion: Outer corrosion can be easily detected through visual examination. Inner corrosion: Inner corrosion is more difficult to detect. Inner corrosion is characterised by the following:

• Absence of gap between the strands in the outer layer of the cable, often in combination with wire breaks in the strands. • The cable diameter varies. The parts of the cable that are bent over discs usually have a decreased diameter. At any sign of corrosion, the cable should be checked by an authorised person. If inner corrosion is detected, the cable must be scrapped.

Surface wear Inner surface wear is caused by friction between the wires and the strands.

26


Outer surface wear is caused by friction between the cable drums (rolls) and the cable under pressure (acceleration and braking). Outer surface wear is visible through the formation of reflected images on the outer wires. Surface wear is increased through faulty or no lubrication, thereby increasing the effect of dirt and dust. Surface wear reduces static tensile strength through reduction in the cable's metallic cross section and dynamic strength through surface wear nicks. If the cable's diameter decreases more than 7% in relation to the nominal diameter of the cable, it must be scrapped. It should then be scrapped even if no wire breaks have been detected.

Deformation of the cable Deformations are characterised by visible deviations from the cable's normal form that lead to uneven voltage distribution in the cable. The following are the primary types of deformations: • Wire displacement • Strand displacement • Waviness • Cracking • Kinks • Flattening • Local cable diameter decrease • Local cable diameter increase • Basket formation

Wire displacement Individual wires or wire groups stick out like hairpins on the side facing away from the drum. Wire displacement is caused by spasmodic loads. Cables with wire displacement must be scrapped.

Figure: Example of wire displacement

27


Strand displacement Strand displacement, which often occurs in conjunction with basket formation, is when the steel core pushes out between the strands. Cables with strand displacement must be scrapped.

Waviness Waviness is a deformation that gives the cable's longitudinal axis a helical curve. Even though wave formation does not necessarily cause weakening of the cable, such a deformation can cause a pulsing movement. After a long time of operation, this can increase surface wear and wire breaks. In the event of waviness, the cable should be scrapped if d1 > 4d/3 d = Cable's nominal diameter d1 = Diameter of the circle that would be formed if the cable were not deformed. Check over a length not exceeding 25d.

Figure: Waviness

Cracks Cracks are deformations through outer, violent influences. Cables with cracks must be scrapped.

Figure: Cracks

28


Kinks A kink is a deformation caused by the cable forming an eye that is contracted with out the cable being able to rotate around its own axle. Strand pitch is altered, which leads a great deal of surface wear and, in severe cases, very low static strength. Cables with kinks must be scrapped.

Figure: Kinks

Flattening Flattening is deformation caused by mechanical damage. Cables with severe flattening must be scrapped.

Figure: Flattening

Local cable diameter decrease Local decrease in cable diameter is often connected to core break. The area near the end attachments must be inspected especially carefully as it can be difficult to detect cable diameter decrease at these spots. Cables with severe cable diameter decrease must be scrapped.

Figure: Local cable diameter decrease

Local cable diameter increase This means repeated thickening of the cable over a long stretch. At the thicker spots, the core pushes out of the cable and causes unevenness of the outer strands.

29


Cables with severe cable diameter increase must be scrapped.

Figure: Local cable diameter increase

Basket formation Basket formation occurs on cables with steel reinforcement or steel core when the outer strand layer becomes longer than the inner strand layer. Basket formation can also be caused by shock loads on slack cables. Cables with basket formation must be scrapped.

Figure: Basket formation

Tensioning the crawler tracks Track tension is checked between the front wheel (3) and support roller (1) when the drill rig is parked on a level surface with the tracks are under normal load. 2

3

1 A

4

7 3 7 1 1 0 0 5 2 1

Figure: Crawler track

30


N.B. The clearance (A, see illustration: Crawler track) between the wooden plank and the crawler track should be between 25 and 50 mm (0.9 and 1.9").

N.B. The grease nipple should not be filled with grease during normal inspection.

1. Place a wooden plank (2, see illustration: Crawler track) on top of each track. 2. Pack with grease via the nipple (4) to tension the track. 3. If necessary, grease can be removed from the tension cylinder by unscrewing the nipple (4).

Air conditioning Safety WARNING

• Refrigerant under pressure • Risk of serious personal injury • Service of refrigerant must always be carried out by authorised personnel Note

Do not use the system with too little refrigerant, leakage or any other fault until it is rectified. Otherwise, there is risk of the compressor breaking down.

31


Environmental issues when handling refrigerant ENVIRONMENTAL DIRECTIONS

• Think of the environment! • Discarding air conditioning refrigerant can be hazardous to the environment. • Air conditioning refrigerant must be sent for destruction in accordance with applicable local regulations.

Changing air filter A D

3 9 2 8 1 0 0 5 2 1

E B

C

A

F b B

b

Figure: Filter - air conditioning. Changing the main filter:

32


• Undo the screws around the cover (C). • Open the cover and lift out the filter. • Fit the new filter in place and screw back the cover. Changing the prefilter: • Undo the screws on the louvre cover (D). • Lift away the louvre cover and the filter. • Fit the new filter in place and screw back the louvre cover. Changing the circulation filters: • Undo the screws on the covers (b). • Lift away the covers and the filters. • Fit the new filters in place and screw back the covers.

Fault finding No cooling Check the following points: • Fuses, electric connections, compressor earth, electromagnets, switches and pressure switches • V-belt and compressor • Expansion valve and temperature control valve • Coolant hoses

Poor cooling Check the following points: • Fresh-air fan and V-belt tension • That the air does not evade the evaporator in the unit • That the evaporator and condenser are not clogged by rubbish and the filter in the air intake is not dirty • That the expansion valve capillary tube is firmly against the evaporator outlet pipe • That the thermostat does not cut out too early

Uneven cooling Check the following points: • That connections to switches, magnetic coupling or pressure switch are not loose • That the expansion valve is not clogged • That the system is filled and the thermostat is not defective

33


Abnormal noise Check the following points: • That the multi-V-belt to the compressor is thoroughly tightened and that the com pressor retaining bolts are tightened. • That the system is filled sufficiently and not overfull • That the expansion valve is in working order • That the airflow across the evaporator is sufficient • That the condenser is clean and the airflow is sufficient Abnormal system noise is often connected to incorrectly assembled components. If the compressor is noisy at a certain speed, for instance, and the noise disappears when the speed increases or decreases, there is probably nothing wrong with the compressor itself. The difference between the pressure on the suction side and the pressure side also affects the level of noise. A compressor with low suction makes more noise than a compressor with high suction. Likewise, a compressor with high high-pressure makes more noise because it puts more load on bearings, etc.

34

Maintenance instructions 2. Transport instructions

2. Transport instructions Hoisting Single-section boom version WARNING

• Hanging load • May cause serious personal injury and damage to property • Do not approach a hanging load • Only use lifting equipment and lifting straps with adequate lifting capacity • Risk of tipping • Lock the track oscillation cylinders before the drill rig is raised

Figure: Hoisting Make sure the chassis is not damaged when you position the feed in the transport/ hoisting position.

