9852 1979 01 Maintenance Instructions R

8/18/2019 9852 1979 01 Maintenance Instructions R

1/107

PM No. 9852 1979 01

2007-08

Atlas Copco

ROC D5/D7/D9

Maintenance instructions


2/107

Atlas Copco Rock Drills ABSE-70191 Örebro, Sweden

SAFETY INSTRUCTIONS

Before starting, read all instructions carefully.

Special attention must be paidto information alongsidethis symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

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


3/107

Safety

3

Safety

Reference ................................................................................................................. 5


4/107

Safety

4


5/107

Safety

5

Reference

Note

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

maintenance work.

1250 0099 89


6/107

Safety

6


7/107


8/107


8

Changing air filter ............................................................................................. 32

Fault finding...................................................................................................... 33

No cooling.................................................................................................... 33

Poor cooling ................................................................................................. 33

Uneven cooling ............................................................................................ 33Abnormal noise ............................................................................................ 34

2. Transport instructions ............................................................................................. 35

Hoisting ................................................................................................................. 35

Single-section boom version............................................................................. 35

Folding boom version ....................................................................................... 37

Transport................................................................................................................ 39

Before loading the drill rig onto the transport vehicle. ..................................... 40

Once the drill rig is loaded onto the transport vehicle. ..................................... 40

Towing ................................................................................................................... 42

3. Drill system ............................................................................................................ 44

Adjusting the damper pressure .............................................................................. 44

Adjusting percussion pressure............................................................................... 45

General.............................................................................................................. 45

Low percussion pressure ...................................................................................47

High percussion pressure.................................................................................. 47

Adjusting drill feed pressure.................................................................................. 48

General.............................................................................................................. 48

Low drill feed pressure .....................................................................................49

High drill feed pressure..................................................................................... 50

Adjusting rotation speed........................................................................................ 52

Setting rotation speed........................................................................................ 54

RPC-F system ........................................................................................................ 54

Adjusting........................................................................................................... 54

Pressure regulator adjustment................................................................................ 57

Anti-jamming protection .......................................................................................57

Air flow monitor B142 ..................................................................................... 58

Adjusting air flow switch.................................................................................. 58

Rotation pressure switch B134 ......................................................................... 59

Adjusting activation pressure............................................................................ 61

Setting lubrication to the rock drill........................................................................ 62ECL collection....................................................................................................... 63

Locations........................................................................................................... 63

ECL collector pressure control valve................................................................63

Function ............................................................................................................64

4. Hydraulic systems .................................................................................................. 67

Environmental considerations when handling oil ................................................. 67

General...................................................................................................................67

Repairing hydraulic components........................................................................... 68

Replacement of hydraulic hoses............................................................................ 68

Hydraulic workshops ............................................................................................. 68


9/107


9

Filter ...................................................................................................................... 69

Return oil filter ................................................................................................. 69

General ......................................................................................................... 69

Changing the return oil filter........................................................................ 69

Breather filter .................................................................................................... 70General ......................................................................................................... 70

Changing the breather filter ......................................................................... 71

Condensation in the hydraulic oil reservoir...................................................... 72

Draining condensation from the hydraulic oil tank ..................................... 72

5. Feeder ..................................................................................................................... 73

6000-series............................................................................................................. 73

Assembling the rock drill ...................................................................................... 73

Preparation........................................................................................................ 73

Assembly .......................................................................................................... 73

Check after four hours........................................................................................... 74Haul and return ropes ............................................................................................ 75

Locations........................................................................................................... 75

Replacing the haul rope .................................................................................... 75

Adjusting haul and return ropes........................................................................ 76

Tension of return rope ........................................................................................... 76

Adjusting the cradle on the feed beam .................................................................. 76

Replacing the slide pieces in the holder ................................................................ 78

Replacing slide rails .............................................................................................. 78

Feed cylinder ......................................................................................................... 79

Dismantling the feed cylinder........................................................................... 79

Tension bushings for spacers ............................................................................ 80

Description ................................................................................................... 80

Dismantling.................................................................................................. 81

Assembly...................................................................................................... 81

Long-term storage............................................................................................. 81

6. Dust collector (DCT).............................................................................................. 82

Dust collector (DCT)............................................................................................. 82

Setting the dust collector (DCT)............................................................................ 83

Preset times ....................................................................................................... 84

Setting the times ............................................................................................... 84Filter test, dust collector (DCT)............................................................................. 84

Dust collector (DCT) filter change........................................................................ 85

7. Radiator .................................................................................................................. 86

Environmental issues when handling coolant ....................................................... 86

Coolant .................................................................................................................. 86

8. Diesel engine .......................................................................................................... 88

Safety..................................................................................................................... 88

Environmental issues when handling oil............................................................... 88

Oil for diesel engine .............................................................................................. 89


10/107


10

Maintenance of components.................................................................................. 90

Air filter, service interval.................................................................................. 90

Cleaning or changing air filter .......................................................................... 91

Cleaning the main cartridge ......................................................................... 92

Checking air filter switches.......................................................................... 93Fuel system ....................................................................................................... 93

Filter ............................................................................................................. 93

Prefilter......................................................................................................... 94

Fine filter ...................................................................................................... 95

Environmental issues when handling fuel ........................................................ 96

Draining the fuel tank ....................................................................................... 96

Belts .................................................................................................................. 97

Belts..............................................................................................................97

Tension gauge............................................................................................... 97

Changing the generator belt ......................................................................... 98

For further instructions, see separate instructions for the diesel engine......... 100

9. Oil and fuel ........................................................................................................... 101

Environmental issues when handling fuel ........................................................... 101

Filling fuel ........................................................................................................... 101

Environmental considerations when handling oil ............................................... 102

Compressor oil..................................................................................................... 102

Oil sampling ........................................................................................................ 104

Filling up with hydraulic oil ................................................................................ 104

Filling manually .............................................................................................. 104

Changing hydraulic oil ........................................................................................105

General............................................................................................................105

Draining ..........................................................................................................105

Lubricating oil ..................................................................................................... 105

For engine oil see section “Diesel engine”.......................................................... 107


11/107

Maintenance instructions1. General

11

1. General

General

Safety

When maintenance work is carried out on the rig, observe the following points:

• Never perform service or maintenance work while the rig is running

• To prevent personal injury during service and maintenance work, all components

that can be brought into motion or fall down must be thoroughly secured.

• Ensure that the hydraulic and pneumatic systems are depressurised before startingwork on them.

• All controls must be deactivated during service and maintenance.

• When changing hydraulic hoses, ensure they are replaced with hydraulic hoses fit-

ted with the correct crimp couplings of correct quality and dimension. All pressu-

rised hydraulic hoses have crimped couplings and should therefore be purchased

ready made from Atlas Copco. Quality classes and hose dimensions are specified

in the spare parts catalogue. Ensure also that all hose connections are clean,

undamaged and securely tightened.

Target group and objective

Note

This chapter (General) contains general recommendations for maintenance of the

drill rig and its peripheral equipment. This means that certain sections may not be

fully adapted to individual components.

