Maintenance Instructions PowerROC T35,T30 and T25

At A t l as Cop Co p c o PowerROC Series Mainteance Instructions

PMI No.9852 3070 01 Reviced 2012-08

© Copyrigh t 2012 2012,, Atlas Copco Copco KK All product names in this publication are trademarks of Atlas Copco. Any unauthorized use or copying of the contents or any part thereof is prohibited. Illustrations and photos may show equipment with optional extras. No warranty is made regarding specifications or otherwise. Specifications and equipment are subject to change without notice. Consult your Atlas Copco Customer Center for specific information.

Translation ranslation of original instructions.

At las Cop co Roc k K K Yoko hama, Japan

Table bl e of Conte Cont ents nt s 1

General General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 Target group and objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3 Contact Contact details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.4 Signs for outsourced components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.5 Dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.6 Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.7 Tightening Tightening torque torque in in bolted bolted joints joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.8 Welding Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.8.1 Points Points to be observed observed when when welding welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.8.2 Electrode Electrode recommendat recommendations ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.8.3 Fault finding finding.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.9 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.9.1 Charging Charging the battery. battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.9.2 Proceed Proceed as follows follows (24V charger) charger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.9.3 Proceed Proceed as follows follows (12V charger) charger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.10Starting with an auxiliary batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.11Steel cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.11.1Scrapping 1.11.1 Scrapping guidelines for steel cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.11.2Wire 1.11.2 Wire break at cable attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.11.3Occurrence 1.11.3 Occurrence of strand breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.11.4Concentrations 1.11.4 Concentrations of wire breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.11.5Effects 1.11.5 Effects of heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.11.6Occurrence 1.11.6 Occurrence of wire breaks due to operating time. . . . . . . . . . . . . . . . . . . . . . . . . 22 1.11.7Reduced 1.11.7 Reduced elasticity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.11.8Decrease 1.11.8 Decrease in cable diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.12Certain number and type of wire breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1.12.1Corrosion 1.12.1 Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1.12.2Surface 1.12.2 Surface wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1.12.3Deformation 1.12.3 Deformation of the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1.12.4Wire 1.12.4 Wire displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.12.5Strand 1.12.5 Strand displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.12.6Waviness 1.12.6 Waviness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.12.7Cracks 1.12.7 Cracks.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.12.8Kinks 1.12.8 Kinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.12.9Flattening 1.12.9 Flattening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.12.10Local cable diameter decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.12.11Local cable diameter increase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.12.12Basket formation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Maintenance Maintenance Checks Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2.1 Service Service Intervals Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2.2 Preventive maintenance summary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.3 Preventive maintenance summary 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2.4 Accumulator Accumulator charge charge pressure pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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2.5 2.6 2.7 2.8

Service Service (Maintenance) (Maintenance) Intervals Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lubrication Items parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 . 36 Servic Servicee Items Items parts parts list . . . . . . . . . . . . . . . . . . . . . . . . 37 Fluid Fluid Capacit Capacities ies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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Chang Changing ing Hydrau Hydraulic lic Retu Return rn Filte Filterr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.1 Changing Changing Hydrauli Hydraulicc Suction Suction Strainer Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 3.2 Filter Locatio Location n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 3.3 Changing Changing Air Cleaner Cleaner Filter Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 3.4 Checking Air Filter Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3.5 Changing Changing fuel fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 3.5.1 3.5.1 Draining Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3.5.2 3.5.2 Changing Changing fuel fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3.6 Changing Changing Engine Engine Oil filter filter and Compressor Compressor Oil filter filter . . . . . . . . . . . . . . . . . . . . . . . . . . 46 3.6.1 3.6.1 Engine Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 3.6.2 3.6.2 Compressor Compressor oil oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 3.7 Changing Changing Air Receiver Receiver Separato Separatorr Element Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3.7.1 3.7.1 Clean Scaveng Scavenger er Line on on Receiver Receiver Separator. Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3.8 Changing DCT Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.8.1 3.8.1 Replacing Replacing the filter filter cartridges. cartridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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Servic Servicee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.1 Routine Routine Service Service Checks Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.2 Lubricator Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.3 Diesel Fuel Fuel Level Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4.4 Diesel Fuel Fuel Water Separato Separatorr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 4.5 Engine Engine Oil Level Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 4.6 Engine Engine Coolant Coolant Level Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 4.7 Battery Water Level Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 4.8 Hydraulic Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 4.9 Separator Separator Tank Oil Level Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 4.10Dust Collector Water Drains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 4.11Water Mist Tank Solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 4.11.1Loose 4.11.1 Loose or Frayed Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 4.11.2Loose 4.11.2 Loose Nuts and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 4.11.3Drill 4.11.3 Drill Steel, Striking Bar, and Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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Fluids Fluids and Lubrica Lubricants. nts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 5.1 Compressor Compressor Oil Oil (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 5.2 Engine Engine Oil (EO) (EO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 5.3 Hydraulic Hydraulic Oil (HO) (HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 5.4 Rock Drill Oil (RDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 5.5 Final Drive Drive Oil (FDO). (FDO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.6 Drill Steel Lubricant (DSL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.7 Water Mist Mist Solution. Solution. (WM) (WM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.8 Grease (GR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.9 Torque Torque specification specificationss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.10Pipe thread fittings and O-ring fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 5.11Pipe thread fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 5.12O-ring fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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5.13JIC Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 5.14Hose fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 5.15Operational Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.15.1Ambient 5.15.1 Ambient Temperature Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.15.2Ground 5.15.2 Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.15.3Maximum 5.15.3 Maximum allowable slope angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.15.4Operating 5.15.4 Operating Conditions for stability.. stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.16Drill Rig Limits of Stability/grade ability Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 5.17Noise and Vibration exposure limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 5.17.1Seating 5.17.1 Seating face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 5.17.2Seat 5.17.2 Seat Back Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 6

Feed wire wire tension tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 6.1 Assembling Assembling the the rock drill drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 6.1.1 Preparation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 6.1.2 Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 6.2 Replacing Replacing the return return wire wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 6.3 Adjusting pull and return wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 6.3.1 Tension Tension of pull pull wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 6.3.2 Adjusting Adjusting the the cradle on the feed beam beam.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 6.3.3 Replacing Replacing the slide slide pieces pieces in the holder. holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 6.3.4 Replacing Replacing slide slide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 6.4 Feed cylinder cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 6.4.1 Dismantling Dismantling the the feed cylinder cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 6.5 Tension bushings for spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 6.5.1 Description Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 6.5.2 Dismantling Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 6.5.3 Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 6.5.4 Long-term Long-term storage storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7

Adjustment Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 7.1 Lubricator Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 7.2 Track Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 7.3 Main Relief Valve Adjustment. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 7.4 Feed Pressure Pressure Adjustmen Adjustmentt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 7.5 Rotation Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 7.6 Damper Flow Flow Adjustmen Adjustmentt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 7.7 Minimum Percussion Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 7.8 Rig Parameter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 7.9 Super Rotation Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 7.10Feed Flow Divider Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 7.11Cop Logic Control Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 7.12Feed Pressure Control Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 7.13Air Pressure Regulator Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 7.14Engine Belts Tension and Torque of Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 7.15DCT adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 7.16Emergency Stop Cable Installation/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 7.17Right hand side toe hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8

Transport Transport Instructi Instruction on.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5

8.1 Operating Operating instructio instruction n of the drill drill rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 8.2 Emergency Emergency Stop Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 8.3 Hoisting Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 . 112 8.3.1 8.3.1 Weight Weight chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 8.4 Lifting Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 . 113 8.5 Positionin Positioning g Hydraulic Hydraulic Cylinder Cylinder Control Control Valves Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 8.6 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 8.7 Towing Towing (Track final final drive disengag disengagement). ement). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6

1 General

1 General 1.1 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 startingwork 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 s pecified in the spare parts catalogue. Ensure also that all hose connections are clean, undamaged and securely tightened.

1.2 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 necessary 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.

7

1 General

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

Country

8

Adress

Phone & Fax

Argentina

Juncal 2869B1640GRE MartinezBuenos Aires

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

Australia

P O Box 6134Delivery CentreBlacktown NSW 2148

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

Austria

Postfach 108A-1111 Vienna

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

Bolivia

P.O. Box 290Santa Cruz de la Sierra

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

Bulgaria

14, Vasil Levski Str., fl. 2North Industrial AreaKazichaneSofia 1532

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

Canada

200 Mumford RoadWalden Industrial ParkLively, Ontario P3Y 1L2

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

Chile

Panamericana Norte 5001 ConchaliSantiago,Chile6553935 Conchali

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

China 1

No. 1, Heng Da RoadNanjing Economic & Technological Development ZoneNanjingPostal code 210038

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

China 2

S-105 23 Stockholm

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

Colombia

A.A. 95310Santafé de Bogotá, D.C.