35


• Move the rock drill to its rear (upper) position • Use the boom and feed controls to lower the feed onto the feed support. • Position the feed against the outer boom. • Make sure that the hydraulic jack is retracted. •

Track oscillation cylinders to LOCKED position. Switch (9) to position (b).

Figure: Drill panel • Make sure that none of the hoses, controls or any other components can fasten or sustain damage when the hoisting slings are tensioned and under load. • Place the hoisting slings under both crawler tracks at points A and B as shown in the illustration Hoisting.

36


Folding boom version WARNING

• Hanging load • May cause serious personal injury and damage to property • Do not approach a hanging load • Only use lifting equipment and lifting straps with adequate lifting capacity • Risk of tipping • Lock the track oscillation cylinders before the drill rig is raised

ROC 1 2 5 0 0 1 2 8 9 5

A

B

Figure: Lifting models with folding boom. To achieve maximum drill rig stability, position the boom, feeder and rock dri ll as follows: • Boom lift cylinder maximum OUT • Boom extension maximum IN • Feed dump cylinder maximum OUT (make sure that the feed does not collide with the lifting equipment)

37


• Rock drill in END POSITION (lower position) • Make sure that the hydraulic jack is retracted. •

Track oscillation cylinders to LOCKED position, switch 9 to position (b)

Figure: Drill panel • Make sure that none of the hoses, controls or any other components can fasten or sustain damage when the hoisting slings are tensioned and under load. • Place the hoisting slings under both crawler tracks at points A and B as shown in the illustration.

38


Transport WARNING

• Risk of tipping • May cause serious personal injury and damage to property • Lock the track oscillation cylinders before the drill rig is raised • Transportation equipment must be adapted for the dimensions and weight of the drill rig • All bodywork hatches must be correctly installed and locked

ROC

1 2 5 0 0 1 2 8 6 9

2 0 9 2 1 0 0 5 2 1

Figure: Transport position for folding boom versions, alternative 1

ROC 1 2 5 0 0 1 2 8 6 9

1 2 5 0

Figure: Transport position for folding boom versions, alternative 2

39

Maintenance instructions 2. Transport instructions A

ROC

4 0 9 2 1 0 0 5 2 1

Figure: Transport position for single-section boom versions, alternative 1 A

ROC

6 0 9 2 1 0 0 5 2 1

Figure: Transport position for single-section boom versions, alternative 2

Before loading the drill rig onto the transport vehicle. • Run the rock drill to its lowest position. Use the boom and feed controls alternately to bring the feed down into the trans port position and firmly down on its jack (A).

Once the drill rig is loaded onto the transport vehicle. • Run the hydraulic jack down.* •

40

Track oscillation cylinders to LOCKED position.


Figure: Drill panel • Switch off the diesel engine. • Support the feed beam against the vehicle to prevent overloading. • Strap the drill rig securely to the vehicle. Attach straps or chains to the lifting eyes on the machine and vehicle. Note

*Extra equipment

41


Towing WARNING

• Danger of moving parts • May cause serious personal injury and damage to property • Place a wedge under both of the track frames, before disengaging the traction gears 1. Remove the two M8 bolts from the cover plate.

1250 0131 32

Figure: 2. Remove the cover plate and turn the outside inwards

1250 0131 33

Figure:

42


3. Refit the cover plate by means of the two M8 bolts.

4 3 1 3 1 0 0 5 2 1

Figure: 4. When the cover plate is in place, the drill rig is ready for towing.

1250 0131 35

Figure: Proceed in the same way on the other track frame The drill rig can now be towed.

43

Maintenance instructions 3. Drill system

3. Drill system Adjusting the damper pressure CAUTION

• Danger of serious equipment damage • An incorrectly adjusted damper pressure can cause serious damage to equipment • Adjustment of damper pressure should only be carried out by trained staff

Figure: Constant flow valve for damper pressure. Note

See also separate rock drill instructions. • Adjustment to be performed without drilling • The diesel engine runs at 1500 rpm • Close constant flow valve (See illustration: Constant flow valve) fully on drill rig. • Connect a pressure gauge to the rock drill between damper nipple and damper hose . • Rock drill disconnected from drill rods and shank adapter relieved of load, in advanced position.

44


• Move switch Drilling/Preheating/Tramming (see illustration: drill panel) to position drilling (a). • The shank adapter should be completely clear of the frame. • Adjust the damper pressure on the constant flow valve . Undo the locking screw (1b) on the constant flow valve and adjust the damper pressure with knob (1a), clockwise to reduce pressure and anticlockwise to increase pressure. • Corresponding pressure on Cab pressure gauge : -

COP-1800 approx. 40 bar.

-

COP-2150/2160 approx. 40 bar

• Factory settings: -

COP-1800 32 - 35 bar

-

COP-2150, COP2160 32 - 35 bar

• Shut down the rig. • Disconnect Pressure gauge and connect the hose to Damper nipple Note

The impact stops automatically if damper pressure rises above 120 bar or drops below 35 bar while drilling is in progress. • Check that the shank adapter goes into “float mode” during drilling. (Constantly pressed out approx. 4 - 6 mm from the frame.

Adjusting percussion pressure General Note

Impact pressure should only be set during drilling and the hydraulic oil should have attained operating temperature, normally 40 C (104 F). °

°

Percussion pressure can be checked on the pressure gauge Percussion pressure (8).

45


1 2 3 4

5 6 7 8 9

6 1 7 7 1 0 0 5 2 1

Figure: Pressure gauge panel Note

Valves Percussion pressure (7 and 8) are located inside the cab (on the right-hand side).

46


8

7

4

3

2

5 RPCF

1 8 1

6

7 7 1 0 0 5 2 1

Figure: Control panel for pressure

Low percussion pressure Setting must be done while drilling. Note

Pressure ex works is 120 bar (factory setting). The switch on the drill lever must be in position LOW PERCUSSION PRESSURE. 1. Undo the lock nut (7). 2. Turn the adjusting screw (7) clockwise to increase low percussion pressure. 3. Turn the adjusting screw (7) anticlockwise to decrease low percussion pressure. 4. Tighten the lock nut (7).

High percussion pressure Setting must be done while drilling. Note

Pressure ex works is 200 bar (factory setting). The switch on the drill lever must be in position HIGH PERCUSSION PRESSURE. 1. Undo the lock nut (8).

47


2. Turn the adjusting screw (8) clockwise to increase high percussion pressure. 3. Turn the adjusting screw (8) anticlockwise to decrease high percussion pressure. 4. Tighten the lock nut (8).

Adjusting drill feed pressure General Note

Feed pressure should only be adjusted during drilling Valves Drill feed pressure (3 and 4) are located inside the cab (on right-hand side).

8

7

4

3

2

5 RPCF

1 8 1

6

7 7 1 0 0 5 2 1

Figure: Control panel for pressure Drill feed pressure can be checked on the Drill feed pressure pressure gauge (1)

48


1 2 3 4

5 6 7 8 9

6 1 7 7 1 0 0 5 2 1

Figure: Pressure gauge panel

Low drill feed pressure Note

Factory setting is 30 bar. Button Percussion pressure (25) in position LOW PERCUSSION PRESSURE (left). Switch Flushing air (21) in position REDUCED FLUSHING AIR/DUST COLLECTOR ON.