The maintenance instructions are intended for mechanics and personnel in mainte-

nance 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 pre-

vented. 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 break-

down.


12/107


12

Contact details

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

Country Address Phone and fax number Argentina Juncal 2869

B1640GRE Martinez

Buenos Aires

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

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

Australia P O Box 6134

Delivery Centre

Blacktown NSW 2148

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

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

Austria Postfach 108

A-1111 Vienna

Phone: +43 - (0)1 -76 01 20

Fax: +43 - (0)1 - 769 56 72

Bolivia P.O. Box 290

Santa Cruz de la Sierra

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

Fax: +591 - 0(3) - 343 69 69Brazil P O Box 12737

Sao Paulo, SP

04744-970

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

Fax: +55 - (0)11 - 55242347

Bulgaria 14, Vasil Levski Str., fl. 2

North Industrial Area

Kazichane

Sofia 1532

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

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

Canada 200 Mumford Road

Walden Industrial Park

Lively, Ontario P3Y 1L2

Phone: +1 - 705 - 673 67 11

Fax: +1 - 705 - 692 31 01

Chile Panamericana Norte 5001 - Conchali

Santiago, Chile

6553935 Conchali

Phone: +56 - (0)2 - 442 3600

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

China 1 No. 1, Heng Da Road

Nanjing Economic & Technological

Development Zone

Nanjing

Postal code 210038

Phone: +86 - 25 - 85 75 76 00

Fax: +86 - 25 - 85 75 75 30

China 2 No. 12, Kun Ming Hu Street

Shenyang Economic & Technological

Development Zone

CN-Shenyang 110027

Phone: +86 - 24 - 25 81 17 19

Fax: +86 - 24 - 25 81 18 67

CMT

International

S-105 23 Stockholm Phone: +46 - (0)8 - 743 80 00

Fax: +46 - (0)8 - 702 21 29

Colombia A.A. 95310

Santafé de Bogotá, D.C.

Phone: +57 - 1 - 291 54 90

Fax: +57 - 1 - 430 6514

Czech Republic Prumyslova 10

Praha 10, Post Code 102 00

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

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

Egypt 520 El-Obour Market

Cairo

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

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


13/107


13

Finland Tuupakankuja 1

SF-01740 Vantaa

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

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

France B.P. 67181

FR-95056 Cergy-Pontoise Cedex

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

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

Germany Postfach 10 02 25

D-46002 Essen

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

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

Ghana P O B 10071

Accra North

Phone: +233 - 21 77 45 12

Fax: +233 - 21 77 61 47

Great Britain P O Box 79

Hemel Hempstead

Herts HP2 7HA

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

Fax: +44 - (0)1442 - 234467

Greece 93, Koropiou - Varis Avenue GR - 194 00

Koropi, Athens

Phone: +30 - (0)210 - 349 96 00

Fax: +30 - (0)1 - 345 47 83

Hong Kong P O Box 1516

Shatin Central Post Office

New Territories

Phone: +852 - 24 88 01 03

Fax: +852 - 24 88 98 63

India Sveanagar

Bombay Pune Road

Dapodi

Pune 411 012

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

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

Indonesia P O Box 7021/JKS CCE

Jakarta 12075

Phone: +62 - 780 10 08

Fax: +62 - 780 18 37

Iran PO Box 13145-1311

Tehran 1345654551

Phone: +98 - 21 - 669 377 11

Fax: +98 - 21 - 669 273 14

Ireland Kylemore Road

Bluebell

Dublin 12

Phone: +353 - (0)1 - 450 5978

Fax: +353 - (0)1 - 456 7686

Italy Casella Postale 77

IT-20092 Cinisello

Balsamo MI

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

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

Japan Sumitomo Fudosan Shipa Bldg 4 llF

13-4 Shiba 2-chome

Minato-ku Tokyo 105-0014

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

Fax: +81 - (0)3 - 57653199

Kazakhstan Kurmangaliev Str 8A

050010 ALMATY

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

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

Kenya PO Box 400 90

Nairobi

Phone: +254 - (0)20 - 660 50 00

Fax: +254 - (0)20 - 82 54 72

Korea C-P.O. Box 8354

Seoul

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

Fax: +82 - (0)2 - 522 82 39

Malaysia 26 Jalan Anggerik Mokara 31/47

Kota Kemuning, Seksyen 31

40460 Shah Alam

Selangor Darul Ehsan

Phone: +60 - (0)3 - 5123 88 88

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

Country Address Phone and fax number


14/107


14

Mexico Apartado Postal Box 104

Tlalnepantla

Edo. De Mexico

Phone: +52 - 5 - 626 06 00

Fax: +52 - 5 - 565 62 65

Morocco P O Box 13 844

20 300 Casablanca

Phone: +212 - 2 - 600 040

Fax: +212 - 2 - 60 05 22

Mongolia Building BP9, Tavan Erdene(MISHEEL)

Center, 2nd Khoroo, Khan Uul District,

Chinggis Avenue, Ulaanbaatar, Mongolia

Phone: +976 - (0)11 - 99 11 48 16

Fax: +976 - (0)11 - 11 31 26 13

Norway P O Box 334

N-1401 Ski

Phone: +47 - 64 - 86 03 00

Fax: +47 - 64 - 86 03 30

Peru Apartado 662

Lima 100

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

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

Philippines P.O. Box 1373

1200 Makati City

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

Fax: +63 - (0)2 - 823 84 59Poland (Sales) ul. Katowicka 32

P-40-173 Katowice

(Service) ul.Krzywa 3,

59-100 Polkowice

Sales

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

Fax: +48 -(0)32 - 209 5776

Service

Phone: +48 76 8474 935

Portugal Apartado 14P-2790-953 Carnaxide Phone: +351 - (0)1- 416 85 00

Fax: +351 - (0)1 - 418 0782 Service

Russia 27, Viatskaya Street, Building 14

127015 Moscow

Phone: +7 - 495 - 933 55 52

Fax: +7 - 495 - 933 55 58

Saudi Arabia P O Box 7330Jeddah 21462

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

Singapore Jurong Point

P O Box 438

Singapore 639456

Phone: +65 - 66 - 68 62 28 11

Fax: +65 - 66 - 68 63 60 98

South Africa P O Box 14110

Witfield 1467

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

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

Spain Apartado 24

E-28820 Coslada

Madrid

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

Fax: +34 - (9)1 - 627 9239

Sweden S-10523 Stockholm Phone: +46 - (0)8 - 743 92 30Fax: +46 - (0)8 - 743 92 46

Switzerland Büetigenstrasse 80

CH-2557 Studen/Biel

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

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

Taiwan P O Box 14-45, Chungli

Tao Yuen Hsien

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

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

Thailand 1696 New Petchburi Road

Bangkapi

Huay Kwang

Bangkok 10320

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

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



15/107


15

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 sepa-

rate document, MI (Machine Identification). Spare parts can always be ordered

through Atlas Copco.

