9852 1979 01 maintenance instructions r
TRANSCRIPT
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PM No. 9852 1979 01
2007-08
Atlas Copco
ROC D5/D7/D9
Maintenance instructions
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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.
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Safety
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Safety
Reference ................................................................................................................. 5
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Reference
Note
Always read the information under Safety before starting to use the rig or starting
maintenance work.
1250 0099 89
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Safety
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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
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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
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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
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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.
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Contact details
Table: Addresses, telephone numbers and fax numbers to Atlas Copco companies
Country Address Phone and fax number Argentina Juncal 2869
B1640GRE Martinez
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
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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
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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
Country Address Phone and fax number
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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
Country Address Phone and fax number
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• 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
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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±
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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
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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
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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
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Explosive gas is formed in the battery during charging. A short circuit, naked flame
or spark in the vicinity of the battery could cause a serious explosion. Ensure good
ventilation. Always turn off the charge current before disconnecting the clips. If the
density has not risen noticeably despite a number of hours of recharging, the battery
is probable expended.
Rapid charging, when carried out correctly, will not damage the battery. However, it
should not be undertaken too often and is not recommended for old batteries.
Repeated discharging for long periods, especially with low current such as leaving
the lights on while the engine is stationary, will impair the service life of the battery.
Discharging with high current is not normally harmful. The battery must be left to
rest between start attempts, however.
Since the drill rig's 24V electrical system is powered by two 12V batteries in series,
the following points should be observed:
• The batteries must have the same capacity (Ah).
• The batteries must be the same age. This is because the charging current required
to bring a battery up to a certain voltage changes with age.
• The batteries must not be loaded unevenly.
• Series coupling maintains the same capacity but increases the voltage (double).
When 2 x 12V 60Ah batteries are connected in series, the voltage will be 24V but
the capacity remains at 60Ah.
• Ensure that the correct voltage is used before connecting a battery charger. Use a
24V charger when recharging both batteries and a 12V charger when 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.
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4. Connect the cable between chassis earth and the negative terminal on G1B.
5. Activate battery switch S300.
Proceed as follows (12V charger)
Before charging
1. Turn off the battery switch S300
2. Disconnect the jumper lead between the negative terminal on battery G1A and the
positive terminal on battery G1B.
3. Connect the positive battery charger cable to the positive terminal on G1A.
4. Connect the batter charger's negative lead to the negative terminal on G1A.
5. Start the battery charger.
6. Once battery G1A is fully charged: Turn off the battery charger.
7. Detach the battery charger's negative lead from the negative terminal on G1A.
8. Detach the battery charger's positive lead from the positive terminal on G1A.
9. Detach the cable between chassis earth and the negative cable on the battery G1B.
10. Repeat steps 3 - 8 on G1B.
After charging
1. Turn off the battery charger
2. Reconnect the jumper lead between the negative terminal on battery G1A and the
positive terminal on battery G1B.
3. Connect the cable between chassis earth and the negative terminal on G1B.
4. Activate battery switch S300.
Starting with an auxiliary battery
Note
Owing to the surge of current, the batteries could explode if a fully-charged battery is
connected to a completely flat one.
The connections to the drill rig's batteries must under no circumstances be broken
during operation as this could lead to faults arising in the generator.
For this reason, proceed as follows:
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Maintenance instructions1. General
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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
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• Certain number and type of wire breaks
• Corrosion
• Surface wear
• Deformation of the cable
• Permanent elongation of the cable
Wire break at cable attachment
Broken wires at cable ends indicate that they have been heavily loaded and can be
caused by faulty end attachments.
Shorten the cable and reattach it. However, the remaining cable length must be 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.
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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
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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
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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
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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
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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.
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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
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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
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Environmental issues when handling refrigerant
Changing air filter
Figure: Filter - air conditioning.
Changing the main filter:
ENVIRONMENTAL DIRECTIONS
• Think of the environment!
• 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
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• 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
Check the following points:
• Fresh-air fan and V-belt tension
• That the air does not evade the evaporator in the unit
• That the evaporator and condenser are not clogged by rubbish and the filter in the
air intake is not dirty
• That the expansion valve capillary tube is firmly against the evaporator outlet pipe
• That the thermostat does not cut out too early
Uneven cooling
Check the following points:
• That connections to switches, magnetic coupling or pressure switch are not loose
• That the expansion valve is not clogged
• That the system is filled and the thermostat is not defective
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Abnormal noise
Check the following points:
• That the multi-V-belt to the compressor is thoroughly tightened and that the com-
pressor retaining bolts are tightened.• That the system is filled sufficiently and not overfull
• That the expansion valve is in working order
• That the airflow across the evaporator is sufficient
• That the condenser is clean and the airflow is sufficient
Abnormal system noise is often connected to incorrectly assembled components. If
the compressor is noisy at a certain speed, for instance, and the noise disappears
when the speed increases or decreases, there is probably nothing wrong with the
compressor itself.
The difference between the pressure on the suction side and the pressure side also
affects the level of noise. A compressor with low suction makes more noise than a
compressor with high suction. Likewise, a compressor with high high-pressure
makes more noise because it puts more load on bearings, etc.
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Maintenance instructions2. Transport instructions
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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
• May cause serious personal injury anddamage to property
• 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
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• 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.
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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
• May cause serious personal injury anddamage to property
• 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
ROC1 2 5 0 0 1 2 8 9 5
A B
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Transport
Figure: Transport position for folding boom versions, alternative 1
Figure: Transport position for folding boom versions, alternative 2
WARNING
• Risk of tipping
• May cause serious personal injury anddamage to property
• Lock the track oscillation cylindersbefore the drill rig is raised
• 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
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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
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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
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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
• May cause serious personal injury anddamage to property
• Place a wedge under both of the trackframes, before disengaging the tractiongears
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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
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Maintenance instructions3. Drill system
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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
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• 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).
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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
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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
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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
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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
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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).
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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
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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
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• 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.
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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• 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
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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.
ENVIRONMENTAL DIRECTIONS
• Think of the environment!
• 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.
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• 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.
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Filter
Return oil filter General
The return oil filter cleans the oil before it is returned to the tank.
There is a return oil filter on the drill rig. A return oil filter consists of a tube 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
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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
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Figure: Breather filter
The breather filter must be