49


15

16

17

18

a b

a

19

e

f

c

d

c

14

20

21

b 13 ? 1 4 8 2 1 0 0 5 2 1

23

22

Figure: Rod handling Lever Feed in position DRILL FEED. 1. Undo the lock nut (3) on the control panel for pressure. 2. Turn adjusting screw (3) on the control panel for pressure clockwise to increase drill feed pressure. 3. Turn adjusting screw (3) on the control panel for pressure anticlockwise to decrease drill feed pressure. 4. Tighten the lock nut (3) on the control panel for pressure.

High drill feed pressure Note

Factory setting is 70 bar. Button Percussion pressure (25) in position HIGH PERCUSSION PRESSURE (right).

50


Figure: Drill panel Activate functions for drilling with full percussion (See drilling). Switch Flushing air (21, see illustration: Rod handling) in position FULL FLUSHING AIR (a).

51


15

16

17

18

a b

a

19

e

f

c

d

c

14

20

21

b 13 ? 1 4 8 2 1 0 0 5 2 1

23

22

Figure: Rod handling handling Lever Feed (26) in position DRILL FEED. 1. Undo the the lock nut (4) (4) on the control control panel panel for pressure. pressure. 2. Turn Turn adjusting adjusting screw (4, see illustration: illustration: Control panel panel for pressure) clockwise clockwise to increase drill feed pressure. 3. Turn Turn adjusting adjusting screw (4, see illustration: illustration: Control panel for pressure) pressure) anticlockwise anticlockwise to decrease drill feed pressure. 4. Tighten Tighten the lock lock nut (4b, see illustration illustration:: Control panel panel for pressure). pressure).

Adjusting rotation speed The valve for Rotation speed (1) is located inside the cab (on the right).

52


8

7

4

3

2

5 RPCF

1

6

8 1 7 7 1 0 0 5 2 1

Figure: Control Control panel for pressure pressure Note

Rotation speed can be set without without drilling. The setting must be made when the diesel engine is at maximum rpm. The hydraulic oil should be at operating temperature, normally 40 °C (104 °F). To measure rotation speed, count the number of revolutions the drill s tring completes per minute (make a mark on the drill drill rod). Alternatively, Alternatively, use an electronic instrument. Correct rotation speed should be set according to the type of drill bit and the properties of the rock. Observe the following guidelines: Table: Basic setting for ordinary button button drill bits Size of drill bit (mm)

76

89

102

115

Size of drill bit (inches)

3

3 1/2

4

4 1/2

Rotation speed (rpm)

120

110

90

70

• Type ype of of dri drill ll bit bit - X drill drill bits (cross-d (cross-drill rill bits) bits) require require a higher higher speed speed than button button drill drill bits (10-20 (10-20 rpm higher) • Rock Rock prop roperti erties es - Soft types types of of rock normally normally require require a higher higher speed, speed, harder harder rock requires requires a lower lower rotation speed.

53


• Jerky rky ro rotati ation - If rotation rotation speed speed is jerky jerky during during drilling drilling (not (not rotating rotating at even speed), speed), this this could indicate that rotation rotati on speed is too low. low. - In certain certain types types of of rock, rock, ballistic ballistic drill drill bits bits can cause jerky jerky rotatio rotation. n. • Drill ill bit wear ear - Diamet Diametric ric wear wear can be be reduced reduced if rota rotatio tion n speed speed is lowered lowered • Drill illing ing rate ate - High High rotatio rotation n speed speed can give give a higher higher drill drilling ing rate. rate. - Ballistic Ballistic button button drill bits normally normally give give a higher higher drilling drilling rate rate - X dril drilll bits bits give give a lower lower drillin drilling g rate. rate. Note

In the case of heavy wear on drill bit diameter (skirt), reduced flushing air must be used

Setting rotation speed • Undo the control control knob (1) on on the control control panel panel for pressure. pressure. • Turn Turn adjustin adjusting g screw screw (1) (1) clockwise clockwise to increase increase rotation rotation speed. speed. • Turn Turn adjustin adjusting g screw (1) anticloc anticlockwise kwise to reduce reduce rotation rotation speed. • Tight ighten en the the loc lock k nut nut (1). (1).

RPC-F system RPCF (Rotation Pressure Controlled Feed) is used to regulate the drill feed pressure in order to maintain the rotation pressure at a sufficient level to keep the joins tight. This is done by the RPCF valve detecting the rotation pressure while drilling. When the rotation pressure exceeds the preset value for the RPCF valve, the feed pressure will be lowered to minimum the low drill feed pressure. As the feed pressure drops, so will the rotation pressure. This means that t hat the feed pressure shown on the pressure gauge while drilling in many cases will not be the same as the high feed pressure setting but a lower pressure. For a more detailed description, refer to the rock drill's “How to use” instructions.

Adjusting The RPCF valve is only to be adjusted while drilling with two drill rods in the drill string and after the hydraulic oil has reached normal operating temperature 40 °C (104 °F). In order to be able to make a good setting, the rock should be reasonably homogenous so that a stable rotation pressure is obtained.

54


8

7

4

3

2

5 RPCF

1 8 1

6

7 7 1 0 0 5 2 1

Figure: Control panel for pressure. 1. Undo the lock nut (2) and turn the adjusting screw (2) clockwise until it stops to disengage the function. Oil may run out from around the adjusting screw while the adjustment is being made. 2. Start drilling and set in a suitable feed pressure, percussion pressure and rotation speed according to the rock drill's “How to use” instructions. See also the chapter on pressure setting in this manual.

55


3. Once an even and stable rotation pressure is achieved (pressure gauge 7), the RPCF valve adjuster screw must be turned anticlockwise until the feed pressure (pressure gauge 1) starts to drop.

1 2 3 4

5 6 7 8 9

6 1 7 7 1 0 0 5 2 1

Figure: Pressure gauge panel. 4. Screw back the adjuster screw clockwise a little way, about 1/2 a turn. The feed pressure will now drop automatically if the rotation pressure exceeds the normal. 5. Tighten the lock nut (2).

56


Pressure regulator adjustment 1

2

3

3 9 5 1 1 0 0 5 2 1

4

Figure: Pressure regulator 1. 2. 3. 4.

Compressor pressure gauge Temperature pressure gauge. Regulator knob. Locking the regulator knob.

Setting the compressor's maximum and operating pressures. Table: Compressor operating pressure Rig model

Max. pressure

Max. temperature

ROC D7

10.5 bar

120 °C

ROC D5

8.5 bar

120 °C

Anti-jamming protection The drill rig is fitted with two types of anti jamming protection. • Air flow switch • Rotation pressure switch Both variants reverse the feed direction if they are activated by insufficient flushing air flow or excessive drill rotation pressure respectively in order to avoid jamming.

57


Air flow monitor B142 The airflow guard is connected after the flushing air valves and monitors the pressure drop through the restriction in the flushing air line. An impaired or non-existent air flow caused by a clogged drill bit, for example, means that the pressure drop will be reduced or cease completely. The rock drill will then reverse automatically until the pressure drop/flow is normal again.

Adjusting air flow switch The airflow guard can be adjusted only while drilling and only with full flushing air flow active.