Dismantling and assembly

Before transporting in shafts or the like it may be necessary to fully or partially dis-

mantle the drill rig. Observe the following when dismantling, lifting and assembling:

Turkey Istasyon Arkasi

81700 Tuzla

Istanbul

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

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

USA PO Box 1159

Commerce City CO 80022

Phone: +1 - 303 - 287 88 22

Fax: +1 - 303 - 217 2839

Venezuela Apartado 76111

Caracas 1071

Phone: +58 - (0)212 - 256 23 11

Fax: +58 -(0)212 - 257 18 10

Vietnam No. 42, Street 37, Thao Dien Ward, District 2,

Ho Chi Minh City

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

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

Zambia P O Box 11291

Chingola

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

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

Zimbabwe P.O. Box CY 935

Causeway

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

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

CAUTION

• Exercise extreme caution when slingingand hoisting heavy objects

• Can cause personal injury

• Hoisting must take place at the centre of

gravity• Only use slings which are intact and

designed for the load they shall carry

• Secure the slings in the lifting eyes,where available



16/107


16

• Before dismantling, hose the entire rig clean with water and/or detergent contain-

ing a grease solvent.

• Observe the strictest cleanliness when dismantling hydraulic, compressed air and

water flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes,

or seal and protect them from dirt in some other suitable way.• Mark hoses, pipes and other connections, where this has not already been done, to

make reassembly easier and prevent mix-ups.

• Use properly secured lifting tackle of generous dimensions.

Note

When the drill rig is scrapped, all materials that are harmful to the environment must

be disposed of in a manner prescribed by the authorities.

ScrappingWhen the entire drill rig or part of the rig is to be scrapped, local regulations in force

regarding handling, waste management, recycling and destruction must be followed.

Collect and dispose of:

• Rest oil and oil spill

• Oil waste such as filters

• Rest fuel and fuel spill

• Rest grease and grease spill

• Batteries• Discarded refrigerant, air conditioning

• Chemicals such as flushing additives, other additives and coolants.

• Metals, e.g. steel and aluminium (metals that are recyclable)

• Plastics and rubber (often marked in various classifications for recycling)

• Electrical components such as cables, electronics

Tightening torque in bolted joints.

All joints are tightened to the torque required by Atlas Copco Standard K 4369 unlessotherwise specifically stated. In such cases, this will be specified in the maintenance

instructions of the module in question.

Table: Atlas Copco Standard torques.

Size Strengthclass

Torque inNm.

Tolerance±

M6 8.8 8 2

M8 8.8 20 5

M10 8.8 41 10

M12 8.8 73 18


17/107


17

Welding

• Applies to drill rigs equipped with one of the following engines:

- CAT 3176

- CAT 3196- CAT 6.6

- CAT 7

- CAT C9

- CAT C10

- CAT C11

- CAT C12

- CAT C13

- CAT C15

Note

It is important to consult Atlas Copco for approval of welding and choice of elec-

trodes.

Points to be observed when welding:

• Disconnect the cables from the generator, the battery and the engine's electronic

module (A).

M14 8.8 115 25

M16 8.8 185 45

M20 8.8 355 85

M24 8.8 600 150

M12 x 1.25 10.9 135 6

M16 x 1.25 10.9 315 15

M18 x 1.25 10.9 460 20

M6 12.9 14 3

M8 12.9 34 8

M10 12.9 70 17

M12 12.9 120 30

M14 12.9 195 45M16 12.9 315 75

M20 12.9 600 150

M24 12.9 1020 250

Size Strengthclass

Torque inNm.

Tolerance±


18/107


18

Figure:

• Grind off rust and paint from the area that is to be welded and carefully prepare the

joint.

• Weld in a dry area.

• Connect the welding earth cable to a clean surface as close as possible to the weld-

ing area. Avoid welding close to bearings and bushes. If these cannot be removed,

connect earth cables on both sides of the weld.

• Alterations and reinforcements must not be made without previous consultation

with Atlas Copco.

• Do NOT weld hydraulic tanks, valve blocks, compressed air tanks or pressure

lines.

• Always keep a fire extinguisher for oil fires near at hand during all types of weld-

ing, 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 gener-

ally recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the

equivalent in accordance with the standard below:

A


19/107


19

Table: Electrode recommendations

The use of MIG welding equipment is perfectly acceptable. The generally recom-

mended type of electrode is ESAB-OK Autorod 12.51 or the equivalent in accord-

ance with the standard below:

Table: MIG electrodes

If in any doubt, contact Atlas Copco for advice.

Fault finding

Fault finding is a logical sequence of activities to locate a fault, thereby making it

possible to rectify the fault as soon as possible.

Always try to investigate the location of the fault in order to limit fault finding to a

certain system or function.

ISO: 2560 E51 5B 120 20 H

SS: 14 3211 H10

DIN 1913: E51 55 B10

AWS: A/SFA 5.1 E 7018

SS: 14 3403 3423

DIN 8559: SG 2

AWS: A/SFA 5.18: ER 70 S-6


20/107


20

Battery

Environmental considerations regarding batteries

Charging the battery

The battery is normally charged by the drill rig's generator. If the battery is fully dis-

charged 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.

ENVIRONMENTAL DIRECTIONS

• Think of the environment!

• Batteries contain acids and heavy metals.For this reason, expended batteries canbe hazardous to the environment and tohealth.

• Expended batteries must be sent fordestruction in accordance with localregulations.

WARNING

• Risk of fire and explosion

• May cause serious personal injury anddamage to property

• Flammable hydrogen gas

• Corrosive fluid

• Avoid naked flames and sparks

• Always detach the negative terminal first,

and connect it last


21/107


21

Explosive gas is formed in the battery during charging. A short circuit, naked flame

or spark in the vicinity of the battery could cause a serious explosion. Ensure good

ventilation. Always turn off the charge current before disconnecting the clips. If the

density has not risen noticeably despite a number of hours of recharging, the battery

is probable expended.

Rapid charging, when carried out correctly, will not damage the battery. However, it

should not be undertaken too often and is not recommended for old batteries.

Repeated discharging for long periods, especially with low current such as leaving

the lights on while the engine is stationary, will impair the service life of the battery.

Discharging with high current is not normally harmful. The battery must be left to

rest between start attempts, however.

Since the drill rig's 24V electrical system is powered by two 12V batteries in series,

the following points should be observed:

• The batteries must have the same capacity (Ah).

• The batteries must be the same age. This is because the charging current required

to bring a battery up to a certain voltage changes with age.

• The batteries must not be loaded unevenly.

• Series coupling maintains the same capacity but increases the voltage (double).

When 2 x 12V 60Ah batteries are connected in series, the voltage will be 24V but

the capacity remains at 60Ah.

• Ensure that the correct voltage is used before connecting a battery charger. Use a

24V charger when recharging both batteries and a 12V charger when chargingeach battery individually.