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

Czech Republic

Prumyslova 10Praha 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 MarketCairo

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

Finland

Tuupakankuja 1SF-01740 Vantaa

Phone: +358 - (0)9 - 296 64 42 Fax: +358 - (0)9 - 29 64 21 8

France

B.P. 67181FR-95056 CergyPontoise Cedex

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

Germany

Postfach 10 02 25D-46002 Essen

Phone: + 49 - (0)201 - 217 70 Fax: + 49 - (0)201 - 217 74 54

Ghana

P O B 10071Accra North

Phone: +233 - 21 77 45 12 Fax: +233 - 21 77 61 47

1 General

Country

Adress

Phone & Fax

Great Britain

P O Box 79Hemel HempsteadHerts HP2 7HA

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

Great Britain

P O Box 79Hemel HempsteadHerts 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 1516Shatin Central Post OfficeNew Territories

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

India

SveanagarBombay Pune RoadDapodiPune 411 012

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

India

SveanagarBombay Pune RoadDapodiPune 411 012

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

Indonesia

P O Box 7021/JKS CCEJakarta 12075

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

Iran

PO Box 13145-1311Tehran 1345654551

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

Ireland

Kylemore RoadBluebellDublin 12

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

Italy

Casella Postale 77IT-20092 CiniselloBalsamo MI

Phone: + 39 - (0)2 - 61 79 91Fax: +39 (0)2 - 66 01 32 99

Japan

Sumitomo Fudosan Shipa Bldg 4 llF13-4 Shiba 2-chomeMinato-ku Tokyo 105-0014

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

Kazakhsta n

Kurmangaliev Str 8A050010 ALMATY

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

Kenya

PO Box 400 90Nairobi

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

Korea

C-P.O. Box 8354Seoul

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

Malaysia

26 Jalan Anggerik Mokara 31/ 47Kota Kemuning, Seksyen 3140460 Shah AlamSelangor Darul Ehsan

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

Mexico

Apartado Postal Box 104TlalnepantlaEdo. De Mexico

Phone: +52 - 5 - 626 06 00 Fax: +52 - 5 - 565 62 6

Morocco

P O Box 13 84420 300 Casablanca

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

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 3

9

1 General

Country

10

Adress

Phone & Fax

Norway

P O Box 334N-1401 Ski

Phone: + 47 - 64 - 86 03 00 Fax: + 47 - 64 - 86 03 3

Peru

Apartado 662Lima 100

Phone: + 47 - 64 - 86 03 00 Fax: + 47 - 64 - 86 03 30

Philippines

P.O. Box 13731200 Makati City

Phone: +63 - (0)2 - 823 8178-80 Fax: +63 - (0)2 - 823 84 59

Poland

(Sales) ul. Katowicka 32P-40-173 Katowice(Service) ul.Krzywa 3,59100 Polkowice

SalesPhone: + 48 - (0)32 - 209 5774

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 14127015 Moscow

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

Saudi Arabia

P O Box 7330Jeddah 21462

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

Singapore

Jurong PointP O Box 438Singapore 639456

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

South Africa

P O Box 14110Witfield 1467

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

Spain

Apartado 24E-28820 CosladaMadrid

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

Switzerlan d

Büetigenstrasse 80CH-2557 Studen/Biel

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

Taiwan

P O Box 14-45, ChungliTao Yuen Hsien

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

Thailand

125 Moo 9, Wellgrow Industrial Estate, Bangna-Trad KM.36, Bangwua Bangpakong, Chachoengsao 24180

Phone: +66(038)562900 Fax: +66(038)562906

Turkey

Istasyon Arkasi81700 TuzlaIstanbul

Phone: +90 - (0)216 - 581 05 81 Fax: +90 - (0)216 - 581 05 82

Ukraine

9, Moskovskiy AvenueBuilding 304073 Kiev

Phone: + 380 - (0)44 499 18 70 Fax: + 380 - (0)44 499 18 77

USA

PO Box 1159Commerce City CO 80022

Phone: +1 - 303 - 287 88 22 Fax: + 1 - 303 - 217 28 39

Venezuela

Apartado 76111Caracas 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

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

1 General

Country

Adress

Phone & Fax

Zambia

P O Box 11291Chingola

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

Zimbabwe

P.O. Box CY 935Causeway

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

1.4 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.

1.5 Dismantling and assembly CAUTION • Exercise extreme caution when slinging and hoisti ng heavy objects • Can cause personal injury. • Hoisting must take place at the centre of gravityOnly use slings whi ch 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 •

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

11

1 General

•

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.

1.6 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:

12

•

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

1 General

1.7 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.

Size

Strength class

Torqu e in Nm.

Tolerance ±

M6

8.8

8

2

M8

8.8

20

5

M10

8.8

41

10

M12

8.8

73

18

M14

8.8

115

25

M16

8.8

185

45

M20

8.8

355

85

M24

8.8

600

150

M12x1.25

10.9

135

6

M16x1.25

10.9

315

15

M18x1.25

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

Table 1 : Atlas Copco standard torques

13

1 General

1.8 Welding Note It is important to consult Atlas Copco for approval of welding and choice of electrodes

1.8.1

Points to be observed when welding •

Disconnect the cables from the generator, the battery and the engine's electronic module (A).

A

Figure 1 QSB 6.7 Tier3 Engine

14

•

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.

1 General

1.8.2

•

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 the equivalent in accordance with the standard below: Table 2 Electrode recommendations

1.8.3

ISO

2560 E51 5B 120 20 H

SS

14 3211 H10

DIN 1913

E51 55 B10

AWS

A/SFA 5.1E 7018

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.

15

1 General

1.9 Battery 1.9.1

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. 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:

16

•

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.

1 General

•

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.

17

1 General

1.9.2

Proceed as follows (24V charger) Before charging 1. Inactivate battery disconnected switch. 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 ch arg in g 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. 4. Connect the cable between chassis earth and the negative terminal on G1B. 5. Activate battery disconnected switch.

1.9.3

Proceed as follows (12V charger) Before charging 1. Turn off the battery disconnected switch. 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.

18

1 General

After ch arg in g 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 disconnected switch. Repeat steps 3 - 8 on G1B.

19

1 General

1.10 Starting with an auxili ary batteries 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: 1 Check that the auxiliary starting batteries (1) have the same voltage as the batteries on the chassis.

Figure 2 Starting assistance 1

Auxiliary batteries

2

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.

20

1 General

1.11 Steel cables 1.11.1 Scrapping gu idelines fo r 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

•

Certain number and type of wire breaks

•

Corrosion

•

Surface wear

•

Deformation of the cable

•

Permanent elongation of the cable

1.11.2 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.

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

1.11.4 Concentrations o f 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 individualstrand, 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.

21

1 General

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

1.11.6 Occurrence of wire breaks du e 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 foreseeable time point for scrapping.

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

1.11.8 Decrease in cable diameter Decrease in cable diameter through material fatigue in the ca ble can have the following causes:

22

•

Inner surface wear and surface wear nicks Inner surface wear through friction between the strands and wires in the cable

•

Fatigue of plastic core

1 General

•

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.

23

1 General

1.12 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 Number of load-bearing wires in the outer strand

Number of visible wire breaks 2 that require 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

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.

1.12.1 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 com bination 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.

24

1 General

At any sign of corrosion, the cable should be checked by an authorised person. If inner corrosion is detected, the cable must be scrapped.

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

1.12.3 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

25

1 General

1.12.4 Wire disp lacement 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 3

Example of wire displacement

1.12.5 Strand di splacement 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.

1.12.6 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 4 : Waviness

26

1 General

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

Figure 5

: Cracks

1.12.8 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 6 Kinks

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

Figure 7 Flattening

27

1 General

1.12.10Local 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 i t can be difficult to detect cable diameter decrease at these spots. Cables with severe cable diameter decrease must be scrapped.

Figure 8 Local cable diameter decrease

1.12.11Local 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. Cables with severe cable diameter increase must be scrapped.

Figure 9 Local cable diameter increase

1.12.12Basket 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 10 Basket formation

28

2 Maintenance Checks

2 Maintenance Checks Visually inspect the machine daily. Do not operate the machine with loose, worn, or broken parts.Inspect the machine and make any necessary adjustments and repairs before starting the machine. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and effect machine life. Make sure all safety devices, including shields are installed and functioning properly.If you do not understand any part of this manual and need assistance, contact your local Atlas Copco Surface Drilling Equipment dealer.

Hour meter

2.1 Service Intervals Use the hour meter as a guide when servicing the machine or rock drill. The hour meter indicates the total number of hours the machine or rock drill has been in operation. Maintenance intervals are based on normal operating conditions. When operating under severe condition, the maintenance intervals should be shortened.

WARNING • Before performing any service on the machine, make sure the machine is sh ut dow n, and the tracks are chocked to prevent movement.