7 9 2 3 1 0 0 5 2 1

Figure: Air flow switch

58

Maintenance instructions 3. Drill system S119

S187

S113

S182

a f d

b

e S167

c S111

S100

H129

S170

S181 6 7 6 3 1 0 0 5 2 1

Figure: Autodrilling panel. 1. Remove the flow switch cover. 2. Drill almost down to the greatest depth that will be drilled in the current position. Make sure full flushing air is active. Switch 21, position a. 3. Turn the flow switch adjuster screw (1) anticlockwise until the rock drill starts to reverse. The higher the number on the adjuster screw scale, the more sensitive the flow switch will be. The factory setting is 30 mbar. 4. Screw back the adjuster screw until the rock drill starts downwards again. 5. Drill another hole to check that the anti-jamming protection does not activate inadvertently due to the setting being made too sensitive. If this is the case, screw back the adjuster screw slightly more. 6. Fit the flow switch cover. When changing dimension of the drill bit or drill steel, or if the drill depth is changed, it may be necessary to readjust the flow switch in order to maintain adequate anti jamming protection.

Rotation pressure switch B134 The rotation pressure switch B134 is connected to valve QDS-K, which monitors the drill rotation pressure while drilling. A considerable increase in rotation pressure indicates that the drill is about to jam. If the rotation pressure rises above the set pres-

59


sure on QDS-K, the rotation pressure switch will receive a signal and the rock drill will reverse automatically. Reverse feed will continue until the pressure has again dropped below the set value. Note

Factory setting is 80 bar.

A

4 3 3 0 0 0 0 5 2 1

B

Figure: Valves A B

60

B134 QDS-K


Adjusting activation pressure

8

7

4

3

2

5 RPCF

1

6

8 1 7 7 1 0 0 5 2 1

Figure: Pressure adjustment panel.

WARNING

• Risk of serious personal injury • During the procedure the rock drill will reverse automatically • Make sure that no personnel are within the rock drill's area of movement The anti-jamming protection activation pressure is adjusted on the QDS-K valve. The activation pressure can be difficult to adjust while drilling as it is often difficult to force the rotation pressure sufficiently high. Instead, it is possible to carry out a simulation. 1. Turn the knob for adjusting the rotation speed (1) anticlockwise until you feel the spring pressure release. The rotation speed will now be 0 rpm. 2. Run the rock drill down until the drill steel sleeve is in the upper drill-steel sup port. Close the drill-steel support to secure the sleeve. 3. Activate drill rotation. 4. Activate drill feed.

61


5. Slowly screw the adjuster knob clockwise while observing the pressure gauge for the rotation pressure. When the pressure exceeds the rotation pressure switch setting, the feed direction will reverse. This can be seen from the pressure on the feed pressure gauge dropping to 0 and the rock drill trying to pull away from the drillsteel support. 6. Screw the adjuster knob anticlockwise to reduce the rotation pressure and allow the feed to move down again. 7. If the pressure switch setting needs to be changed, it can be done by turning its adjusting screw clockwise to increase the activation pressure or anticlockwise to reduce it. 8. Repeat steps 1 - 6 to check the new setting. 9. Restore the rotation speed to its normal setting.

Setting lubrication to the rock drill The relays for ECL and ECG located in the A1 cabinet. The pulse length and pause length can be adjusted on the relays. These adjustments can be made without starting the drill rig. 2

1

3

4

5

6

4 4 3 0 1 0 0 5 2 1

10

7

Figure: Electric cabinet.

62

8

9


The upper adjusting screws on the ECL/ECG relays (3 and 4) adjust the pulses/min and the lower adjusting screws adjust the delay time. To increase the values, turn the adjusting screws clockwise, and to decrease them, turn the adjusting screws anticlockwise. • Factory settings ECL: - Pulses: 20 - 25 pulses/min - Extended time: 30 seconds • Factory setting ECG: - Pulses: 20 - 25 pulses/min - Extended time: 0 seconds Rock drill lubrication must be set with regard to local conditions. Make sure the threads on the shank adapter/drill rod lubricated by air flushing. To check that the diode on the lubricating pumps flash, this indicates the pumps are working.

a

2 9 5 1 1 0 0 5 2 1

b

Figure: Diode on ECG/ECL pumps. a b

ECL ECG

ECL collection Locations ECL collector pressure control valve The pressure to the ECL system limitation is set with the pressure control valve. The pressure must be between 5 and 5-1/2 bar.

63


6 3 6 8 1 0 0 5 2 1

Figure: Pressure control valve.

Function

A

0 1 6 0 1 0 0 5 2 1

B Figure: Collecting tank. The system consists of a collecting tank with two pressure sensors, control lamps and strainer.

The system collects the ECL oil that has passed the rock drill via a hose to the collecting tank (A). Strainer (E) should be cleaned every 40th percussion hour.

64


E

3 1 7 0 1 0 0 5 2 1

Figure: Strainer The collecting tank must be emptied via the cock (B) underneath the tank every time ECL oil is filled. Note

The collected oil must be sent for disposal and not reused! The system is monitored by two pressure sensors:

B38

B381

Figure: Pressure sensor. • B381 - Detects low pressure in the system (0.4 bar). The low pressure indicator lamp (H381) will come on if the pressure is too low. - If the (H381) indicator comes on, check the airflow through the system and remove any impurities.

65


• B382 - Detects high pressure pressure from the the pressure pressure sensors sensors to the the collecting collecting tank tank (1.5 bar). (H382) on the display will come on if the pressure is too high. - If the indicator indicator comes comes on, check the the airflow airflow through through the system system and and remove remove any impurities, in this case between the pressure sensor and the collecting tank.

H180

P352

H207 H211

H212 H214

H213

H215

H203

H382

H381 7 1

R354

66

7 7 1 0 0 5 2 1

Maintenance instructions 4. Hydraulic systems

4. Hydraulic systems Environmental Environmental considerations when handling oil ENVIRONMENTAL ENVIRONMENT AL DIRECTIONS

• Thin Think k of of the the envir environ onme ment nt!! • Leakin Leaking g hydr hydraul aulic ic connec connection tions s and and lubrication grease are environmentally hazardous • Changi Changing ng oils, oils, replac replacing ing hydr hydraul aulic ic hoses hoses and different types of filter can be environmentally hazardous. • Always Always coll collect ect oil resi residue due,, oil oil spilla spillage, ge, waste with oil content, and lubrication grease residue and spillage. Treat in accordance with local regulations. • Use biodeg biodegrada radable ble hydrau hydraulic lic fluid fluids s and and lubrication oils for Atlas Copco products wherever possible. Contact your local Atlas Copco office for further information.

General The hydraulic system is sensitive to impurities. The environment in which a drill rig normally operates is usually unsuitable for repairing hydraulic components. Work on the hydraulic system on-site should therefore be limited to absolute necessities, i.e. only changing components. When changing valves, the unit in question must be well strapped and supported. Components should then be repaired in a suitable environment. Observe the following points to avoid breakdowns and interruptions in operation due to fouled hydraulic oil: • Keep the the drill rig clean. clean. Hose Hose it down down at regular regular intervals, intervals, preferably preferably with an added grease solvent. • Before opening opening any any connec connection, tion, clean the area area round round it. • Use clean clean tools tools and work work with with clean clean hands. hands. • Always plug hydraulic hydraulic connecti connections ons immediate immediately ly after they have have been been detached. detached.