Proceed as follows (24V charger)

Before charging

1. Inactivate battery switch S300.

2. Detach the cable between chassis earth and the negative cable on the battery G1B.

3. Connect the positive battery charger cable to the positive terminal on G1A.

4. Connect the negative charger cable to the negative terminal on G1B.

5. Start the battery charger.

After charging

1. Turn off the battery charger

2. Detach the battery charger's negative lead from the negative terminal on G1B.

3. Detach the battery charger's positive lead from the positive terminal on G1A.


22/107


22

4. Connect the cable between chassis earth and the negative terminal on G1B.

5. Activate battery switch S300.

Proceed as follows (12V charger)

Before charging

1. Turn off the battery switch S300

2. Disconnect the jumper lead between the negative terminal on battery G1A and the

positive terminal on battery G1B.

3. Connect the positive battery charger cable to the positive terminal on G1A.

4. Connect the batter charger's negative lead to the negative terminal on G1A.

5. Start the battery charger.

6. Once battery G1A is fully charged: Turn off the battery charger.

7. Detach the battery charger's negative lead from the negative terminal on G1A.

8. Detach the battery charger's positive lead from the positive terminal on G1A.

9. Detach the cable between chassis earth and the negative cable on the battery G1B.

10. Repeat steps 3 - 8 on G1B.

After charging

1. Turn off the battery charger

2. Reconnect the jumper lead between the negative terminal on battery G1A and the

positive terminal on battery G1B.

3. Connect the cable between chassis earth and the negative terminal on G1B.

4. Activate battery switch S300.

Starting with an auxiliary battery

Note

Owing to the surge of current, the batteries could explode if a fully-charged battery is

connected to a completely flat one.

The connections to the drill rig's batteries must under no circumstances be broken

during operation as this could lead to faults arising in the generator.

For this reason, proceed as follows:


23/107


23

1. Check that the auxiliary starting batteries (1) have the same voltage as the batter-

ies on the chassis.

Figure: Starting assistance

1 Auxiliary batteries2 Drill rig batteries

2. First connect the positive terminal of the auxiliary battery to the positive terminal

of the chassis battery (2).

3. Then connect the negative terminal of the auxiliary battery (1) to earth on the

chassis (not to the chassis battery's negative terminal).

4. Once the engine has started, first remove the starter cable between the chassis and

the negative terminal on the auxiliary battery (1).

5. Then remove the cable between the positive terminals of the batteries.

Steel cables

Scrapping guidelines for steel cables

Steel cables should be scrapped when they display any of the following:

• Wire break at attachment

• Occurrence of strand breaks

• Concentrations of wire breaks

• Effects of heat

• Occurrence of wire breaks due to operating time.

• Reduced elasticity• Decreased cable diameter

1

1250 0064 41


24/107


24

• Certain number and type of wire breaks

• Corrosion

• Surface wear

• Deformation of the cable

• Permanent elongation of the cable

Wire break at cable attachment

Broken wires at cable ends indicate that they have been heavily loaded and can be

caused by faulty end attachments.

Shorten the cable and reattach it. However, the remaining cable length must be suffi-

cient.

Occurrence of strand breaks

If there are strand breaks, the cable must be scrapped

Concentrations of wire breaks

If there are concentrations of cable breaks, the cable must be scrapped.

If such concentrations occur within a length less than 60 cm or on an individual

strand, the cable must be scrapped.

If this is the case, the cable must be scrapped even if the number of wire breaks is lessthan the maximum specified in the table.

Effects of heat

Cables exposed to extreme heat must be scrapped. The effects of heat can be estab-

lished through annealing colour.

Occurrence of wire breaks due to operating time.

Wire breaks occur first after a certain operating time depending on operating condi-

tions and subsequently occur more frequently.

If this is the case, the number of wire breaks in relation to the operating time should

be determined and documented.

This can then be used to estimate the future increase in wire breaks and the foreseea-

ble time point for scrapping.

Reduced elasticity

Under certain conditions, the cable loses its elasticity.


25/107


25

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 indi-

vidual cable wires.

Reduced elasticity can lead to sudden cable breaks during heavy loads. The cable

should be scrapped.

Decrease in cable diameter

Decrease in cable diameter through material fatigue in the cable can have the follow-

ing causes:

• Inner surface wear and surface wear nicks

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

• Fatigue of plastic core

• Break in steel core

• Break in inner layer in multi-strand cable

If the cable's diameter decreases more than 10% in relation to the nominal diameter

of the cable, it must be scrapped.

It should then be scrapped even if no wire breaks have been detected.

Certain number and type of wire breaks

The cable drums are designed in such a way that the cables do not have an unlimited

service life. Wire breaks can therefore occur during operation.

On 6 and 8-strand cables, wire breaks are primarily superficial.

The cables should be scrapped if the number of wire breaks specified in the table

have been detected


26/107


26

Table:

d = Cable diameter

1 = Filler wire is not considered load-bearing.

In cables with several layers of strands, only the outer, visible layer is considered.

In cables with steel cores, the core is regarded as an inner strand and is not included.

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

Corrosion

Corrosion is especially problematic in marine environments and in areas where the

air is polluted by industrial emissions.

Corrosion can reduce operational strength through rust spots and static tensile

strength through a reduction in the cross section of the metallic cable.

Severe corrosion can reduce elasticity.

Outer corrosion: Outer corrosion can be easily detected through visual examina-

tion.

Inner corrosion: Inner corrosion is more difficult to detect. Inner corrosion is char-

acterised by the following:

• Absence of gap between the strands in the outer layer of the cable, often in combi-

nation with wire breaks in the strands.

• The cable diameter varies.

The parts of the cable that are bent over discs usually have a decreased diameter. At

any sign of corrosion, the cable should be checked by an authorised person. If inner

corrosion is detected, the cable must be scrapped.

Surface wear

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

Number of load-bearing

wires in the outer strand 1

n

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


27/107


27

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 theeffect of dirt and dust.

Surface wear reduces static tensile strength through reduction in the cable's metallic

cross section and dynamic strength through surface wear nicks.

If the cable's diameter decreases more than 7% in relation to the nominal diameter of

the cable, it must be scrapped.

It should then be scrapped even if no wire breaks have been detected.

Deformation of the cableDeformations are characterised by visible deviations from the cable's normal form

that lead to uneven voltage distribution in the cable.

The following are the primary types of deformations:

• Wire displacement

• Strand displacement

• Waviness

• Cracking

• Kinks

• Flattening

• Local cable diameter decrease

• Local cable diameter increase

• Basket formation

Wire displacement

Individual wires or wire groups stick out like hairpins on the side facing away from

the drum. Wire displacement is caused by spasmodic loads.

Cables with wire displacement must be scrapped.

Figure: Example of wire displacement


28/107


28

Strand displacement

Strand displacement, which often occurs in conjunction with basket formation, is

when the steel core pushes out between the strands.

Cables with strand displacement must be scrapped.

Waviness

Waviness is a deformation that gives the cable's longitudinal axis a helical curve.