29


2.2 Preventive maintenance summary 1

30


2.3 Preventive maintenance summary 2

31


Preventive maintenance summary 3

32


2.4 Accumulator charge pressure COP1840

COP1640

COP1240

Intake

70 bar

70 bar

70 bar

Damper

25 bar

25 bar

25 bar

Note

Use a high quality SAE 15W-15 heavy duty engine oil which meet API performance classification CH-4.Do no use API cd.API CE and API CG oils.API CF-4 oil is minimum acceptable oil classification for QSC engine mounted on this machine.In area where CH-4 oils are not available.API CF-4 oil drain interval is 250 hours or 3 monthes, whichever comes first

33


2.5 Service (M (Maintenance intenance)) Intervals ntervals MAINTENANCE INTERVAL (HOURS)

Every 10 Hours or Daily Daily Routi ne Service Service

TYPE OF SERVICE

SERVICE LUBRI POINTS CANT

Check view monitor and indicator lamps

CHECK (Warning Lights)

3

Check engine coolant level

CHECK (To level)

1

AF*

Check engine oil level

CHECK (Dipstick)

1

EO*

Check level in fuel strainer / sedimanter

CHECK (Drain / clean)

1

Check fuel level

CHECK (Tube)

1

Check hyd tank oil level

CHECK (Sight Glass)

1

HO*

Check compressor oil level

CHECK (Sight Glass)

1

CO*

Check rock drill oil level in lubrication and flow rate

CHECK (To level / 1 drop/10 sec)

1

RDO*

Check grease tank level

CHECK (To level)

1

GR*

Check air cleaner connections

CHECK (Rectify defects)

1

Drain off water from compressor air receiver tank

DRAIN (Hand)

1

Drain off water from drain plug of fuel tank

DRAIN (Hand)

1

Drain off water from fuel filter water separator

DRAIN (Hand)

1

Drain off water from DCT air filter

DRAIN (Hand)

1

Grease drill mounting guide rollers / hose tension sprockets LUBE (EP2)

4

GR*

Grease chain sprockets

LUBE (EP2)

2

GR*

Check functionality of emergency stops

CHECK

3

Check hoses and fittings showing wear or leaks

CHECK (Replace if defective)

-

Check attachement, tightning bolted joints

CHECK (Torque to spec)

-

Note * EP2 indicates "Extreme Pressure Multi purpose Grease NLGI Grade 2 MAINTENANCE INTERVAL (HOURS)

Every 50 Hours Hours or Weekly Routine Service

TYPE OF SERVICE


Check and clean up oil cooler fins

CHECK (CLEAN)

2

Check adjust track link tension

CHECK

2

GR*

Grease all grease fittings

LUBE * EP-2

36

GR*

Check torque on rock drill assembly bolts

CHECK (F-650Nm, RR -300Nm)

Drain off water from hyd tank

DRAIN (Hand)

1

Check drill feed chain tension

CHECK

1

Check hose reel travel chain tension

CHECK

1

Check clearance between mounting plate & guide

CHECK

2

2(F)+4(R)

MAINTENANCE INTERVAL (HOURS)

Every 250 250 Hours or Mont hly Routi ne Service

TYPE OF SERVICE


Replace hyd oil return filter

REPLACE

1

Check engine V-belt tension

CHECK

-

Check compressor belt tension

CHECK

-

Check adjustment, wear and cracks for drill steel support half CHECK (Centralizer) and RHS clamp tooth

6

Check rockdrill accumulator pressure

3

34

CHECK


Service (Maintenance) Intervals MAINTENANCE INTERVAL (HOURS)

Every 500 Hours

TYPE OF SERVICE


Replace engine oil

REPLACE

1

Replace engine oil filter

REPLACE

1

Replace fuel filter

REPLACE

1

Replace corrosion resistor

REPLACE

1

Replace compressor oil

REPLACE

1

Replace compressor oil filter

REPLACE

1

Replace engine and compressor air cleaner primary filter

REPLACE

2

Replace engine and compressor air cleaner safety filter

REPLACE

2

Replace, check engine coolant DCA level

CHECK (refer engine manual)

1

Check air conditioning filter

CHECK

3

Check and tightening engine mounting bolts CHECK Check cracks and wear of engine rubber coupling (Between CHECK engine and hyd pump) Check mounting and tightning for hyd pump CHECK


Every 1000 Hour Hour s

TYPE OF SERVICE

EO*

CO*

12 8


Replace hyd oil and clean hyd tank

REPLACE

1

Replace hyd suction strainer

REPLACE

1

Replace compressor air receiver tank element

REPLACE

1

Replace sedimenter / water separator

REPLACE

1

Clean scavenge line on compressor air receiver tank

CLEAN

1

Replace gear oil of tramming motor

REPLACE

2

FDO*

Replace gear oil of feed motor

REPLACE

1

FDO*

Check DCT skirt

CHECK

1

Check engine valve clearance

CHECK (refer engine Manual)

-


Every 2000 Hour Hour s

TYPE OF SERVICE

HO*


Replace battery

REPLACE

2

Replace fuel filter water separator

REPLACE

1

Replace DCT filter cartridge

REPLACE

10

Replace engine coolant

CHECK (refer engine Manual)

-

AF*

* Legend for abbreviation of lubricants : AF = Anti-Freeze, GR = Grease, CO = Compressor Compressor Oil, HO = Hydraulic Oil, EO = Engine Oil, RDO = Rock Drill Oil, FDO = Final Drive Oil

35


2.6 Lubrica Lubricatio tion n Ite Items ms pa parts rts list Rock drill oil (Light)

Rock drill oil (Medium)

Rock drill oil (Heavy)

Co n tai n er s i ze



1 Gallon

1 Gallon

1 Gallon

5 Gallon

5 Gallon

5 Gallon

55 Gallon

55 Gallon

55 Gallon

Hydraulic Hydraulic Oil Premium multi-viscosity (ISO46)

Compressor Oil Normal temp (-23 to +52 deg)



1 Gallon

36

5 Gallon

5 Gallon

PAROIL M

55 Gallon

55 Gallon

PAROIL M

Container size

Part No

4.2 gallon Pumpable

2653182143


2.7 Service Items parts list NAME OF PART ELEMENT, SAFETY (INNER ENGINE AIR FILTER)

T35

T30

T25

2653270682

2653207460

ENGINE AIR FILTER)

2653270682

2653207460

ELEMENT, PRIMARY (OUTER COMPRESSOR AIR FILTER)

2653207395

2653207395

ELEMENT, SAFETY (INNER COMPRESSOR AIR FILTER)

2653207387

2653207387

ELEMENT, SAFETY (INNER

Air filter in AIR CONDITIONER

2653252359

Air filter in Cabin back side

2653252367

FILTER, OIL (ENGINE OIL FILTER)

3222999091

2653231445

FILTER, FUEL (LOCATED ON ENGINE)

2653270542

2653231452

WATER SEPARATOR FUEL(LOCATED ON ENGINE)

2653270559

2657828816

ELEMENT, RETURN FILTER (HYDRAULIC RETURN FILTER)

2653096434

FILTER,SUCTION(HYDRAULI C SUCTION FILTER)

2653252433

ELEMENT ASSY (COMPRESSOR OIL FILTER)

1613610500

2636897353

ELEMENT, SEPARATOR (COMPRESSOR AIR / OIL SEPARATOR TANK)

1626016380

2622402325

ENGINE DRIVE BELT (AC COMPRESSOR)

2653090502

2653226908

ENGINE DRIVE BELT (ALTERNATOR & WATER PUMP)

2653286654

2653231437

CENTRALIZER HALF BUSHING(T38 /55DIA COUPLINDG)

2653110938

CENTRALIZER HALF BUSHING(T45 /63DIA COUPLINDG)

2653234779

2653158077

CARTRIDGE, FILTER (DUST COLLECTOR)

2653254470

2653254470

SEAL, FILTER (DUST COLLECTOR)

2651325272

2651325272

PROXMITY SWITCH

2653210001

PROXMITY SWITCH

2653126447

37


2.8

Fluid Capacities FLUID CAPACITIES

T35

T30

HYDRAULIC TANK* (Hydraulic Oil ISO Grade 46)

200 l / 53 gallons /

FUEL TANK (Diesel Fuel #ULSD)

380 l / 100 gallons

Diesel engile, cooling water

33 l 8.7 gallons

32 l 8.4 US gal

COMPRESSOR RECEIVER TANK (PAOIL M)

35 l /9.3 gallons

12 l / 3.2 gallons

TRAM MOTOR FINAL DRIVE (Gear Oil GL-5)

2.75 quarts

LUBRICATOR (Rock Drill Oil #100) ENGINE OIL (Engine Oil 15W40 CJ-4)

0.7 quarts 25 l / 6.6 gallons

10 l / 2.6 gallon

* Hydraulic tank volume does not include refilling the hydraulic lines on the machine.Other capacities are for complete refill. Maximum allowable air cleaner restriction = 25 in. H2O Maximum allowable hydraulic filter restriction = 21.3 psi

38

(while drilling with warm oil)

3 Changing Hydraulic Return Filter

3 Changing Hydraulic Return Filter The return oil filter cleans the oil before it is returned to the tank.

The filter inserts must be changed according to the maintenance schedule. Note The filter cartridges cannot be cleaned but must be replaced when they are clogged.

Changing t he return o il fi lter The filter inserts can be dismantled by removing the cover and lifting them up. 1. Clean on and around the filter cap and unscrew the bolts (A). 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 anti clockwise. 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.

39


3.1 Changing Hydraulic Suction Strainer

Take extra care when working around or on the Hydraulic system to ensure its com plete cleanliness. The filter inserts must be changed according to the maintenance schedule. 1) Position machine on stable, level surface and retract all Hydraulic cylinders. 2) Ensure container with capacity of at least 53 gallon (255 liter) is placed under drain point to collect used oil. 3) Open the drain valve 4) Allow all the oil to drain and close the drain. 5) Dispose of used oil in accordance with local guidelines. 6) Remove the cover plate to access the suction strainer. 7) Remove the suction strainer and clean the interior of the tank. 8) Reinstall the new suction strainer. 9) Replace the cover plate taking care not to allow contamination of the interior of the tank.

40


3.2 Filter Location Compressor Air Cleaner Filter

Engine Air Cleaner Filter

Fuel Filter Compressor Oil Filter Fuel Filter Water Separator

Engine Oil Filter Figure: PowerROC T35

41


3.3 Changing Air Cleaner Filter

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

If the warning symbol for clogged air filter remains vis ible, the safety cartridge must also be replaced. 1 Undo clamps (1) and remove the cover (2) 2 Remove the main cartridge (3). 3 Clean inside the filter housing and lid with a clean, dry rag. 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.