67


• Use Use clea clean n pro protec tectiv tivee plu plugs gs.. • Hydraulic Hydraulic compon components, ents, such such as hoses, hoses, valves, valves, motors, motors, must always be kept kept with suitable protective plugs fitted. • Spare parts for for hydraulic hydraulic compon components ents must must always always be kept kept in sealed sealed plastic plastic bags. bags. • Change Change filter filter cartridg cartridges es as soon as the filters indicate indicate clogging clogging..

Repairing hydraulic components components Repairing and/or reconditioning hydraulic components should be carried out by expert personnel and in a suitable place. The following alternatives are possible: • Suitable Suitable premises premises for for hydraulic hydraulic repairs to be arranged arranged at the workplace. workplace. Repairs Repairs to to be carried out by your own specially trained personnel, personnel, the manufacturer's technicians or Atlas Copco personnel. • Componen Components ts to be sent sent to the manufactu manufacturer's rer's local local agent agent for for repair repair. • Component Component repairs are carried carried out by Atlas Atlas Copco. Copco. Repair Repair instructio instructions ns are availaavaila ble for the most important and most complicated hydraulic components. components.

Replacement of hydraulic hoses The high system pressure, with safety valves set at 280 bar, together with vibrations and other mechanical strain, puts high demands on hydraulic hoses. All the hydraulic hoses have crimped couplings and should therefore be purchased ready-made from Atlas Copco. Hose dimensions and qualities are specified in the spare parts lists for the relevant drill rig.

Hydraulic workshops Workshops used for the repair r epair of hydraulic components must: • Be separate separate from from activities activities which which generate generate dust dust and particles, particles, such as welding, welding, grinding, the transportation of vehicles, etc. • Have their their own own suitable suitable washing washing equipme equipment nt which which is required required for repairing repairing the components. • Have the the necessary necessary tools, tools, both both standard standard and special, special, and and that are only only used in the hydraulic workshop. • Have a ventilatio ventilation n system system that that does does not admit dust into the premises. premises. • Have Have wel well-t l-trai raine ned d mech mechan anics ics..

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Filter Return oil filter General The return oil filter cleans the oil before it is returned to the tank. There is a return oil filter on the drill rig. A return oil filter consists of a tube containing three filter inserts. The tubes are mounted inside the hydraulic oil reservoir. The filter inserts must be changed according to the maintenance schedule, but if the pressure gauge for the return filter indicates “filter clogged” (the red zone on the scale), all the return oil filters must be changed immediately.

4 8 7 7 1 0 0 5 2 1

40

60

20 80 0

Figure: Pressure gauge for return filter with symbol Note

The filter cartridges cannot be cleaned but must be replaced when they are clogged.

Changing the return oil filter The filter inserts can be dismantled by removing the cover and lifting them up.

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1. Clean on and around the filter cap and unscrew the nuts (A). A B E

D 4 6 7 9 0 0 0 5 2 1

C

Figure: Changing filter 2. Lift off the cap (B) and change the O-ring (C) if it is damaged. 3. Lift up the whole filter canister by the handle. 4. Detach the overflow valve (E) by pressing down and turning the handle anticlockwise. 5. Take out the filter cartridges (D) and replace with new ones. 6. Refit the overflow valve and filter canister and screw on the cap.

Breather filter General There is a breather filter (A) fitted on the hydraulic oil reservoir. The purpose of the breather filter is to equalise the pressure differences in the tank that would otherwise arise when the level in the tank changes if, for example, a jack is lowered.

70


A

5 6 7 9 0 0 0 5 2 1

Figure: Breather filter The breather filter must be replaced as set forth in the maintenance s chedule and also if it is severely fouled. Note

If the breather filter becomes covered in oil it will be ruined. This can happen if the tank is overfilled. The filter must then be changed.

Changing the breather filter 1. Wash clean on and around the filter (A). A

5 6 7 9 0 0 0 5 2 1

Figure: Breather filter 2. Unscrew the old filter. 3. Fit a new filter. 4. Tighten the filter by hand.

71


Condensation in the hydraulic oil reservoir Water in the hydraulic oil can seriously damage components in the hydraulic system and cause corrosion. Before draining the hydraulic oil tank, the system must stand unused for approx. 12 hours so that any condensation has had time to sink to the bottom of the tank. The water can then be drained off through the ball valve on the bottom of the tank.

A 0 0 8 9 0 0 0 5 2 1

Figure: Ball valve underneath hydraulic oil tank

Draining condensation from the hydraulic oil tank 1. Underneath the hydraulic oil tank is a ball valve. On the ball valve there is a plug. Remove the plug. 2. Place a receptacle under the ball valve. 3. Open the ball valve and allow the water to run out. 4. Close the valve when the water has been replaced with oil. 5. Screw back the plug to protect the valve.

72

Maintenance instructions 5. Feeder

5. Feeder 6000-series

6 3 7 1 1 0 0 5 2 1

Figure: BMH 6000

Assembling the rock drill Preparation Preparatory measures: Clean the feeder free from rust inhibitor.

Assembly 1. Remove burrs, paint or other coatings from the cradle and the contact surfaces on the rock drill. 2. Remove the mounting bolts from the cradle.

73


3. Position the rock drill with any shims on the cradle and refit the bolts. Make sure the rock drill fits firmly in place. 4. Tighten the rock drill into place. Tighten the bolts (four pcs.) alternately until a torque of 200 Nm (20 kgf m) has been attained. 5. Connect and fit the hoses to the rock drill. 6. Adjust slide rails and hoses according to the directions in this instruction manual.

Check after four hours 1. Check and tighten all bolted joints. 2. Check and adjust the tension of the ropes. 3. Check all hoses for leaks. 4. Tighten and adjust the tension of the hoses if necessary. 5. Check and adjust the slide rail alignment on the feed beam.

74


Haul and return ropes Locations B C

D

A

E

1250 0102 99

Figure: Locations A B C D E

Adjustment for haul rope Adjustment for return rope Scraper plate Haul rope tensioner Holder for intermediate drill-steel support

Replacing the haul rope 1. Run the rock drill to about half its length of travel. 2. Slacken the tension on the ropes, bolt A and nut B. 3. Detach the pull rope from its front attachment on the rock drill cradle. 4. Remove the scraper plate C from the intermediate drill-steel support. 5. Loosen the intermediate drill-steel support holder E so that the intermediate drillsteel support can be lifted. 6. Remove the rope from the rope tensioner D in the rear part of the beam. Note

Make sure the new rope is fitted in the same hole as the old one.

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7. Fit the new rope and bolt the scraper plate back on. 8. Adjust the ropes as described below.

Adjusting haul and return ropes 1. The haul rope is adjusted with bolt A and the return rope with nut B. 2. The cradle's position on the feed beam should be adjusted when it is in its rear position and when the drill steel with bit is fitted on the rock drill. 3. Adjust the ropes so that the bit is behind the spike.