Even though wave formation does not necessarily cause weakening of the cable, such

a deformation can cause a pulsing movement.

After a long time of operation, this can increase surface wear and wire breaks.

In the event of waviness, the cable should be scrapped if

d1 > 4d/3

d = Cable's nominal diameter

d1 = Diameter of the circle that would be formed if the cable were not deformed.

Check over a length not exceeding 25d.

Figure: Waviness

Cracks

Cracks are deformations through outer, violent influences.

Cables with cracks must be scrapped.

Figure: Cracks


29/107


29

Kinks

A kink is a deformation caused by the cable forming an eye that is contracted with

out the cable being able to rotate around its own axle.

Strand pitch is altered, which leads a great deal of surface wear and, in severe cases,very low static strength.

Cables with kinks must be scrapped.

Figure: Kinks

Flattening

Flattening is deformation caused by mechanical damage.

Cables with severe flattening must be scrapped.

Figure: Flattening

Local cable diameter decrease

Local decrease in cable diameter is often connected to core break.

The area near the end attachments must be inspected especially carefully as it can be

difficult to detect cable diameter decrease at these spots.

Cables with severe cable diameter decrease must be scrapped.

Figure: Local cable diameter decrease

Local cable diameter increase

This means repeated thickening of the cable over a long stretch. At the thicker spots,

the core pushes out of the cable and causes unevenness of the outer strands.


30/107


30

Cables with severe cable diameter increase must be scrapped.

Figure: Local cable diameter increase

Basket formation

Basket formation occurs on cables with steel reinforcement or steel core when the

outer strand layer becomes longer than the inner strand layer.

Basket formation can also be caused by shock loads on slack cables.

Cables with basket formation must be scrapped.

Figure: Basket formation

Tensioning the crawler tracks

Track tension is checked between the front wheel (3) and support roller (1) when the

drill rig is parked on a level surface with the tracks are under normal load.

Figure: Crawler track

4

A

1

23

1 2 5 0

0 1 1 7 3

7


31/107


31

N.B.

The clearance (A, see illustration: Crawler track) between the wooden plank and

the crawler track should be between 25 and 50 mm (0.9 and 1.9").

N.B.

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

1. Place a wooden plank (2, see illustration: Crawler track) on top of each track.

2. Pack with grease via the nipple (4) to tension the track.

3. If necessary, grease can be removed from the tension cylinder by unscrewing the

nipple (4).

Air conditioning

Safety

Note

Do not use the system with too little refrigerant, leakage or any other fault until it is

rectified. Otherwise, there is risk of the compressor breaking down.

WARNING

• Refrigerant under pressure• Risk of serious personal injury

• Service of refrigerant must always becarried out by authorised personnel


32/107


32

Environmental issues when handling refrigerant

Changing air filter

Figure: Filter - air conditioning.

Changing the main filter:



• Discarding air conditioning refrigerantcan be hazardous to the environment.

• Air conditioning refrigerant must be sentfor destruction in accordance withapplicable local regulations.

B

A

A

1 2 5 0 0

1 8 2 9

3

F

bb

D

A

B

CBE


33/107


33

• Undo the screws around the cover (C).

• Open the cover and lift out the filter.

• Fit the new filter in place and screw back the cover.

Changing the prefilter:

• Undo the screws on the louvre cover (D).

• Lift away the louvre cover and the filter.

• Fit the new filter in place and screw back the louvre cover.

Changing the circulation filters:

• Undo the screws on the covers (b).

• Lift away the covers and the filters.

• Fit the new filters in place and screw back the covers.

Fault finding

No cooling

Check the following points:

• Fuses, electric connections, compressor earth, electromagnets, switches and pres-

sure switches

• V-belt and compressor

• Expansion valve and temperature control valve

• Coolant hoses

Poor cooling


• Fresh-air fan and V-belt tension

• That the air does not evade the evaporator in the unit

• That the evaporator and condenser are not clogged by rubbish and the filter in the

air intake is not dirty

• That the expansion valve capillary tube is firmly against the evaporator outlet pipe

• That the thermostat does not cut out too early

Uneven cooling


• That connections to switches, magnetic coupling or pressure switch are not loose

• That the expansion valve is not clogged

• That the system is filled and the thermostat is not defective


34/107


34

Abnormal noise


• That the multi-V-belt to the compressor is thoroughly tightened and that the com-

pressor retaining bolts are tightened.• That the system is filled sufficiently and not overfull

• That the expansion valve is in working order

• That the airflow across the evaporator is sufficient

• That the condenser is clean and the airflow is sufficient

Abnormal system noise is often connected to incorrectly assembled components. If

the compressor is noisy at a certain speed, for instance, and the noise disappears

when the speed increases or decreases, there is probably nothing wrong with the

compressor itself.

The difference between the pressure on the suction side and the pressure side also

affects the level of noise. A compressor with low suction makes more noise than a

compressor with high suction. Likewise, a compressor with high high-pressure

makes more noise because it puts more load on bearings, etc.


35/107

Maintenance instructions2. Transport instructions

35

2. Transport instructions

Hoisting

Single-section boom version

Figure: Hoisting

Make sure the chassis is not damaged when you position the feed in the transport/

hoisting position.

WARNING

• Hanging load


• Do not approach a hanging load

• Only use lifting equipment and liftingstraps with adequate lifting capacity

• Risk of tipping

• Lock the track oscillation cylindersbefore the drill rig is raised


36/107


36

• Move the rock drill to its rear (upper) position

• Use the boom and feed controls to lower the feed onto the feed support.

• Position the feed against the outer boom.

• Make sure that the hydraulic jack is retracted.

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

Figure: Drill panel

• Make sure that none of the hoses, controls or any other components can fasten orsustain damage when the hoisting slings are tensioned and under load.

• Place the hoisting slings under both crawler tracks at points A and B as shown in

the illustration Hoisting.


37/107


37

Folding boom version

Figure: Lifting models with folding boom.

To achieve maximum drill rig stability, position the boom, feeder and rock drill as

follows:

• Boom lift cylinder maximum OUT

• Boom extension maximum IN

• Feed dump cylinder maximum OUT (make sure that the feed does not collide with

the lifting equipment)

WARNING

• Hanging load


• Do not approach a hanging load

• Only use lifting equipment and liftingstraps with adequate lifting capacity

• Risk of tipping


ROC1 2 5 0 0 1 2 8 9 5

A B


38/107


39/107


39

Transport

Figure: Transport position for folding boom versions, alternative 1

Figure: Transport position for folding boom versions, alternative 2

WARNING

• Risk of tipping



• Transportation equipment must beadapted for the dimensions and weight ofthe drill rig

• All bodywork hatches must be correctlyinstalled and locked

ROC1 2 5 0 0 1

2 8 6 9

1 2 5 0

0 1 2 9

0 2

ROC1

2

5

0

0

1

2

8

6

9

1

2

5

0


40/107


40

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

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

Before loading the drill rig onto the transport vehicle.

• Run the rock drill to its lowest position.

