Reg.

code AIB ROC 203PC 2000-05

Operators Instructions for Pneumatic Crawler Drills

ROC 203PC

No. AIB 181 00 10

ATLAS COPCO ROCK DRILLS AB REBRO l SWEDEN

PM No. 9852 1453 01

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

1250 0071 04

Copyright 2005, 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.

The owner of the equipment is granted permission to take copies of this publication solely for internal use, however, it is recommended to order further copies from the Atlas Copco representative in order to benefit from the latest revision. Atlas Copco Rock Drills reserves the right to make changes in its product without notice in order to improve design or performance characteristics. The information in this publication is assumed to be accurate at the time of publication, but is subject to change in order to remedy detected deficiencies or to follow changes in the product. Any user of this publication is requested to inform Atlas Copco Rock Drills AB of deficiencies detected in this publication, particularly in product safety matters.

Foreword
This instruction book is part of the complete delivery of the pneumatic crawler drills ROC 203PC . It gives information on features and handling of the rig and contains advice and measures necessary to keep the rig operational. This instruction book does not replace a thorough training on the rig. The documentation is made up from the following:

Section 1 Operating safety Section 2 Equipment description Section 3 Operation Section 4 Settings and maintenance by the operator Section 5 Technical Data

This instruction book shall be read in advance by everyone who is tasked to operate the rig or carry out maintenance or repairs to it.

Table of contents

Operating safety General safety advice Special safety advice Danger zone Equipment description Features & Controls overview ROC 203PC-00 Operating controls ROC 203PC-00 Hydraulic control panel Pneumatic control panel Controls General air and oil flow controls Track oscillation shut-off valve Level indicator Principal system functions Pneumatic system Hydraulic system Operation Daily checks Extra safety check Topping-up liquids Connecting air supply Functional checks Manoeuvring Tramming Towing Hoisting Drilling Set-up for drilling Collaring & drilling down the first rod Adding rods Withdrawing the drill string When the drillstring gets stuck during withdrawing Reconnection of the boom swing cylinder Settings and maintenance by the operator Replacing the oil filter cartridge Cleaning the strainer Tensioning the crawler tracks Setting the lubricating valves Technical data Masses Performance Hydraulic system Component specifications Recommended hydraulic oils and lubricants Volumes Tightening torques Transport dimensions Coverage areas Annex: Documentation Feedback form

Page 5 5 8 9 10 11 12 12 13 14 14 15 15 16 16 16 17 17 18 20 21 22 25 25 27 31 32 32 34 36 38 42 43 45 45 46 46 47 48 48 48 48 49 51 51 51 52 53 56

Operating safety
Dear Operator, like driving a car, drilling bears hazards to you and your environment. Good training, discipline and well maintained equipment are the keys to safe operation. This instruction book is no replacement for a thorough training on the rig, but as a training aid and a reference book it shall help you to maintain a safe working environment and the operability of your rig. Yours faithfully Atlas Copco Rock Drills AB

General safety advice

Intended use: The pneumatic drill rig ROC 203PC is solely designed for drilling holes in surface working, i.e. usually quarries, opencast mines and construction engineering. Any use going beyond this shall be considered not to be intended use. Not-intended use is e.g.: Lifting and transport of loads Lifting and transport of personnel Stabilization of other equipment The manufacturer is not liable for damage incurred as a result; this shall be at the owners risk. Proper use also includes observation of operating, servicing and maintenance instructions stipulated by the manufacturer. The ROC 203PC may only be operated, serviced and repaired by personnel familiar with it and informed of the dangers. Relevant accident prevention regulations as well as other generally recognized safety, occupational medicine and traffic regulations must be observed. The manufacturer is not liable for any damage caused by unauthorized alterations made to the crawler drill. Organizational measures: 1. The pneumatic drill rig ROC 203PC shall be operated only by personnel, which has been given a practical training on the rig. Particular emphasis shall be laid on safety precautions. 2. Keep this instruction book as well as the other instructions books listed in the chapter, "Separate Instruction Books on the rig at any time.