42

3 Changing Hydraulic Hydraulic Return Filter

3.4 Checking hecking Air Filte Filterr Indica Indicators tors Check Che ck ECM monito r

Indicators

To ensure filter clogging is detected, the function of the filter indicators must be checked regularly. This is done by gradually blocking the air intakes, one at a time. The filter indicators 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.

43


3.5 Chang hangin ing g fuel fuel filte fil ter r

Fuel filtr Water separator

Drain

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 clea ned once a month. Change the filter insert if it is damaged.The diesel engine fine filter must be changed and not cleaned:

3.5.1

Dr ai ai n i n g Drain the water from the prefilter container daily by closing the fuel cock and opening the drain cock adjacent to the filter.

3.5.2

Changi hanging ng fuel fuel filte filter r • Remove the filter bowl and clean it with pure diesel fuel. • Remove the fuel filter 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 back in place.

44


1 Clos Closee the the fuel fuel cock cock 2 Loosen Loosen the the fuel fuel filter filter usin using g a suitab suitable le tool tool and and unscre unscrew w it. 3 Coll Collec ectt any any res resid idua uall fuel fuel.. 4 Clean Clean the the filter filter holder holder sealing sealing surface surface.. 5 Oil the the rubber rubber seal seal of the the new new fuel fuel filter filter sparin sparingly gly.. 6 Screw Screw in the the filter filter by hand hand until until the the gasket gasket is is home. home. 7 Tight Tighten en the the filte filterr an additio additional nal half half turn. turn. 8 Open Open the the fue fuell coc cock. k. 9 Chec Check k that that the the fuel fuel filt filter er doe doess not not leak leak

45


3.6 Changing Engine Oil filter and Compressor Oil filter Figure: owerROC T35

Compressor Oil Filter Engine Oil Filter

3.6.1

Engine oil filter Replace the engine oil filter cartridge. Note Refer to the engine instruction book for specific requirements on preventive maintenance for the engine in this unit.

3.6.2

Compressor oil filter 1 Clean areas around compressor oil filter. 2 Place container under filter to collect any escaping oil during removal. 3 Unscrew used filter using wrenches. Discard used filter in accordance with local guidelines. 4 Clean sealing surface of dual filter head. 5 If necessary, replace O-rings of the filter head. 6 Fill new filter with clean compressor oil and lubricate O-ring seal with clean oil. 7 Install new filter as specified in the parts manual. Follow any instructions sup plied with the new filter. 8 After start-up, check machine for any leak at operating temperatures.

46


3.7 Changing Air Receiver Separator Element Scavenger

Figure:PowerROC T35

Replace the compressor oil separator element as follows ; 1) Remove the separator tank cover after disconnecting the scavenger hose and fittings. 2) Remove the ring of screws and lift out the cover complete with the old separator element. 3) Inspect the interior of the tank and if OK install the new element and gasket. Note Check that there is at least 5mm clearance between the end of scavenge dip tube and the bottom of the element. If not, shorten the tube by cutting the tube at an angle of 45 degree.

3.7.1

Clean Scavenger Line on Receiver Separator 1) Before reconnecting the scavenge hose to the dip tube fitting, ensure there is no restriction that would prevent scavenged oil from flowing to the air end port. Call for service assistance to check the scavenge line. Note

If this line is restricted the result will be excessive compressor oil carry-over into the discharge air

47


3.8 Changing DCT Filter 4 3 2

1

DCT filters

Inspect the condition of the filter cartridges every week by opening the inspection door attached to the outside of the body and replace the bag filter cartridges if necessary.Damaged cartridges may cause damage to the blower fan and the motor. Inspect the condition of the steel plate attached to the inlet port of the body and repair the plate by welding if necessary. A broken plate may cause shorter life of the filter cartridges. Check around the blower for oil leaks, abnormal vibration and noise. Check the suction hose for wear and crack

3.8.1

Replacing the filter cartridges 1 Open the hatch (1) 2 Remove the bolt and turn the lever (2) to vertical position. 3 Remove the bolts (3) and pull out the filter cartridges with bracket (4) from the body. 4 Remove the bolts and replace cartridges with a new one 5 Reassemble the components in reverse order of disassembly. Make sure the filter cartridges are sealed properly.

48

4 Service

4 Service If you are considering servicing the machine without the assistance of an Atlas Copco Surface Drilling Equipment Dealer, remember this is a complex machine which often involves complex service procedures. There are also many components which are not user serviceable. Do not attempt any service which you do not fully understand, nor any service that you cannot do accurately and safely with proper tools and equipment. If you encounter a problem that you do not understand or cannot solve, contact your Atlas Copco Surface Drilling Equipment dealer.

4.1 Routine Service Checks The operator will perform the following routine ser vice checks on the machine at the beginning of each day, his/her shift, or before any drilling operation. As described in the following paragraphs, the operator will perform these tasks to keep the machine in a good operating condition. The following paragraphs will explain what the operator is to check and the proper fluids to be added.

4.2 Lubricator Oil Level Every five hours of operation check the lubricator oil level. The oil level of the lubricator should be 1/2 inch (12.7mm) from the top of the glass bowl. When checking or adding, shutdown the machine and bleed the air pressure. To add rock drill oil to the lubricator, hold the metal guard and glass bowl, squeeze the locking tabs and twist the locking ring to remove. Fill the glass bowl to 1/2 in (12.7mm) below the top of the bowl. The lubricator takes approximately 3/4 quart (.7 L) of rock drill oil when empty. Refer to Section 8 for the proper type of rock drill oil to be used, and for the proper viscosity of rock drill oil to use during different weather conditions. (Refer to Section 8 for the proper viscosity and specifications to use during different weather conditions

49

4 Service

4.3 Diesel Fuel Level To check the diesel fuel level, turn the Key Switch to the RUN position and observe the indicator lamp on gauge panel. Add fuel as required. It is recommended to top off the diesel fuel tank at the end of each shift. This will help prevent condensation in the fuel tank. The fuel tank holds approximately 106 Gallons (400 L) when full

Low Fuel Indicator

Diesel Fuel Filler Cap

Diesel Fuel Drain

50

4 Service

4.4 Diesel Fuel Water Separator Shut off the engine. Drain the water and segmenter from the separator daily. Drain the filter sump until clear fuel is visible.

Water Drain

51

4 Service

4.5 Engine Oil Level When checking or adding oil to the engine, shutdown the machine. To check the engine oil level, remove the dipstick. Never operate the engine with the oil level below the “ADD” mark or above the “FULL” mark

Dipstick Oil Fill

Engine Oil Drain

52

4 Service

4.6 Engine Coolant Level CAUTION • Never check the engine coolant while the machine is running, or w hen hot. • To check or add antifreeze, remove the radiator cap and fil l to th e bottom of the fill er neck. refer to sectio n 5 for the proper antif reeze mixtur e to us e during different weather condit ions

Radiator Cap

Sight Glass

Engine Coolant Drain

53

4 Service

4.7 Battery Water Level WARNING • Never check the battery level with a flame, or while smoking. • Do not check the battery by placing a metal object across the battery posts. • D o not allow acid to come into contact with skin or clothing.

Remove the battery caps and check the electrolyte level. The electrolyte level must be 1/2 inch (12.7 mm) above the top of the plates. Add only distilled water as required

Batteries

54

4 Service

4.8 Hydraulic Oil Level WARNING • Do not start the engine unless the hydraulic tank is full of hydraulic oil. • Hydraulic pump damage will occur if operated without hydraulic oil

When checking the hydraullic oil level ,showdown the engine. Observe the sight glass on the side of hydraulic tank.

Low Hyd Oil Indicator

Hydraulic Oil Fill

Sight Glass

Hyd Oil Drain

55

4 Service

4.9 Separator Tank Oil Level WARNING • Shut down the engine before performing any maintenance on the compressor system. • Completly bleed down all pressure from the system.

Shut down the engine before performing any maintenance on the compressor system.completly bleed down all pressure from the system. when checking or adding the compressor oil shut down the engine.Obsereve the sight glass on the side of the separator tank .The compressor oil level should be a t he top mark.

Tank Fill Plug

Sight Glass

Figure;PowerROC T35

Compressor Oil Drain

To add compressor oil, remove the tank fill plug and add compressor oil until the oil level is at the top mark of the sight glass.

56

4 Service

4.10 Dust Collector Water Drains Open the water drain (as shown) to allow water to drain

Water Drain

57

4 Service

4.11 Water Mist Tank Solution WARNING • Shutdown the engine before performing any maintenance on the compressor system. • Completely bleed down all pressure from the system

WARNING • Opening the filler valve without shutting the machine down, or opening it wi thout bl eeding off the air pressure, can cause solution to s pray

. .

Filler Valve

Drain Valve

When checking or adding the water mist solution, shutdown the machine, and bleed down the air pressure. Slowly open the filler valve. The water mist tank holds approximately 40 Gallons (151 L) when full. When filling, do not overfill the water mist tank.

58

4 Service

4.11.1 Loose or Frayed Hoses It is necessary to do an overall check for loose or frayed hoses. A frayed hydraulic hose can instantly break open; spraying hot hydraulic fluid on a person; causing severe burns. Always replace a worn or damaged hose immediately.