Use the boom and feed controls alternately to bring the feed down into the trans-

port position and firmly down on its jack (A).

Once the drill rig is loaded onto the transport vehicle.

• Run the hydraulic jack down.*

• Track oscillation cylinders to LOCKED position.

1 2 5 0

0 1 2 9

0 4

A

ROC

1 2 5 0 0

1 2 9 0

6

A

ROC


41/107


41

Figure: Drill panel

• Switch off the diesel engine.

• Support the feed beam against the vehicle to prevent overloading.

• Strap the drill rig securely to the vehicle.

Attach straps or chains to the lifting eyes on the machine and vehicle.

Note

*Extra equipment


42/107


42

Towing

1. Remove the two M8 bolts from the cover plate.

Figure:

2. Remove the cover plate and turn the outside inwards

Figure:

WARNING

• Danger of moving parts


• Place a wedge under both of the trackframes, before disengaging the tractiongears

1250 0131 32

1250 0131 33


43/107


43

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

Figure:

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

Figure:

Proceed in the same way on the other track frame

The drill rig can now be towed.

1 2 5 0 0

1 3 1

3 4

1250 0131 35


44/107

Maintenance instructions3. Drill system

44

3. Drill system

Adjusting the damper pressure

Figure: Constant flow valve for damper pressure.

Note

See also separate rock drill instructions.

• Adjustment to be performed without drilling

• The diesel engine runs at 1500 rpm

• Close constant flow valve (See illustration: Constant flow valve) fully on drill rig.

• Connect a pressure gauge to the rock drill between damper nipple and damper

hose .

• Rock drill disconnected from drill rods and shank adapter relieved of load, in

advanced position.

CAUTION

• Danger of serious equipment damage

• An incorrectly adjusted damper pressurecan cause serious damage to equipment

• Adjustment of damper pressure should

only be carried out by trained staff


45/107


45

• Move switch Drilling/Preheating/Tramming (see illustration: drill panel) to

position drilling (a).

• The shank adapter should be completely clear of the frame.

• Adjust the damper pressure on the constant flow valve . Undo the locking

screw (1b) on the constant flow valve and adjust the damper pressure with knob (1a), clockwise to reduce pressure and anticlockwise to increase pressure.

• Corresponding pressure on Cab pressure gauge :

- COP-1800 approx. 40 bar.

- COP-2150/2160 approx. 40 bar

• Factory settings:

- COP-1800 32 - 35 bar

- COP-2150, COP2160 32 - 35 bar

• Shut down the rig.

• Disconnect Pressure gauge and connect the hose to Damper nipple

Note

The impact stops automatically if damper pressure rises above 120 bar or drops

below 35 bar while drilling is in progress.

• Check that the shank adapter goes into “float mode” during drilling. (Constantly

pressed out approx. 4 - 6 mm from the frame.

Adjusting percussion pressureGeneral

Note

Impact pressure should only be set during drilling and the hydraulic oil should have

attained operating temperature, normally 40 ° C (104 ° F).

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


46/107


46

Figure: Pressure gauge panel

Note

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

side).

1 2 5 0

0 1 7 7

1 6

1

2

3

4

5

6

7

8

9


47/107


47

Figure: Control panel for pressure

Low percussion pressure

Setting must be done while drilling.

Note Pressure ex works is 120 bar (factory setting).

The switch on the drill lever must be in position LOW PERCUSSION PRESSURE.

1. Undo the lock nut (7).

2. Turn the adjusting screw (7) clockwise to increase low percussion pressure.

3. Turn the adjusting screw (7) anticlockwise to decrease low percussion pressure.

4. Tighten the lock nut (7).

High percussion pressure

Setting must be done while drilling.

Note

Pressure ex works is 200 bar (factory setting).

The switch on the drill lever must be in position HIGH PERCUSSION PRESSURE.

1. Undo the lock nut (8).

RPCF

1 2 5 0

0 1 7 7

1 8

6

8

4

2

1

7

5

3


48/107


49/107


49

Figure: Pressure gauge panel

Low drill feed pressure

Note

Factory setting is 30 bar.

Button Percussion pressure (25) in position LOW PERCUSSION PRESSURE(left).

Switch Flushing air (21) in position REDUCED FLUSHING AIR/DUST COLLEC-

TOR ON.

1 2 5 0

0 1 7 7

1 6

1

2

3

4

5

6

7

8

9


50/107


50

Figure: Rod handling

Lever Feed in position DRILL FEED.

1. Undo the lock nut (3) on the control panel for pressure.

2. Turn adjusting screw (3) on the control panel for pressure clockwise to increase

drill feed pressure.

3. Turn adjusting screw (3) on the control panel for pressure anticlockwise to

decrease drill feed pressure.

4. Tighten the lock nut (3) on the control panel for pressure.

High drill feed pressure

Note

Factory setting is 70 bar.

Button Percussion pressure (25) in position HIGH PERCUSSION PRESSURE

(right).

?

13

14

19

e

15 16 17 18

20

21

23 22

af

d

b

c

a

b

c

1 2 5 0

0 1 2 8

4 1


51/107


51

Figure: Drill panel

Activate functions for drilling with full percussion (See drilling).

Switch Flushing air (21, see illustration: Rod handling) in position FULL FLUSH-

ING AIR (a).


52/107


52

Figure: Rod handling

Lever Feed (26) in position DRILL FEED.

1. Undo the lock nut (4) on the control panel for pressure.

2. Turn adjusting screw (4, see illustration: Control panel for pressure) clockwise to

increase drill feed pressure.

3. Turn adjusting screw (4, see illustration: Control panel for pressure) anticlockwiseto decrease drill feed pressure.

4. Tighten the lock nut (4b, see illustration: Control panel for pressure).

Adjusting rotation speed

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

?

13

14

19

e

15 16 17 18

20

21

23 22

af

d

b

c

a

b

c

1 2 5 0

0 1 2 8

4 1


53/107


53

Figure: Control panel for pressure

Note

Rotation speed can be set without drilling. The setting must be made when the diesel

engine is at maximum rpm.

The hydraulic oil should be at operating temperature, normally 40 °C (104 °F).

To measure rotation speed, count the number of revolutions the drill string completes

per minute (make a mark on the drill rod). Alternatively, use an electronic instrument.

Correct rotation speed should be set according to the type of drill bit and the proper-

ties of the rock.

Observe the following guidelines:

Table: Basic setting for ordinary button drill bits

• Type of drill bit

- X drill bits (cross-drill bits) require a higher speed than button drill bits (10-20

rpm higher)

• Rock properties

- Soft types of rock normally require a higher speed, harder rock requires a lower

rotation speed.

Size of drill bit (mm) 76 89 102 115Size of drill bit (inches) 3 3 1/2 4 4 1/2

Rotation speed (rpm) 120 110 90 70

RPCF

1 2 5 0

0 1 7 7

1 8

6

8

4

2

1

7

5

3


54/107


54

• Jerky rotation

- If rotation speed is jerky during drilling (not rotating at even speed), this could

indicate that rotation speed is too low.