As far as necessary or required by regulations use personal protective equipment. In case of possibly safety relevant changes of the rig or its operational behavior immediately shut down the rig and investigate the problem (seek advice from your Atlas Copco representative if necessary). 5. Keep the warning plates attached to the rig complete and legible. 6. Have the daily safety check carried out as described in this instruction and follow the maintenance measures as described in the service schedule. 7. Works to the hydraulic system shall be carried out only by personnel with particular skills and experience. 8. Any welding shall be carried out only by an authorised welder qualified acc. to EN 287 part 1 or equivalent. 9. Following repair, the rig shall be inspected and approved by the proper authorities before being put back into normal service. 10. Never carry out alterations or modifications to the rig, which might affect the operating safety, without full approval of the manufacturer. 11. The sound power level at the operators place are 126 dB(A). Operation and maintenance: 1. Apart from this instruction book also follow the generally recognized safety and accident prevention regulations. 2. Prior to starting-up get familiar with the rigs features, controls and their functions. This instruction as well as the others listed on page 3 will help you. 3. Make sure the required maintenance measures acc. to the service schedule have been carried out and carry out the ,,Daily checks prior to each shift. Never operate the rig when its safety is doubtful. 4. Always wear a hard hat, ear mufflers and well-fit clothes. Wear protective gloves when you handle drill rods, couplings can be hot. Wear a breathing mask during drilling (rock drill exhaust air contains oil spray). 5. Check the vicinity of the drill rig. During drilling and travelling there should be no unauthorized personnel around. At critical locations, however, like close to unsecured benches, a supervisor should be present. Care for sufficient sight. Check the travel path if necessary. 6. Prior to pressurizing put all levers and switches to NEUTRAL. 7. Never leave the rig unobserved during drilling. 8. Be careful when you handle hydraulic oils (avoid contact with skin and eyes). 9. Always shut down the rig and depressurize the air system before you carry out any disconnection work to the pneumatic or hydraulic system. 10. Be extremely careful searching leakages in the pneumatic or hydraulic system. Highly pressurized liquids (like hydraulic oil) or pressurized air could penetrate clothes and skin and cause heavy injuries or infections. In case of such accidents always look for a doctor immediately. 11. Dispose oils and filters environmentally. 12. Avoid the employment of cleaning agents containing solvents (e.g. carbon tetrachloride). There are alternatives available being much less dangerous to health and environment. 13. Spare parts shall at least comply with the standards as stipulated by the end manufacturer. 14. Operate the rig in daylight only. This is guaranteed e.g. by the employment of genuine Atlas Copco parts.

3. 4.

Frequently encountered safety risks 1. During transportation and particularly during hoisting there is an increased hazard of overturning. During hoisting the Track oscillation shut-off valve must be in position BOTH CYLINDERS CLOSED. 2. The rig could tip over during tramming in extreme terrain. In order to avoid overturning during tramming: - Keep Track oscillation shut-off valve in position BOTH CYLINDERS OPEN - Lay down feed resp. to provide an optimum center of gravity - Max. inclination in tramming direction: 20 solo machine (feed laid down) - Max. lateral inclination: 20 solo machine (feed laid down) - Operate the rig from the uphill side 3. The rig could tip during drilling in extreme positions. In order to avoid tipping during drilling: - Keep Track oscillation shut-off valve in position BOTH CYLINDERS CLOSED - Max. inclination in tramming direction: 20 - Max. lateral inclination : 20 - Operate the rig from the uphill side 4. When the drill string gets stuck never grip the drill steel nor apply a spanner or similar tool while the rotation motor is under pressure. The drill steel could suddenly break free and squeeze the arm resp. toss about or fling the tool all of which could lead to severe injury or death. 5. Before maintenance depressurize the rig.

Special Safety advice:

On the rig or in this instruction book you may find the following signs:

DANGER

This indicates immediate hazards, which WILL lead to serious personal injury or death.

WARNING

This sign indicates hazards or unsafe practices, which COULD lead to serious personal injury or death.

CAUTION

This sign indicates hazards or unsafe practices, which could lead to minor personal injury or damage to property.

NOTE

This sign indicates advice for the efficient, economic and environmentally compliant use of the rig.

... and last but not least a request:

We spent a lot of care to create this instruction book. Still it might happen that you find a description inadequate or insufficient, or a safety hazard not or insufficiently referred to. In such case please take a copy of the reporting form at the end of this book, fill it in and send it to the address specified on the form. Please let us participate in your experience, so you can participate in other peoples experience!

Read the instruction manual before starting the rig. Incorrect handling of the machine can incur the risk of injury to personel and damage to equipment. To avoid serious injury or damage to equipment, learn the meanings of the various warning signs and follow the instructions carefully. Danger - slewing or clamping components. Can cause serious injury to personel. Do not trespass into danger zones during operation.

Danger Zone
Any zone within and / or around the drill rig in which a person is exposed to risk of injury or damage to health.

7m

7m

7m

Bench drilling

2m

7m

7m

2m

Tramming

Working area The area near the drill rig in which its tools are moved in order to carry out work.

Equipment description

10
ATLAS COPCO

12

14 6

8 7 17 11
Max. 9106 1073 06 9106 1073 21

a x. M

9106 1071 00

1 3 16

15 5 10 4 13

Features & Control overview ROC 203PC

1 2 3 4 5 6 7 8 9 10 Air inlet ( pages 14 & 21) Main valve ( page 14) Dirt filter Hydraulic tank ( page 14, 45 & 46) Hydraulic traction unit ( page 28) Track oscillation valve ( page 15) Hydraulic control panel ( page 12) Pneumatic control panel ( page 13) Chain feed BMM 35K BBR 4 Rotation Unit - Down - The - Hole (DTH) or BBC 120F Drifter for Top Hammer (TH) Feed gear and -motor Boom Traction motor valve ( page 14) Dust collector DCT-60E * Extra air outlet ( page 14) Tow hook ( page 29) De-clutching lever