3 8 3 3 1 0 0 5 2 1

350mm

Figure: Adjustment measurement M1

Tension of return rope 1. Place a plank between the rock drill cradle and the intermediate drill-steel support. 2. Run the cradle forward until it stops against the plank. Keep the feed force applied. 3. Tension the return rope so there is no risk of it jumping out of the cable drum. Do not tension the cable too tightly. There should be a couple of centimetre's of slack remaining when the cable is correctly tensioned.

Adjusting the cradle on the feed beam The cradle plates for the rock drill, the intermediate drill-steel support and the hose drum are guided along the feed beam with the help of holder A. Each pair of holders is locked in position with bolts B. The bolt holes in the holders have been made as angled grooves. By offsetting the holders longitudinally, the cradle can be adjusted on the feed beam. Make sure the holders are turned as shown in the figure so that the outer part of the angled grooves is turned to the back of the beam. Make sure the feeder is horizontal and that the drill steel is threaded onto the rock drill.

76


D A C

B 1250 0064 90

Figure: Adjusting the cradle holders 1. Remove the bolts B securing the holders. 2. Start by adjusting the upper holders so the cradle is lying straight on the beam and is 5 - 7 mm above the beam. In this way, the rock drill adapter will be at the c orrect height.

1250 0064 91

Figure: Adjustment measurement 3. Then shift the lower holders lengthways until a clearance of 1 mm has been attained between the lower holder and feed beam. 4. Tighten the bolts B. 5. Check by running the cradle along the entire beam. The pressure required to run the cradle forwards should be max 30 bar with the hydraulic oil at operating tem perature. If the pressure exceeds 30 bar, this means that the holders are too tight and must be readjusted. 6. Replace damaged hoses and tighten leaking connections. The hoses are correctly adjusted when they do not hang down when the feeder is in the horizontal position.

77


Replacing the slide pieces in the holder Each holder has replaceable slide pieces. The slide piece C is kept in place by three keys D. The slide pieces must be replaced at regular intervals so that the steel in the holder does not wear against the beam. Replace if there is less than 1 mm of wear allowance on the slide piece. It is a good idea to replace all the slide pieces at the same time, even if some of them are slightly thicker.

D A C

B 1250 0064 90

Figure: Replacing slide pieces 1. Prise off the slide pieces C from the holder using a screwdriver and remove the keys D. 2. Slide new slide pieces into the holder track and fit new keys. 3. Make sure the holders are refitted correctly in the cradle and are adjusted according to the directions.

Replacing slide rails Slide rails should be replaced if they are worn or severely scratched.

A

1 1 0 2 0 0 0 5 2 1

Figure: Replacing slide rails

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1. Remove the cradle for the rock drill, intermediate drill-steel support and the hose drum from the beam. 2. Remove the old slide rails A by prising the lower edges of the bars outwards using a screwdriver. 3. Clean the beam surfaces thoroughly. 4. Fit the new slide rails. The larger edge on the slide rail must be facing upwards. The rails should be pressed in place by hand. 5. Refit the rock drill cradles, intermediate drill-steel support and water-hose drum. Adjust the holders on the cradles as described in the instructions. Note

Always replace the slide pieces when replacing slide rails!

Feed cylinder Dismantling the feed cylinder

WARNING

• Hazardous hydraulic oil and water pressure • Risk of personal injury • Ensure that the system is depressurised before work • Never replace high-pressure hoses with hoses of lower quality than the original or with hoses with detachable couplings 1. Run the rock drill cradle to about half the feeder length. 2. Relieve the tension on the haul and return ropes, bolt A and nut B. 3. Remove the hose drum by undoing the 4 bolts in the centre of it and lifting off the entire drum. 4. Detach the hoses at the hose retainer.

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5. Undo bolts C and D on cradle plates E and F.

C E B

SP

G

D

H

N

F A

K L

M

I

1250 0020 87

Figure: Dismantling the feed cylinder. 6. Remove bolt A completely. Remove also end piece G and the end plate H. 7. The cylinder and fork can now be pulled backwards out of the beam. 8. If necessary, dismantle the fork I by knocking away the pin K. Note

Avoid dismantling the spacer L. If it must be dismantled, measure SP first so that the spacer can be refitted in the same position. Measurement SP = 492 mm

Tension bushings for spacers Description The spacer at the front end of the cylinder is kept in place with a tension bushing. In order for the feed to function properly, the measurement SP on the spacer must be correct. The measurement varies depending on the feed length and type of feed.

80


0 3 5 6 0 0 0 5 2 1

Figure: Spacer and tension bushing

Dismantling 1. Remove the plastic plugs M from their holes. 2. Unscrew the bolts N from the bushing. 3. Fit the bolts into the threaded holes and pull them alternately until the bushing parts.

Assembly 1. Assemble the bushing as illustrated but do not tighten the bolts. 2. Fit the spacer and bushing into the sleeve and make measurement SP is the same as before. 3. Tighten the bolts N alternately until a torque of 38 Nm (3.8 kgf m) is attained.

Long-term storage 1. Clean the feeder thoroughly. 2. Lubricate as directed, see maintenance schedule Feed. 3. Protect unpainted surfaces with rust inhibitor. 4. Store the feeder in a dry and clean environment.

81

Maintenance instructions 6. Dust collector (DCT)

6. Dust collector (DCT) Dust collector (DCT) A

B

1 2 5 0 0 1 3 5 8 9

Figure: Dust collector (DCT). •

Ignition key in position IGNITION.

Drilling button in DRILLING position. Button (30) on ri ght control panel. Note

A timer starts as soon as drilling is terminated by activating DCT, button (7) on left control panel. • Set the dust collector button to “On”. Make sure flushing air is in position “Reduced flushing air”. Activate the flushing air with the drill lever by moving it max to the left. Terminate the function by pressing the rocker switch on the drill lever. - The LEDs on the air valves (A, B and C) flash at intervals. • Measure the pulse duration of one of the air valves (A, B or C). Adjust the time to 0.5 seconds in the DCT menu. • Measure the time between the pulse by air valve (A) and air valve (B). Adjust the pause time to 3 seconds in menu DCT. • Number of After Clean Pulses - All indicator flash at the same time. Count the number of pulses. Factory setting is 4 - 6 pulsed during the cleaning time.

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• Cease drilling with the rocker switch on the drill lever, all the indicator diodes on the cleaning valve will flash at the same time. Note

See setting for DCT, Maintenance instructions; drilling system.

Setting the dust collector (DCT) C1 S456 S457 S458 S459

S456 S457 S458 S459

C4 C2 C5 C3

C1

S456

S457

S458

S459

C4

C2

C5C3

A1

B1

15

t2

K542 t 1

16

18

A 2

2489.9870

Figure: A1 electric cabinet •

Ignition key in position IGNITION.

Switch Tramming/Drilling in position DRILLING. Note

Duration is counted as soon as switch Dust collector and flushing air is in position FULL FLUSHING AIR/DUST COLLECTOR ON.

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• Set switch Dust collector and flushing air in position FULL FLUSHING AIR/ DUST COLLECTOR ON.