4.11.2 Loose Nuts and Bolts It is necessary to do an overall check for loose nuts and bolts. All nuts and bolts must be kept properly tighten at all times.

4.11.3 Drill Steel, Striking Bar, and B its The bits, drill steel, and striking bar must be checked for wear, cracks, and damage. Any one of these problems should be corrected right away. The bits should also be checked for missing carbides. If the striking bar needs to be replaced, refer to the drifter instruction manual for proper replacement.

59

4 Service

60

5 Fluids and Lubricants

5 Fluids and Lubricants 5.1 Compressor Oil (CO) The compressor oil specified by Atlas Copco Surface Drilling Equipment for use in all PowerROC T Series compressor applications is PAROIL M shall be used. Refer to Table 7 for the proper compressor oil to be used during different weather conditions

5.2 Engine Oil (EO) Refer to the engine manual for the proper type of engine oil to use. Refer to Table 3 for the proper engine oil to be used during different weather conditions. Note Use a high quality SAE 15W-40 heavy duty engine oil, which meet API performance classification CH-4. Do not use API Cd, API CE and API CG oils.API CF-4 oil is minimum acceptable oil classification for QSB engine mounted on this machine.In area where CH-4 oils are not available, API CF-4 oil drain interval is 250 hours or 3 months, whichever comes first.

5.3 Hydraulic Oil (HO) The hydraulic oil used in the machine must be a premium high viscosity index hydraulic oil with rust and oxidation, and anti.foam additives. It must be also extremely shear stable. Refer to Table 6 for the proper hydraulic oil to be used during different weather conditions.

5.4 Rock Drill Oil (RDO) The rock drill oil used in the machine must be a well refined petroleum lubricating oil.It must be suitably compounded to provide the specified consistency and film strength and be further compounded to provide steam emulsion number. The latter is to provide a satisfactory lubricant for such drills where water or wet air is encountered. The rock drill oil must be substantially noncorrosive to steel, bronze, and contain little or no sulphur. It must also have a high viscosity index, and must conform

61


to the physical and chemical properties located in Table 9. Refer to Table 8 for the proper rock drill oil to be used during different weather conditions.

5.5 Final Drive Oil (FDO) The gear oil used in the machine must meet API classification GL.5 and MIL.21205C. Refer to Table 8 for the proper final drive oil to be used during different weather conditions.

5.6 Drill Steel Lubricant (DSL) The drill steel lubricant used must be lead free and pumpable.

5.7 Water Mist Solution. (WM) This Water Mist solution is a commercial detergent mixed with water. Several commercial detergent agents are available for use with the Water Mist Dust Control System. The following agent and mixture is recommended: Agent: Surfax 5107 Mixture: 1 gallon (3.79 liters) of detergent plus 9 gallons (34.1 liters) of water equals 10 gallons (37.9 L) of concentrated solution. Note

10 gallons (37.9 liters) of concentrated solution equals 320 cups. 1 cup of concentrated solution treats 20 gallons (75.7 liters) of fresh water. The final solution is; 2 cups of concentrated solution for every 40 gallons (151.4 liters) of fresh water.

5.8 Grease (GR) The recommended grease for all pressure gun grease fittings should be premium lithium or lithium complex grease with extreme pressure additives. It must have excellent water resistance and rust preventive properties. Refer to Table 5 for the proper grease to be used during different weather conditions.

62


Table 3

(EO) Engine Oil Visco sit y recommendati ons EMA LRG-1,API CH-4,API CG-4,API CF-4 15W-40

All season

10W-30 5W-40

Winter conditions

5W-30 0W-40

Arctic conditions

0W-30 0W-20

Temp Range

C F

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 104

40 104

50 122

30 104

40 104

50 122

Table 4

(AF) Ant i-freeze recommendatio ns Mobi le DTE 15M

All season

1-R Perform, 500 synthetic oil 5 gal

Arctic contusions Temp Range

C F

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

Note Note for use in this environment,follow the antifreeze manufactures’s recommendations.

63


Table 5

(GR) Grease recommendations NGLi GRADE2

Desert conditions NGLi GRADE1

Winter conditions

NGLi GRADE2 SYNTHETIC

Arctic conditions Temp Range

C F

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 104

40 104

50 122

Note Note: all greases must be lithimm extreme pressure grease Table 6

(HO) Hydraulic Oil Viscosity recommendations Mobile DTE16M

Desert conditions

Mobile DTE 15M

All season MOBIL DTE 13M

Winter conditions

1-R Perform, 500 synthetic oil 5 gal=35382936/55 GAL=35382944


C F

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 104

40 104

50 122

40 104

50 122

Table 7

(CO)Compressor oil viscosit y recommendations All season PAROIL M


64

C F

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 104


Table 8

(FDO) Final Drive oil viscosity recommendations SAE 80W-90 FOR API SERVICE GL5

All season

SAE 75W-90 SYNTHEIC


C F

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 104

40 104

50 122

65


Table 9 8.8 ty Rock 4.8 drill oil viscosi 10.9 9.8 recommendations Desert conditions

12.9 Heavy

All season

Medium

10 Light

5

Winter conditions Arctic conditions

Synthetic

Temp Range

C F

-40 -40

-30 -22

-20 -4

10

-10 14

0 32

12

10 50

20 68

30 104

40 104

50 122

Note: all greases must be lithimm extreme pressure grease

Note Note: all greases must be lithimm extreme pressure grease

Table 10 Test procedure

Below 20F (-7C)

20Fto90F (-7Cto32C)

Above90F (32C)

SUS at 100F(38C)

ASTM-D2161

175min

450min

750min

SUS at 210F(99C)

ASTM-D2161

46min

65min

85min

CST at 104F

ASTM-D445

37min

105min

160min

CST at 212F

ASTM-D445

6min

11min

16min

Pour point max

ASTM-D97

-10F (-23C)

-10F (-23C)

0F (-18C)

Pour point min

ASTM-D92

370F (188C)

400F (204C)

450F (232C)

Viscosity index min.

ASTM-D2270

90

90

90

Stream Emulsion No

ASTM-D1935-65

1200

1200

1200

Stringly

Stringly

Stringly

Char act is tic Viscosity:

Consistency Falex load test lbs(kg)(MIN)

ASTM-D2670

2,000lbs 907kg

2,000lbs 907kg

2,000lbs 907kg

Imken E.P. Test lbs(kg)(MIN)

ASTM-D2782

30lbs 14kg

30lbs 14kg

30lbs 14kg

Table 11 Rock Drill oil specifications

66


5.9 Torque specifications 1 or 2

Property class and Head Markings Property class and Nut Markings

5

5.1

5.2

5

2

8.2

8

8

Class 4.8

Class 8.8 or 9.8

Class 10.9

Class 12.9

Lubricated

Lubricated

Lubricated

Lubricated

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

M6

4

3

7.5

5.5

11

8

13

9.5

M8

10

7

18

13

25

18

30

22

M10

20

14

35

26

55

41

65

48

M12

35

26

65

48

95

70

110

81

M14

55

41

100

74

150

111

175

129

M16

85

63

180

118

235

173

275

203

M18

115

85

225

166

320

236

375

277

M20

165

122

320

236

455

366

535

395

M22

225

167

435

321

620

457

725

535

M24

285

210

555

409

790

583

925

682

M27

415

306

810

597

1155

852

1360

996

M30

585

417

1100

811

1570

1158

1835

1353

M33

770

568

1500

1106

2135

1575

2500

1844

M36

990

730

1925

1420

2740

2021

3205

2364

Table 12 SAE Torqu e Specifi cation s Do not use these values if a different torque value or ighting procedure is given for a specific application.Torque values listed are for general use only.Fasteners are selected based on load carrying requirements(Always replica fasteners with identical grade as specified.)Lubiiricated means coated with a lubricant such as engine oil,or fasteners with phosphate and oil coatings. Fasteners should be replaced with the same for tighter grade (if higher garee fasteners are su sed there's should only be tightened to the strength tothh thoriginal)make sure fasteners \therewd are clean and that you proplerly start thread engagment.this will prevent them from failoing when tighteing tighten toothed or serrated-type lock nuts to the full torque value.

67


SAE Grade and head Markings SAE Grade and head Markings Grade 1

Grade 2

Grade 5,5,1 or 5,2

Grade 8 or 8.2

Lubricated

Lubricated

Lubricated

Lubricated

size

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

1/4

3.5

2.5

5

4

8

6

12

8.5

5/16

7

5

10

7.5

16

12

24

18

3/8

12

8.5

19

14

30

22

41

30

7/16

19

14

30

22

47

35

68

50

1/2

24

21

47

35

75

55

102

75

9/16

41

30

68

50

108

80

149

110

5/8

54

40

88

65

149

110

203

150

3/4

102

75

163

120

258

190

366

270

7/8

163

120

163

120

414

305

590

435

1

244

180

244

180

624

420

861

650

1-11/8

346

255

348

255

780

575

1248

920

1-11/4

488

360

488

360

1098

810

1763

1300

1-3/8

637

470

637

470

1438

1061

2312

1705

1-1/2

848

625

848

625

1912

1410

3065

2260

Table 13 Metric bolt torque specifications Do not use these values if a different torque value or Tighteing procedure is given for a specific application.Torque values listed are for general use only.Fasteners are selected based on load carrying requirements(Always replica fasteners with identical grade as specified.)Lubiiricated means coated with a lubricant such as engine oil,or fasteners with phosphate and oil coatings. Fasteners should be replacement with the same for tighter grade (if higher garee fasteners are used these should only be tightened to the str ength make sure fasteners \therewd are clean and that you proplerly start thread engagment.this will prevent them from failoing when tighteing tighten toothed or serrated-type lock nuts to the full torque value.