- In certain types of rock, ballistic drill bits can cause jerky rotation.

• Drill bit wear

- Diametric wear can be reduced if rotation speed is lowered

• Drilling rate

- High rotation speed can give a higher drilling rate.

- Ballistic button drill bits normally give a higher drilling rate

- X drill bits give a lower drilling rate.

Note

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

Setting rotation speed

• Undo the control knob (1) on the control panel for pressure.

• Turn adjusting screw (1) clockwise to increase rotation speed.

• Turn adjusting screw (1) anticlockwise to reduce rotation speed.

• Tighten the lock nut (1).

RPC-F system

RPCF (Rotation Pressure Controlled Feed) is used to regulate the drill feed pressure

in order to maintain the rotation pressure at a sufficient level to keep the joins tight.

This is done by the RPCF valve detecting the rotation pressure while drilling. When

the rotation pressure exceeds the preset value for the RPCF valve, the feed pressure

will be lowered to minimum the low drill feed pressure. As the feed pressure drops,

so will the rotation pressure. This means that the feed pressure shown on the pressure

gauge while drilling in many cases will not be the same as the high feed pressure set-

ting but a lower pressure. For a more detailed description, refer to the rock drill's

“How to use” instructions.

Adjusting

The RPCF valve is only to be adjusted while drilling with two drill rods in the drill

string and after the hydraulic oil has reached normal operating temperature 40 °C

(104 °F). In order to be able to make a good setting, the rock should be reasonably

homogenous so that a stable rotation pressure is obtained.


55/107


55

Figure: Control panel for pressure.

1. Undo the lock nut (2) and turn the adjusting screw (2) clockwise until it stops to

disengage the function. Oil may run out from around the adjusting screw while the

adjustment is being made.

2. Start drilling and set in a suitable feed pressure, percussion pressure and rotation

speed according to the rock drill's “How to use” instructions. See also the chapteron pressure setting in this manual.

RPCF

1 2 5 0

0 1 7 7

1 8

6

8

4

2

1

7

5

3


56/107


56

3. Once an even and stable rotation pressure is achieved (pressure gauge 7), the

RPCF valve adjuster screw must be turned anticlockwise until the feed pressure

(pressure gauge 1) starts to drop.

Figure: Pressure gauge panel.

4. Screw back the adjuster screw clockwise a little way, about 1/2 a turn. The feed

pressure will now drop automatically if the rotation pressure exceeds the normal.

5. Tighten the lock nut (2).

1 2 5 0

0 1 7 7

1 6

12

3

4

5

6

7

8

9


57/107


57

Pressure regulator adjustment

Figure: Pressure regulator

1. Compressor pressure gauge2. Temperature pressure gauge.3. Regulator knob.4. Locking the regulator knob.

Setting the compressor's maximum and operating pressures.

Table:

Anti-jamming protection

The drill rig is fitted with two types of anti jamming protection.

• Air flow switch

• Rotation pressure switch

Both variants reverse the feed direction if they are activated by insufficient flushing

air flow or excessive drill rotation pressure respectively in order to avoid jamming.

Compressor operating pressure

Rig model Max. pressure Max. temperature

ROC D7 10.5 bar 120 °C

ROC D5 8.5 bar 120 °C

1 2 5 0 0

1

1 5

9 3

1

2

3

4


58/107


58

Air flow monitor B142

The airflow guard is connected after the flushing air valves and monitors the pressure

drop through the restriction in the flushing air line. An impaired or non-existent air

flow caused by a clogged drill bit, for example, means that the pressure drop will bereduced or cease completely. The rock drill will then reverse automatically until the

pressure drop/flow is normal again.

Adjusting air flow switch

The airflow guard can be adjusted only while drilling and only with full flushing air

flow active.

Figure: Air flow switch

1 2 5 0 0

1 3 2

9 7


59/107


59

Figure: Autodrilling panel.

1. Remove the flow switch cover.

2. Drill almost down to the greatest depth that will be drilled in the current position.

Make sure full flushing air is active. Switch 21, position a.

3. Turn the flow switch adjuster screw (1) anticlockwise until the rock drill starts to

reverse. The higher the number on the adjuster screw scale, the more sensitive the

flow switch will be. The factory setting is 30 mbar.

4. Screw back the adjuster screw until the rock drill starts downwards again.

5. Drill another hole to check that the anti-jamming protection does not activate

inadvertently due to the setting being made too sensitive. If this is the case, screw

back the adjuster screw slightly more.

6. Fit the flow switch cover.

When changing dimension of the drill bit or drill steel, or if the drill depth is changed,it may be necessary to readjust the flow switch in order to maintain adequate anti-

jamming protection.

Rotation pressure switch B134

The rotation pressure switch B134 is connected to valve QDS-K, which monitors the

drill rotation pressure while drilling. A considerable increase in rotation pressure

indicates that the drill is about to jam. If the rotation pressure rises above the set pres-

1 2 5 0

0 1 3 6 7

6

a

b

c

d e

f

S119 S187 S113 S182

S167

S100

S181S170

H129

S111


60/107


60

sure on QDS-K, the rotation pressure switch will receive a signal and the rock drill

will reverse automatically. Reverse feed will continue until the pressure has again

dropped below the set value.

Note Factory setting is 80 bar.

Figure: Valves

A B134B QDS-K

A

B

1 2 5 0

0 0 0 3 3

4


61/107


61

Adjusting activation pressure

Figure: Pressure adjustment panel.

The anti-jamming protection activation pressure is adjusted on the QDS-K valve. The

activation pressure can be difficult to adjust while drilling as it is often difficult to

force the rotation pressure sufficiently high. Instead, it is possible to carry out a simu-lation.

1. Turn the knob for adjusting the rotation speed (1) anticlockwise until you feel the

spring pressure release. The rotation speed will now be 0 rpm.

2. Run the rock drill down until the drill steel sleeve is in the upper drill-steel sup-

port. Close the drill-steel support to secure the sleeve.

3. Activate drill rotation.

4. Activate drill feed.

WARNING

• Risk of serious personal injury• During the procedure the rock drill will

reverse automatically

• Make sure that no personnel are withinthe rock drill's area of movement

RPCF

1 2 5 0

0 1 7 7

1 8

6

8

4

2

1

7

5

3


62/107


62

5. Slowly screw the adjuster knob clockwise while observing the pressure gauge for

the rotation pressure. When the pressure exceeds the rotation pressure switch set-

ting, the feed direction will reverse. This can be seen from the pressure on the feed

pressure gauge dropping to 0 and the rock drill trying to pull away from the drill-

steel support.

6. Screw the adjuster knob anticlockwise to reduce the rotation pressure and allow

the feed to move down again.

7. If the pressure switch setting needs to be changed, it can be done by turning its

adjusting screw clockwise to increase the activation pressure or anticlockwise to

reduce it.