Preset times •

Pulse time S457: 02-03 seconds

•

Pause time S458: 5 seconds

•

Propagation time S459: 50 seconds

Setting the times To increase the times: Hold in S456 and press the respective button. (S457 for pulse time, S458 for pause time, S459 for propagation time) To decrease the times: Press the respective button. (S457 for pulse time, S458 for pause time, S459 for propagation time) Check the times: Hold in button S456 so that PLC/X37 comes on and the times are checked.

Filter test, dust collector (DCT)

a

9 0 6 1 1 0 0 5 2 1

Figure: Measuring points for dust collector filter. For checking filters in dust collector. Unscrew plugs (a) and apply a differential pressure gauge to the two holes.

84


Measure the pressure drop while air flushing is activated. If the drop is greater than an 800 mm (wg) column of water, all the filters should be changed.

Dust collector (DCT) filter change The dust collector filters are located in the dust collector. Open the hatch (a) and change all the filters. Use a ring spanner to unscrew the filters. Screw the nuts on the bottom of the filters anticlockwise.

a

1 4 6 1 1 0 0 5 2 1

b Figure: Dust collector

85

Maintenance instructions 7. Radiator

7. Radiator Environmental issues when handling coolant ENVIRONMENTAL DIRECTIONS

• Think of the environment! • Chemicals, e.g. flushing additives, other additives and coolants, can be environmentally hazardous. • Treat in accordance with local regulations in force for both handling and waste disposal.

Coolant WARNING

• Danger of scalding and pressure • Can cause serious personal injury • Release the pressure in the radiator before removing the radiator cap

CAUTION

• Danger of serious equipment damage • Mixing coolant can seriously damage the equipment

N.B. See separate instruction manual for details of diesel engine maintenance.

86

Maintenance instructions 7. Radiator

N.B. The cooling system is protected ex works from freezing at temperatures down to -30 C. °

N.B. The cooling system is factory-filled with Caterpillar coolant EL205

1. Loosen the radiator cap (1) to the stop position, release the pressure in the cooling system and only then remove the cap. 2

1

1 4 7 1 1 0 0 5 2 1

Figure: Radiator 2. Check the coolant level (2, see illustration: Radiator). Note

The level should be 1 cm under the filler cap. 3. Top up as necessary. Note

Never mix coolants! Only use CAT ELC205. Note

Apart from elements for engine coolant the radiator also has elements for cooling hydraulic oil, compressor oil and intercooler air.

87

Maintenance instructions 8. Diesel engine

8. Diesel engine Safety WARNING

• • • •

Danger of rotating parts Hot engine and components Can cause serious personal injury Maintenance work on the drill rig must only be carried out when the engine is switched off

Environmental issues when handling oil ENVIRONMENTAL DIRECTIONS

• Think of the environment! • Leaking hydraulic connections and lubrication grease are environmentally hazardous. • Changing oils, replacing hydraulic hoses and different types of filter can be environmentally hazardous. • Always collect oil residue, oil spillage, waste with oil content, and lubrication grease residue and spillage. Treat in accordance with local regulations in force. • Use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products wherever possible. Contact your local Atlas Copco office for further information.

88


Oil for diesel engine N.B. See also the separate instruction manual for the diesel engine, for details of diesel engine maintenance.

N.B. Top up if the oil level is below or level with the lower mark. (Refer to the engine maintenance manual for oil specifications.)

1. Check that the oil level is between the upper and lower marks on the dipstick (10). 4

9 5 7

5 7 3 8 1 0

3

0 5 2 1

2

10

6 8

1

Figure: Diesel engine 2. Top up (8) if the oil level is below or level with the lower mark. (Refer to the diesel engine's maintenance manual for oil specifications.)

89


Maintenance of components Air filter, service interval The air filters comprise filter housing, a main cartridge and a safety cartridge. The main cartridge can be cleaned and reused up to three times if service is performed correctly. The safety cartridge, however, must never be cleaned and reused and must be changed at least once for every four times the main cartridge is serviced. The intervals specified in the maintenance schedule for changing and cleaning the main air filter cartridge are given only as guidelines. The actual interval can vary between different workplaces and applications. Working in extremely dusty conditions may require shorter change intervals. In order to indicate when a main cartridge requires changing or cleaning, there is a service indicator mounted on each air filter housing. Both indicators are connected to a warning lamp (H207) on the engine VDO panel in the cab.

90


H180

P352

H207 H211

H212 H214

H213

H215

H203

H382

H381 7 1 7 7 1 0

R354

0 5 2 1

Figure: Warning lamp for clogged air filter The filter cartridges, therefore, do not require service until the indicators warn otherwise. The cartridges should, however, be checked for damage to the filter material at the specified intervals. Table: Example Hours

0

250

500

750

1000

Main cartridge service

New

Changing

Changing

Changing

Changi ng

Safety cartridge service

New

Changi ng

Cleaning or changing air filter Note

Never clean the filter cartridges. The safety cartridge must not be cleaned and reused.

91


When a drain valve is damaged, change it. If the warning symbol for clogged air filter remains visible, the safety cartridge must also be replaced. 1. Undo clamps (1) and remove the cover (2). 1 2 3

4

4 1 6 2 0 0 0 5 2 1

1

Figure: Air filter 2. Remove the main cartridge (3). 3. Clean inside the filter housing and lid with a clean, dry rag. Note

NOTE! If the safety cartridge has also been removed for changing, the filter housing air outlet must be completely covered with adhesive tape before cleaning the filter housing. 4. Check that the evacuation valve (4) is not damaged. Change it if necessary. 5. Remove any adhesive tape there may be on filter housing air outlet. 6. Install a new safety cartridge and a new main cartridge. 7. Refit the cover and fasten the clamps.

Cleaning the main cartridge The filter cartridges are easily damaged. Cleaning can damage the filter material and sealing surfaces, reducing service life or causing engine and compressor breakdown. Note

Never run the engine without the air filters in place.

92


Never clean filters by tapping them or tapping them against the ground. This can damage the sealing surfaces and deform the filter cartridge. Never clean filters in water or cleaning agent. Never use a damaged filter cartridge! For further information, see the diesel engine's maintenance manual.

Checking air filter switches

6 5 2 6 2 0 0 0 5 2 1

Figure: Air filter switch. To ensure filter clogging is detected, the function of the filter switches (6) must be checked regularly. This is done by gradually blocking the air intakes, one at a time. The filter switches should trip and the filter warning light come on. If the lamp does not light, start by checking the cable connections. If there are no problems with the connections, the switch is faulty and must be changed.

Fuel system Filter There are two fuel filter for the diesel engine. The engine's diesel filter and a prefilter. The prefilter has a loose insert that must be cleaned once a month. Change the filter insert if it is damaged. The diesel engine fine filter must be changed and not cleaned:

93


Prefilter 4

9 5

7

5 7 3 8 1 0

3

0 5 2 1

2

10

6 8

1

Figure: Diesel filter Draining

• Drain the water from the prefilter container (3) daily by closing the fuel cock (9) and opening the drain cock adjacent to the filter. Changing fuel filter:

• Remove the filter bowl (3) and clean it with pure diesel fuel. • Remove the fuel filter (3) and clean the sealing surface on the base of the filter. Make sure all the remnants of the gasket have been removed. • Apply pure diesel oil to the new fuel filter gasket. • Screw on the new fuel filter on the base of the filter until the gasket makes contact with the filter base. Use the twist marks to aid tightening. Tighten the filter a further three quarters of a turn by hand. Do not tighten the filter too hard. • Screw the clean filter bowl (3) back in place.