68


5.10 Pipe thread fit tings and O-ring fit tings

5.11 Pipe thread fittings Make sure the threads and sealing surfaces are free from nicks,burrs,dirts,etc Tighten the fitting approximately 3 turns past finger tight.Using a thread sealant such as Loctite VVibraseal is recommeded over pipe dope or teflon tape.Teflon tape can plug filters,drain orifices,etc.and can cause hydraulic system failure.

69


5.12 O-ring fittings

Make sure the threads and sealing surfaces are free from nicks,burrs,dirts,etc Lubricate the0-ring with a light coat of hydraulic oil.Adjustable o-ring fittings;Hold fitting, and tighten nut.Non-adjustable o-ring fit tings:Tighten fitting.

Size

70

Thread

Torque

2

5/16”-24

7 - 8 foot pounds (10-11Nm)

3

3/8”-24


4

7/16”-20


5

1/2”-20


6

9/16”-18


8

3/4”-16


10

7/8”- 14


12

1 1/16”-12

98 - 102foot pounds (133-138Nm)

16

1 5/16”-12

146 - 154 foot pounds (198-209Nm)


5.13 JIC Fittings

Make sure the threads and sealing surfaces are free from nicks,burrs,dirts,etc Tighten the fitting finger tight. Then tighten the fitting an additional number of flats as the chart indicates.One flat equals 1/6 of a turn. Overtightening the fitting may deform or break the female side of the fitting. re-stricting oil flow or causing a leak.

Flats from fi nger tight Size

New fittings

Loose fittings

4(1/4)

2-2 1/2

3/4 - 1

6(3/8)

2-2 1/4

1

8(1/2)

1 1/2 - 1 3/4

1

10(5/8)

1 1/2 - 1 3/4

3/4

12(3/4)

1 1/2

3/4

14(7/8)

2

1 1/4

16(!)

1 1/4- 1 1/2

3/4 - 1

20(1 1/4)

1 1/2

3/4 - 1

24(1 1/2)

1 1/4- 1 1/2

1-1 1/4

32(2)

1 1/4

3/4 -1

71


5.14 Hose fittings

Make sure the threads and sealing surface are free from nicks,burrs,dirts,etc. Tighten the hose fitting finger tight. Then tighten the hose fitting with Torque value as the chart indicates. Overtightening the hose fitting may deform or break the female side of the hose fitting,restricting oil flow or causing a leak.

HOSE

72

THREAD TORQUE

SIZE

(UNIF)

(PF)

-04

7/16”-20

1/4

15 -22 foot pounds (20 - 30 Nm)

-06

9/16”-18

3/8

20 - 26 foot pounds (27 - 35 Nm)

-08

3/4”-16

1/2

50 - 55 foot pounds (66 - 74 Nm)

-12

1 1/16”-12

3/4

93 - 100 foot pounds (126 - 134 Nm)

-16

1 5/16”-12

1

125 - 140 foot pounds (170 - 190 Nm)

-20

1 5/8”-12

1-1/4

162 - 177 foot pounds (220 - 240 Nm)


5.15 Operational Limitations 5.15.1 Ambi ent Temperature Limi ts The PowerROC Series are designed for 50 degree C standard ambient temperature.

5.15.2 Ground Pressure The PowerROC Series is provided with tracked type undercarriage with design ground pressure of 10 psi (0.7 kg/cm2)

5.15.3 Maximum allowable slope angle The standard PowerROC Series has a 30 deg. slope grad ability. The reference to 30 deg. slope is theoretical limit and Atlas Copco Surface Drilling Equipment do not authorize use on slopes exceeding 20 deg. unless an appropriate Atlas Copco Surface Drilling Equipment approved winch installation is used to provide adequate stability (as required by Clause 5.15.3 of EN 791:1995).

5.15.4 Operating Conditions fo r stability. Stability is affected by the Drill Guide position and orientation of the machine on the slope, surface stability (bearing strength), and wind conditions. Refer to “Limits of Stability/Grad ability Chart” for further guidance.

73


5.16 Drill Rig Limits of Stabili ty/grade ability Chart Drill rig limits of stability g / Gadability chart

74

Boom & Guide Position:TrammingPosition Travel Direction:Down Hill (Down Grade)

Boom & Guide Position:TrammingPosition Travel Direction:Down Hill (Down Grade)

Boom & Guide Position:TrammingPosition Travel Direction:Down Hill(Down Grade) Permissible Slope Angle: Over 20(Using winch)

Boom & Guide Position:TrammingPosition Travel Direction:Down Hill(Down Grade) Permissible Slope Angle: Over 20(Using winch)

Boom & Guide Position:TrammingPosition Travel Direction:Down Hill(Down Grade)





WARNING • Maximum slope values are based uopn calculations incl ude approved options. • Actual values for maximum slope may vary, depending on familiarity with t he rig and considering smoothn ess of slope, operator skill and experience, wind speed, trammi ng sp eed and acceleration. • The values are STATIC values and are not int ended as a recomm endation fo r acceptable operation.

CAUTION • Operation on Grade angles above 20 deg must use a win ch for additi onal stabili ty(EN791 requir ement)

75


5.17 Noise and Vibration exposure limitations NOISE: Tests conducted in accordance with ISO 4872. T35

T30

T25

Left Ear

78.3 db(A)

82.0 db(A)

80.4 db(A)

Right Ear

80.1 db(A)

82.2 db(A)

81.5 db(A)

Location

T35

T30

T25

1

----

2

88

3

----

4

88

5

----

6

87

7

----

8

86

9

----

10

99

11

----

---90.3

91.3 ----

91.3

91.9 ----

86.6

86.6 ----

86.5

86.7 ----

92.0

91.6 ----

12

86.2

86.7

Note Location values correspond to microphone positions per iso4872.7.2.3, alternative B

SURFACE SOUND PRESSURE LEVEL CALUCULATED “A” WEIGHTED SOUND POWER LEVEL LWA (db)

T35

T30

T25

88.3 db(A).

90.5 db(A)

91.4 db(A)

120 db.

121 db.

121.3 db.

VIBRATION: Tests conducted in accordance with ISO2631.

The following is the geometric sum of the weighted overall values of vibration recorded for the three axis of the basicentric coordinate system.

76


5.17.1 Seating face T35

T30

T25

X

X=0.0146 (m/s2)

X=0.033 (m/s2)

X=0.039 (m/s2)

Y

Y=0.0076 (m/s2)

Y=0.065 (m/s2)

Y=0.051 (m/s2)

Z

Z=0.0226 (m/s2)

Z=0.067 (m/s2)

Z=0.078 (m/s2)

Vibration Vector Sum

0.032(m/s2)

0.123(m/s2)

0.119(m/s2)

5.17.2 Seat Back Rest T35

T30

T25

X

X=0.0068 (m/s2)

X=0.055 (m/s2)

X=0.054 (m/s2)

Y

Y=0.0054 (m/s2)

Y=0.020 (m/s2)

Y=0.017 (m/s2)

Z

Z=0.0402 (m/s2)

Z=0.228 (m/s2)

Z=0.357 (m/s2)

0.234(m/s2)

0.361(m/s2)

Vibration Vector Sum

77


78

6 Feed wire tension

6 Feed wire tension

Return wire

Pull wire

6.1 Assembling the rock drill A Adjustment for return wire B Adjustment for pull wire C Scraper plate D Return wire tensioner E Holder for intermediate drill-steel support

6.1.1

Preparation

Preparatory measures:Clean the feeder free from rust inhibitor.

79

6 Feed wire tension

6.1.2

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. 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. 7

Figure: Locations

Figure 11 Locations

A Adjustment for return wire B Adjustment for pull wire C Scraper plate D Return wire tensioner E Holder for intermediate drill-steel support 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

80

Check and adjust the slide rail alignment on the feed beam.

6 Feed wire tension

6.2 Replacing the return wire 1 Run the rock drill to about half its length of travel. 2 Slacken the tension on the wires, bolt A and nut B. 3 Detach the pull wire 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 drill steel support can be lifted. 6 Remove the wire from the wire 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.

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

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

91mm

81

6 Feed wire tension

6.3.1

Tension of pull wire 1 Place a plank between the rock drill cradle and the intermediate drill-steel sup port. 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.

6.3.2

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.

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 correct height

82

6 Feed wire tension

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.

6.3.3

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

83

6 Feed wire tension

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.

6.3.4

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

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. 5 The rails should be pressed in place by hand. Refit the rock drill cradles, intermediate drill-steel support and water-hose drum. 6 Adjust the holders on the cradles as described in the instructions. Note Always replace the slide pieces when replacing slide rails!

84

6 Feed wire tension

6.4 Feed cylinder 6.4.1

Dismantling the feed cylinder 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. 5 Undo bolts C and D on cradle plates E and F

6 6. Remove bolt A completely. Remove also end piece G and the end plate H. 7 7. The cylinder and fork can now be pulled backwards out of the beam. 8 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 = 605mm

85

6 Feed wire tension

6.5 Tension bushings for spacers 6.5.1

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

6.5.2

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.