8. Repeat steps 1 - 6 to check the new setting.

9. Restore the rotation speed to its normal setting.

Setting lubrication to the rock drill

The relays for ECL and ECG located in the A1 cabinet. The pulse length and pause

length can be adjusted on the relays. These adjustments can be made without starting

the drill rig.

Figure: Electric cabinet.

1 2 5 0

0 1 0 3

4 4

12

3

4

5

78

10

6

9


63/107


63

The upper adjusting screws on the ECL/ECG relays (3 and 4) adjust the pulses/min

and the lower adjusting screws adjust the delay time. To increase the values, turn the

adjusting screws clockwise, and to decrease them, turn the adjusting screws anti-

clockwise.

• Factory settings ECL:

- Pulses: 20 - 25 pulses/min

- Extended time: 30 seconds

• Factory setting ECG:

- Pulses: 20 - 25 pulses/min

- Extended time: 0 seconds

Rock drill lubrication must be set with regard to local conditions.

Make sure the threads on the shank adapter/drill rod lubricated by air flushing.

To check that the diode on the lubricating pumps flash, this indicates the pumps are

working.

Figure: Diode on ECG/ECL pumps.

a ECL b ECG

ECL collection

Locations

ECL collector pressure control valve

The pressure to the ECL system limitation is set with the pressure control valve. The

pressure must be between 5 and 5-1/2 bar.

a

b

1 2 5 0

0 1 1

5

9 2


64/107


64

Figure: Pressure control valve.

Function

Figure: Collecting tank.

The system consists of a collecting tank with two pressure sensors, control lamps andstrainer.

The system collects the ECL oil that has passed the rock drill via a hose to the col-

lecting tank (A).

Strainer (E) should be cleaned every 40th percussion hour.

1 2 5 0

0 1 8 6

3 6

1 2 5 0

0 1 0 6

1 0

A

B


65/107


65

Figure: Strainer

The collecting tank must be emptied via the cock (B) underneath the tank every timeECL oil is filled.

Note

The collected oil must be sent for disposal and not reused!

The system is monitored by two pressure sensors:

Figure: Pressure sensor.

• B381

- Detects low pressure in the system (0.4 bar). The low pressure indicator lamp

(H381) will come on if the pressure is too low.

- If the (H381) indicator comes on, check the airflow through the system and

remove any impurities.

E

1 2 5 0 0

1 0 7 1

3

B381

B38


66/107


66

• B382

- Detects high pressure from the pressure sensors to the collecting tank (1.5 bar).

(H382) on the display will come on if the pressure is too high.

- If the indicator comes on, check the airflow through the system and remove any

impurities, in this case between the pressure sensor and the collecting tank.

1 2 5 0

0 1 7 7

1 7

H207

H382

H381

H215

H203

P352H180

H214

H212

H213

H211

R354


67/107

Maintenance instructions4. Hydraulic systems

67

4. Hydraulic systems

Environmental considerations when handling oil

General

The hydraulic system is sensitive to impurities. The environment in which a drill rig

normally operates is usually unsuitable for repairing hydraulic components. Work on

the hydraulic system on-site should therefore be limited to absolute necessities, i.e.

only changing components. When changing valves, the unit in question must be well

strapped and supported. Components should then be repaired in a suitable environ-ment.

Observe the following points to avoid breakdowns and interruptions in operation due

to fouled hydraulic oil:

• Keep the drill rig clean. Hose it down at regular intervals, preferably with an

added grease solvent.

• Before opening any connection, clean the area round it.

• Use clean tools and work with clean hands.

• Always plug hydraulic connections immediately after they have been detached.



• Leaking hydraulic connections andlubrication grease are environmentallyhazardous

• Changing oils, replacing hydraulic hosesand different types of filter can beenvironmentally hazardous.

• Always collect oil residue, oil spillage,waste with oil content, and lubricationgrease residue and spillage. Treat inaccordance with local regulations.

• Use biodegradable hydraulic fluids andlubrication oils for Atlas Copco productswherever possible. Contact your local

Atlas Copco office for further information.


68/107


68

• Use clean protective plugs.

• Hydraulic components, such as hoses, valves, motors, must always be kept with

suitable protective plugs fitted.

• Spare parts for hydraulic components must always be kept in sealed plastic bags.

• Change filter cartridges as soon as the filters indicate clogging.

Repairing hydraulic components

Repairing and/or reconditioning hydraulic components should be carried out by

expert personnel and in a suitable place. The following alternatives are possible:

• Suitable premises for hydraulic repairs to be arranged at the workplace. Repairs to

be carried out by your own specially trained personnel, the manufacturer's techni-

cians or Atlas Copco personnel.• Components to be sent to the manufacturer's local agent for repair.

• Component repairs are carried out by Atlas Copco. Repair instructions are availa-

ble for the most important and most complicated hydraulic components.

Replacement of hydraulic hoses

The high system pressure, with safety valves set at 280 bar, together with vibrations

and other mechanical strain, puts high demands on hydraulic hoses. All the hydraulic

hoses have crimped couplings and should therefore be purchased ready-made fromAtlas Copco. Hose dimensions and qualities are specified in the spare parts lists for

the relevant drill rig.

Hydraulic workshops

Workshops used for the repair of hydraulic components must:

• Be separate from activities which generate dust and particles, such as welding,

grinding, the transportation of vehicles, etc.• Have their own suitable washing equipment which is required for repairing the

components.

• Have the necessary tools, both standard and special, and that are only used in the

hydraulic workshop.

• Have a ventilation system that does not admit dust into the premises.

• Have well-trained mechanics.


69/107


69

Filter

Return oil filter General

The return oil filter cleans the oil before it is returned to the tank.

There is a return oil filter on the drill rig. A return oil filter consists of a tube contain-

ing three filter inserts. The tubes are mounted inside the hydraulic oil reservoir.

The filter inserts must be changed according to the maintenance schedule, but if the

pressure gauge for the return filter indicates “filter clogged” (the red zone on the

scale), all the return oil filters must be changed immediately.

Figure: Pressure gauge for return filter with symbol

Note

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

Changing the return oil filter

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

0

40

80

60

20

1 2 5 0

0 1 7 7 8

4


70/107


70

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

Figure: Changing filter

2. Lift off the cap (B) and change the O-ring (C) if it is damaged.

3. Lift up the whole filter canister by the handle.

4. Detach the overflow valve (E) by pressing down and turning the handle anticlock-

wise.

5. Take out the filter cartridges (D) and replace with new ones.

6. Refit the overflow valve and filter canister and screw on the cap.

Breather filter

General

There is a breather filter (A) fitted on the hydraulic oil reservoir. The purpose of the

breather filter is to equalise the pressure differences in the tank that would otherwise

arise when the level in the tank changes if, for example, a jack is lowered.

A

B

E

D

C 1 2 5 0

0 0 9 7

6 4


71/107


71

Figure: Breather filter

The breather filter must be

9852 1979 01 Maintenance Instructions R

Documents

Transcript of 9852 1979 01 Maintenance Instructions R