94


Fine filter 1. Close the fuel cock (1). 4

9 5

7

5 7 3 8 1 0

3

0 5 2 1

2

10

6 8

1

Figure: Fuel filter. 2. Loosen the fuel filter (2) using a suitable tool and unscrew it. 3. Collect any residual fuel.

Figure: Changing fuel filter 4. Clean the filter holder sealing surface. 5. Oil the rubber seal of the new fuel filter sparingly.

95


6. Screw in the filter by hand until the gasket is home.

Figure: Changing fuel filter 7. Tighten the filter an additional half turn. 8. Open the fuel cock. 9. Check that the fuel filter does not leak.

Environmental issues when handling fuel ENVIRONMENTAL DIRECTIONS

• Think of the environment! • Fuel spillage is environmentally hazardous and a fire risk. • Always collect fuel residue and spillage. Treat in accordance with local regulations in force.

Draining the fuel tank Always fill the fuel tank with clean diesel oil and fuel of the correct grade for the temperature. 1. Undo the front protective plate on the underside of the drill rig. 2. Undo the bottom plug by holding the nut with a 22 mm ring spanner and unscrewing with an 8 mm Allen key. Allow the water to drain. 3. Use track oscillation to tilt the drill rig so that the tank drains completely. 4. Tighten the plug so the diesel oil cannot leak out.

96


Belts Belts The belts for the diesel engine must be replaced if necessary.

1 4 3 6 8 1 0 0 5 2 1

2 3

1 2 3

V-belt - generator. V-belt - air conditioning. V-belt - water pump.

Tension gauge Check the belt tension with a tension gauge.

97


1. Press down the arm (1) in the gauge.

Figure: Belt gauge 2. Place the guide (3) on the belt (2) between the two belt pulleys, making sure the stop fits laterally. 3. Press the button (4) at right angles to the belt (2) so that the spring can be felt or heard to release. 4. Carefully lift up the gauge without changing the position of arm (1). 5. Read off the value at the intersection (arrow) of the scale (5) and the arm (1). 6. Readjust the tension if necessary.

Changing the generator belt Change belts only when the engine is stationary. 1. Remove the belt cover

98


2. Undo the nut for the generator mounting.(1) 2 1

3

1 2 5 0 0 0 0 1 9 3

Figure: Generator. 3. Relieve the tension of the belts by screwing the upper adjuster arm nut away from the stop (2). 4. Loosen and pull out the four bolts in the shaft coupling until there is some clearance (4).

5

5

4

Figure: Undo the bolts.

99


5. Change belts by inserting them through the clearance between the coupling rubber and the shaft flange. 6. Screw back the coupling rubber and tighten the bolts (185Nm). 7. Tension the belts by screwing the top adjuster arm nut towards the stop (2). 8. Once the belts are sufficiently taut (use the tension gauge), the adjuster arm must be locked by screwing the lower adjuster arm nut against the stop (3). 9. Tighten the nut for the generator bracket (1). 10. Refit the belt cover.

For further instructions, see separate instructions for the diesel engine.

100

Maintenance instructions 9. Oil and fuel

9. Oil and fuel Environmental issues when handling fuel ENVIRONMENTAL DIRECTIONS

• Think of the environment! • Fuel spillage is environmentally hazardous and a health risk. • Always collect fuel residue and spillage. Treat in accordance with local regulations in force.

Filling fuel Turn off the engine before topping up the fuel. Do not handle fuel in the vicinity of hot surfaces, sparks or naked flames.

a

9 8 6 3 1 0 0 5 2 1

Figure: Filling fuel (a) Location of fuel filler orifice.

101


Environmental considerations when handling oil ENVIRONMENTAL DIRECTIONS

• Think of the environment! • Leaking hydraulic connections and lubrication grease are environmentally hazardous. • Changing oils, replacing hydraulic hoses and different types of filter can be environmentally hazardous. • Always collect oil residue, oil spillage, waste with oil content, and lubrication grease residue and spillage. Treat in accordance with local regulations in force. • Always use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products wherever possible. Contact your local Atlas Copco office for further information.

Compressor oil WARNING

• • • •

Danger of rotating parts Hot engine and components Can cause serious personal injury Maintenance work on the drill rig must only be carried out when the engine is not running

See also compressor instruction manual for details of compressor maintenance. The compressor oil level can be read in the sight glass on the front of the air receiver.

102


2 1

4 0 8 0 1 0 0 5 2 1

Figure: Compressor tank 1. Make sure the needle (1) is in the green zone.

3

1 5 9 0 1 0 0 5 2 1

Figure: Air Bleed 2. Depressurise the system by opening the extra air outlet (3). 3. Top up (2) if necessary. Unscrew the filler plug when filling (see table “Recommendations for hydraulic oil and lubricants”). Note

Make sure the drill rig is standing horizontally before the check. This must always be done when checking fluid levels in the drill rig.

103


Oil sampling An oil sample gives a good indication of how well the hydraulic system has been maintained.

Filling up with hydraulic oil Filling manually CAUTION

• Protect your eyes from hydraulic oil • Use protective goggles 1. Check the return oil filter. 2. Make sure all the couplings and hoses normally filled with oil are clean. 3. Pump manually with the hand pump (3) 4. The hydraulic oil level can be read in the sight glass on the front of the hydraulic oil tank. The lower sight glass (1) should be full and the upper sight glass (2) should be half full.

2

1

4 3 5

9 6 9 0 1 0 0 5 2 1

Figure: Hydraulic oil reservoir Note

Do not fill too much hydraulic oil as it can clog the breather filter.

104


Changing hydraulic oil General The hydraulic oil need not be changed as long as filter changes have been carried out as directed and oil cooling has been working satisfactorily. If oil samples show signs of oxidation or high water content, however, the oil must be changed.

Draining 1. Underneath the hydraulic oil tank is a ball valve (A). On the ball valve there is a plug. Remove the plug.

A 0 0 8 9 0 0 0 5 2 1

Figure: Ball valve underneath hydraulic oil tank 2. Screw a hose to the ball valve and place the other end of the hose into an empty oil drum. 3. Drain the oil from the tank by opening the ball valve. 4. Close the ball valve once the oil has stopped running out of the hose. 5. Unscrew the hose. 6. Screw back the plug to protect the ball valve.

Lubricating oil The lubricating oil tank is mounted on the dust collector.

105


N.B. If the lubricating system oil is drained completely the system will have to be bled. So make sure that the reservoir is never emptied more than three-quarters, i.e. that it is always at least one-quarter full.

1. Make sure the level is always above the 2nd sight glass from the bottom. 2. Top up (1) as necessary (see table “Recommended hydraulic oil and lubricants”).

1

1 0 1 1 1 0 0 5 2 1

Figure: Lubricating oil tank

a

2 9 5 1 1 0 0 5 2 1

b Figure: ECG/ECL Pump for thread lubrication (a) (ECG) Pump for lubricating rock drill (b) (ECL)

106

9852 1979 01 Maintenance Instructions R

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