6.5.3

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 43Nm (4.3 kgf m) is attained.

86

6 Feed wire tension

6.5.4

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

87

6 Feed wire tension

88

7 Adjustment

7 Adjustment To ensure maximum life and performance of the machine, it is important that the adjustments be made, periodically checked, and readjusted when necessary.

7.1 Lubricator WARNING • Shut down the machine and relieve all in ternal air pressure before loosening or removin g the lubricator bowl.

Be sure that the lubricator is filled with rock drill oil.Remove the plastic cap, and turn the lubricator adjustment screw on the lubricator in a clock wise direction until the lubricator adjustment screw is completely closed. Observe the sight glass on top of the lubricator. You will see a hook inside the sight glass.Start the engine. Let the machine run for a few minutes.ly open the lubricator adjustment screw. Oil will build up on the end of the hook and will Slow form a drop.Make adjustments so there are 10 drops every minute, or one drops every six seconds.The shank of the striking bar should stay oily.Frequently check the lubrication setting of the lubricator during drilling operations. The flow of oil is affected by changes in ambient temperature, and pressure. Readjust the lubricator as required.Adjust the rock drill air regulator to read 43.5psi (3.0 bar) while the drifter is drilling.

Rock drill Air Regulator Adjustment Knob

Lubricator Adjustment

Sight Glass

89

7 Adjustment

7.2 Track Chain Tension The proper tension must be maintained on the track chain so that it does not come off the idler or sprocket while traveling. Place a straight edge over the top of the track chain. Measure the sag; the sag should be no more than 1/2 in. (13mm). Use the following steps to tighten or loosen the track chain for the proper tension: a. Remove the inspection cover. b. To Tighten Track. Pump grease through the lubrication fitting (1) until the proper tension is reached. c. To Loosen Track. Loosen the lubrication fitting (1) on the track adjuster and allow the grease to run out. Do not remove this fitting. Once the proper tension is reached, tighten the lubrication fitting

90

7 Adjustment

7.3 Main Relief Valve Adjustment

7 8

1 6 5 4 3 2

Pressure check ports

T35

T30

T25

No.1 (LH Tramm./Percussion)

24MPa

24MPa

No.2 (RH Tramm./Percussion)

24MPa

24MPa

No.3 (DCT/RHS/Hyd. Cylinder)

19Mpa

21Mpa

No.4 (Over Drive Tramming)

17Mpa

17Mpa

No.5 (Rotation)

14Mpa

14Mpa

No.6 (Oil Cooler)

16Mpa

16Mpa

No.7 (Damper)

13Mpa

13Mpa

No.8 (Pilot Pressure)

3Mpa

3Mpa

Note Please don’t touch. Factory pre-set only.

91

7 Adjustment

7.4 Feed Pressure Adjustment This machine is equipped with remote controlled feed pressure adjusting system which adjusts the feed force according to the drilling conditions (hardness of the rock or ground stratum). The appropriate feed force will vary depending on the ease of penetration of the rock by the particular combination of drifter model and type of drill bit used. When drilling softer or broken ground, the feed hydraulic pressure required will be less than for drilling solid or harder ground. The rate of feed will tend to increase under these softer /broken ground conditions.

Feed Pressure Control

Feed Pressure Gauge

When actually drilling the feed force can be adjusted by adjusting the feed pressure control valve based on the pressures indicated below. . Vertical hole (downward) drilling........ 40-60 kg/cm 2 (4 - 6MPa.). . Horizontal hole drilling....................... 50-70 kg/cm 2 (5 - 7MPa.). Refer to the forward feed pressure gauge when adjusting the pressure. 1.Feed pressure gauge 2.Feed pressure control knob

92

7 Adjustment

7.5 Rotation Speed Adjustment The Rotation Speed Control will adjust the rotation speed of the drifter to accommodate different ground conditions. It is used only when the Rotation Control Lever is activated, and the Dust Collector/Rod Changer mode switch is in the Dust Collector mode. This adjustment becomes inoperative when the Dust Collector/Rod Changer mode switch is in the Rod Changer mode. Rotation Speed Control

Figure: Rotation control valve

Do not alter factory setti ng.

Rotation speed adjustment based on the drill bit size will result in longer bit life and more stable drilling. The rotation speed should be adjusted based on the values shown below Hole (Bit) size

76mm

89mm

102mm

150-170 rpm

130-150 rpm

110-130 rpm

100-120 rpm

Button Bit Recommended Rotation 130-150 rpm Speed Range (rpm)

110-130 rpm

90-110 rpm

80-100 rpm

Cross Bit Recommended Rotation Speed Range (rpm)

64mm

93

7 Adjustment

7.6 Damper Flow Adjustment

Figure: Damper flow valve for damper pressure. Do not alter factory setting.

Damper Gauge

Damper Flow Rate Priority Valve

Note Please don’t touch. Factory pre-set only. Rig with Cop logic system only

If it is read off the damper pressure gauge on the control panel, it should be 40-45 bar

94

7 Adjustment

7.7 Minimum Percussion Pressure Adjustment

Low (110 bar)

Middle (130 bar) Selector Switch in Cabin High (150 bar)

Contoroller in Relay Box

Setting Condition 1 During drilling, feed pressure below 3 MPa by feed remote control valve. 2

Select the switch (L, M, H).

3 Confirm the percussion pressure gauge at the swing arm control panel. 4 Set the NULL, ST1 or ST2. (CW: Increase, CCW: Decrease) Note Please don’t touch. Factory pre-set only. COP LOGIC model only

95

7 Adjustment

7.8 Rig Parameter Check

A B C

Rig with COP Logic system only

D

Atlas Copco Recommendations Rock Condition / Penetration rate (m/min) Hard/0.2-1.5

C B A

D

96

Impact pressure (Bar) Rotation pressure (Bar) Drill feed pressure (Bar) Dampening pressure (Bar)

Medium /1.5-2.5

T35

T30

T25

T35

T30

H igh

190 -210 *

19 0-20 0*

19 0-2 00*

1 70-1 90*

1 70-1 90*

Low

130/150*

120*

120*

130/150*

120*

Soft/ >2.5

T25

T35

1 70-1 90* 16 0-17 0 120*

T30

T25

1 70 -19 0* 15 0-17 0*

110/130

Full drilling

The rotation pressure is a result of the feed pressure.

Manual Adjustment

30 - 40

120*

120*

35

40

-

35

35

-

35

35

-

Full drilling

45-70

45-70

-

45-60

40-60

-

45-55

40-55

-

Collaring drilling

40-45

40-45

-

40-45

40-45

-

35-40

35-40

-

Idling

7 Adjustment

7.9 Super Rotation Valve Adjustment

Figure: Super rotation valve.

Super Rotation Flow Rate


97

7 Adjustment

7.10 Feed Flow Divider Valve Adjustment 1 2 3

Do not alter factory setting.

1 Feed speed flow rate adjustable 2

RHS forward feed speed flow rate adjustable for connecting coupling

3 RHS backward feed speed flow rate adjustable for disconnecting coupling 4 Max percussion pressure main relief (22Mpa) Note Please don’t touch. Factory pre-set only.

98

7 Adjustment

7.11 Cop Logic Control Valve Adjustment

Figure: Cop logic valve.


99

7 Adjustment

7.12 Feed Pressure Control Valve Adjustment

1 2

Figure: Feed Pressure valve


1 : Max Feed back brake pressure (21MPa) 2 : Max Feed Forward brake pressure (10.5MPa)

100

7 Adjustment

7.13 Air Pressure Regulator Valve Adjustment

Half Blow Adjustable Knob

Air Press Regulator

Figure 12 Sepalator tank


101

7 Adjustment

7.14 Engine Belts Tension and Torque of Bolts T35 3

1

2

Figure 13 QSB6.7 T30/T25

1

3

2

4

Figure 14 QSB4.5

1 Check both alternator and air conditioner belts for tension, wear, breaks, cracks or other damage. Replace belts if necessary. 2 Remove belt guard to check belt tension or replace belts. 3 9.5-12.7mm. deflection with 6kg. of thumb pressure on mid span position is recommended. 4 Ensure that the belt guard is replaced and secured.

102

7 Adjustment

Torque of bolts when the Engine belts replacement T35

T30

T25

1

12kgf-m (118N-m)

14 kgf-m (137N-m)

2

20.6kgf-m (202N-m)

14 kgf-m (137N-m)

3

20.6kgf-m (202N-m)

12 kgf-m (117N-m)

4

9 kgf-m (88 N-m)

7.15 DCT adjustment

ON Time

OFF Time

Power Switch

When the DC switch is turn On from the cab , power is supply to the timer card through Wire # 82 as shows above. There is a Power On/Off switch in this timer card, this switch is normally in On position all time and the PL light will light up. Machine deliver from factory is normally set with Off time 10 seconds. You can shorten this Off time interval if more regular purging is needed. On the Timer card you can see there is a COM wire and wire # 1, 2 and 3. This timer card will control the purging interval.

103

7 Adjustment

Explain: if Off time is set at 10 seconds meaning electrical supply is available to the wire # 1 , 2 and 3 separately. Therefore the solenoid valve will deliver purge air one at a time. Please note there is a 2 Amp fuse in this Timer Card.

7.16 Emergency Stop Cable Installation/Adjustment

1 Attach the stop to its rigid support. 2 Fix the cable supports, if any, on one or more rigid supports. A cable support is essential for cable lengths of more than 32 feet (10m). 3 Fix the spring to the last support. 4 Fix the end of the cable on the spring. 5 Pass the cable through the supports, if any. 6 Cut the cable to length at the button in order to obtain the length necessary for correct winding (1.5 turns minimum.) 7 Engage the cable on the tensioner. 8 Turn the adjustment nut to the center of the index. 9 Reset, release and repeat the operation.

104

(B.: Index. C.: Authorized Operating Zone)

7 Adjustment

10 Check the position of the index and re-center it if necessary. (d: Green. E.: Yellow) 11 To slacken the cable, push on the attachment ring with your finger and then loosen the nut until the required cable tension is obtained.

105

7 Adjustment

7.17 Right hand side toe hole Note This information on right hand side toe hole is only for PowerROC Series The following modification for the Dump Base is required when you drill for right hand side toe hole.Perform the modification according to the following instruction

1 Before attempting to change the Guide Swing Cylinder Pin in the Dump Base, first bring the drill guide into toe hole drilling position along the center-line of the machine so as to prevent the drill guide falling down while replacing the pin. (Figure 1) 3

Figure:1

7

2

4

6

5

Do not force the drill guide onto the ground. Too much forcing may cause difficulty of taking the pin out from the Dump Base. 2 Loosen the lock-screw for the lock-pin. And remove the lock-pin from the Mounting Pipe. 3 Insert the lock - pin to lock the Dump Base to the Dump Base to the Moving Pipe. 4 Loosen the lock - screw for the Guide Swing Cylinder Pin. 5 Remove the Guide Swing Cylinder Pin with an appropriate plastic hammer. 6 Extend the Piston Rod of the Guide Swing Cylinder. 7 Match the holes for the Dump Base and Guide Swing Cylinder. 8 Insert the pin to lock the Dump Base to the guide Swing Cylinder. 9 Put the rocker - pin to the Mounting Pipe.And lock it with the lock - screw.

106

8 Transport Instruction

8 Transport Instruction 8.1 Operating instruction of the drill rig 3

1

Figure: Engine control panel

2

5

4

1 Ignition Power Switch The Ignition Power Switch is used to provide electrical power to the machine. Removal of the key prevents unauthorized starting. Key Positions: First Position OFF ………. Off Second Position (CW) ACC …………. Accessories (Lights) Third Position (CW) IGN / ACC …. Accessories and Run 2 Engine Speed Control Switch The engine speed control switch has 3 positions: 1

Turn the engine speed control switch to the “L=Low ” position – the engine rpm will operate at low idle speed 1,200 rpm.

Note

When you start or stop the engine, be sure to set the engine speed control valve in position “ L=Low “. 2

3

Turn the engine speed control switch to “ H=High “ position when the engine will operate at high idle speed up to maximum 2,300 rpm Cold Weather Switch (Option)

107


The Cold Weather Switch is used to operate the cold start system. If it is difficult to start engine for extreme cold weather, continue to push down the switch to ON position, the baby compressor activated for load reduction of engine start. Hold down the switch and then shift the engine key to start. After engine start, release the switch for cold weather. 4 Horn The Horn Button activates the horn. 5 Drill Selection Function Control The Drill Selection Function is a three position switch commands the machine to operate in the TRAM MODE , START MODE , or DRILL MODE , (EX, The machine will only start in the START MODE, the machine will only drill in the DRILL MODE, the machine will only tram in the TRAM MODE.) Note This switch must be in START MODE When start the engine. The machine won’t start the switch in other position.

1 2

3 4

108


1

Tram Control ( L.H. )

2

Tram Contr ol ( R.H.)

The tramming control levers ( 1, 2 ) controls the L.H. Side track’s and the R.H. Side track’s direction, speed of travel, and service braking function. Use the following steps to property tram the machine: a．To tram forward - push the both control levers forward. b．To tram backward - pull the both control levers back. c．To make a right turn – move the L.H. side control to the forward and move the R.H. side control to the back d ．To make a left turn – move the R.H. side control to the forward and move the L.H. side control to the back.

3

Oscillation Lock Switch

（Left Hand Side） The Oscillation Lock Switch ( Left Hand ) is used to help stabilize t he machine when tramming or setting up to drill on rough terrain. Move the switch to the unlocked position and the right hand track can be raised or lowered using the Oscillation Control Lever. Move the switch to the locked position and the right hand track is locked in the selected position Note This should be in the unlocked position during tramming.

4

Oscillation Lock Switch

（Right Hand Side） The Oscillation Lock Switch ( Right Hand ) is used to help stabilize the machine when tramming or setting up to drill on rough terrain.

109


Move the switch to the unlocked position and the left hand track can be raised or lowered using the Oscillation Control Lever. Move the switch to the locked position and the left hand track is locked in the selected position. Note This should be in the unlocked position during tramming.

Note

Both oscillation ( left and right) switches must be open when tramming over uneven terrain to allow hydraulic interaction between oscillation cylinders which will help to maintain stability of the machine. Both switches must be closed when drilling to prevent the machine from tilting out of drilling position

110


8.2 Emergency Stop

1 2

3

1. Emergency st op but ton The emergency stop button is used to shut down the machine in an emergency situation. Push to stop will stop the machine completely.To release the emergency stop button after being pressed; turn the button clockwise to release the button from itsengaged position.

2. Safety wir e on f eeder This wire is a safety device used for operator protection. In the event of an emergency, pulling the wire will shutdown the machine completely. This is used to reset the switch, after is has been tripped.

3. Battery switch Press the battery switch to disconnect the battery from the wiri ng harness.This action will protect the electrical systems when carrying out maintenance operations in the engine compartment.To reconnect the battery it is necessary to reset the switch before the machine can be restarted. To reset turn the switch when the button will return to its active position. Note Confirm to reset the button of all devices before starting the engine.

111


8.3 Hoisting WARNING • When you lifting the drill rig, you have to use a lift hanger. • May cause serious personal injury and damage to property. • Do not approach a hanging load. • Only use lifting equipment and lifting straps with adequate lift ing capacity. • Lock the track oscillation cylinders before the drill r ig is raised.

Figure1 : PowerROC T35 Hoisting (Side View)

A

112

B


8.3.1

Weight chart Standard unit excluding all options and drill st eel (KG)

Boom type

T35

T30

T25

Single (Kg)

12,100

11,900

11,800

Extendable(KG)

12,500

12,300

8.4 Lifting Points 1. Loading machine by lifting equipment for transporting. 1 Always use appropriately rated chains or slings attached to the four (4) lift points marked with symbol. 2

Always use appropriately rated lifting tackle. Refer to the total weight indicated on the machine identification plate located on the machine (refer to INTRODUCTION to this manual).

3 Ensure appropriate lifting equipment is rated to the machine weight before lifting (Refer Operating Weight marked on machine serial number plate).

2.Securing machine to transporter (tie-down). 1 After loading machine to the transporter, ensure that all pivoting assemblies are locked positions and there are not unsecured items which could dislodge during transportation.

113


2 Shut down engine and remove ON/OFF switch key. 3 Chock the tracks. 4 Tie-down machine using a chain and tensioning device or other appropriate equipment to the five (5) tie-down points 1,2 and 3 marked with symbol. 5

The driver of the transport must be aware of its total weight load on the axles and overall dimensions of the machine.

1 1

2 3

114


8.5 Positioning Hydraulic Cylinder Control Valves Make sure the chassis is not damaged when you loaded in the transport/ hoisting position.Use the boom extend / lift / swing and guide dump / swing / extension controls to lever And, make a low position of the drill guide.Put the drill guide onto the support bracket .Run the rock drill to the centralizer side (front).Track oscillation cylinders to LOCKED position. Oscillation R / L switch to position ( b).

WARNING • 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 both track frame at points A ,B and C as shown in t he illustration hoisting

1

Boom Extension

2

Boom lift

3

Boom swing

4

Feed dump

5

Feed swing

6

Feed extention

7

Oscillation

115


8.6 Loading WARNING • May cause serious personal injury and damage to property • Lock the track oscillation cylinders before the drill r ig is raised • Transportation equipment must be adapted for the dimensions and weight of t he drill rig

When the PowerROC is carried to a transport vehicle, the maximum top part must be 3,900mm or less.

Please confirm with your local traffic low.

The drill rig is loaded onto the transport vehicle.

IGN Swit ch

OFF ACC IGN/ACC

1 Switch off the diesel engine. 2 Strap the rock drill securely to the vehicle. 3 Fix chains block to the lifting eyes on track frame of the machine and vehicle.

116


8.7 Towing (Track final drive disengagement) In case of emergency case only.

Cover plate & Two M8 bolts

＊ The track final drive must be disengaged when towing the dril l rig .

WARNING • Always chock tracks before releasing brakes • Danger of moving parts • May cause serious personal injury and damage to property

CAUTION • Never tow the machine faster than its rated speed • 2 MPH 3.2 KMH) as severe damage can occu r to the tram motor s as a result of o ver speeding

Procedure Remove the two bolts (M8) and the plate in the middle of the drive cover. Turn the plate over and reinstall using the same two bolts (M8). Tighten the bolts until the plate Is flush with the outer surface of the outer drive cover.

117


118

119

Maintenance Instructions PowerROC T35,T30 and T25

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