11 12 13 14 15 16 17

* optional

11

Operating controls ROC 203PC

Hydraulic control panel
1 Feed extension a) UP b) NEUTRAL c) DOWN Feed swing a) CLOCKWISE (view from rear) b) NEUTRAL c) ANTI-CLOCKWISE (view from rear) Feed dump a) SPIKE FORWARDS b) NEUTRAL c) SPIKE BACKWARDS Boom lift a) UP b) NEUTRAL c) DOWN
9106 1071 00

11

2 3 4 5 6

12

a b c

Boom swing a) LEFT b) NEUTRAL c) RIGHT Track oscillation a) REAR EDGE OF PLATFORM RISES 9 b) NEUTRAL c) REAR EDGE OF -PLATFORM LOWERS Left track a) FORWARD b) NEUTRAL c) BACKWARD Right track a) FORWARD b) NEUTRAL c) BACKWARD

10 a b 7 a b c 8

* optional

12

De-clutching left a) ON b) OFF

11

2 3 4 5 6

12

10 De-clutching right a) ON b) OFF 11 Signal Horn

a b c

12 Button Emergency stop closes the valve 'air supply' (disengage before restart)

Pneumatic control panel

20 DCT (Dust collector) * a) CLEANING b) OFF c) ON 21 Set screw Feed pressure - REDUCE (anti-clockwise) + INCREASE (clockwise) 22 Gauge Feed pressure 23 Feed speed a) RAPID FEED ON b) RAPID FEED OFF 24 Feed (speed and direction) a) REVERSE FEED / RAPID REVERSE FEED** b) NEUTRAL c) DRILL FEED / RAPID FEED** 25 Rotation (speed and direction) a) REVERSE b) NEUTRAL c) DRILL ROTATION 26 Impact / Flushing (DTH) a) NEUTRAL b) MAX. IMPACT / FLUSHING 27 Flushing air (TH) a) NEUTRAL b) MAX. FLUSHING AIR 28 Button emergency stop Closes the valve 'air supply' (disengage before restart) * optional ** this function is possible when lever 23 is ON
b a

9106 1071 00

10 a b 7 a b c 8

21

-+
a b 22 28

20 c

23

24

25
c

27
b

26
a

13

Controls
General air and oil flow controls
1 2 3 Air inlet Main air valve Pneumatically operated Lubrication valve (rock drill) See chapter "Settings and maintenance by the operator" Tramming valve a) CLOSED b) OPEN Pressure regulating valve (pump motor, rock drill, flushing air T.H.) INCREASE (clockwise) DECREASE (anti-clockwise) Lubrication valve (rock drill, tramming motor, extra air outlet) See chapter "Settings and maintenance by the operator" Extra air outlet a) CLOSED b) OPEN

2 3 1

5 7b 4a 4b

7a

Gauge Hydraulic oil return filter pressure Too high pressure (needle in red field) indicates that filter cartridge requires replacement Level glass Hydraulic oil level Level shall be between max. and min. markings

14

Track oscillation shut-off valve

1 2 LEFT CYLINDER RIGHT CYLINDER a) OPEN both cylinders OPEN (to be used for tramming) b) CLOSED both cylinders CLOSED (to be used when rig is set up for drilling or lifting and transport condition

Gradient meter
Indicates angles for safe operation of the drill rig, specified in the Technical data. The rig might tip over the angles specified.
1 3 2 5 4 4 2 3 01 5
0

5 4 3 2 1

30
0

01 2 3 4

30 2 0

10

0 02 10

300 200 100 00

100 2

00 300

15

Principal system functions

Pneumatic system

hyd. pump

feed motor

rock drill

feed control air motor

rotation control

impact control

flushing control

Emergency stop extra air outlet lubricating oil tank lubrication valve lubrication valve dust trap main valve

Emergency stop

DCT*

inlet

*optional

Hydraulic system
Positioning cylinders: - feed extension - feed swing - feed dump - boom lift - boom swing

track oscillation shut-off valve

track oscillation cylinders

positioning control

left track control return oil filter air motor

right track control

hydraulic pump hydraulic oil tank

16

Operation
Daily checks

Carry out "Daily checks" Prior to each shift !

For inspection/maintenance every 40, 125, 500 and 1500 hours of operation follow separate instruction: Service Schedule for Pneumatic Crawler Drills ROC 203PC Printed matter no. ASB 181 00 10

17

! Extra safety check

12*

ATLAS COPCO

11*

10*

9 14 4

7 3 5 6

13 1

15

18

Before each shift commences, an extra and thorough safety check shall be carried out, intended to detect: l cracks or fractures in materials or at welded points. l damage, which could cause structural weakness or fracture, l wear, with the risk of the same consequences, l loose junctions, loose threaded unions.

If the crawler has been subjected to abnormally high stress, then vital load-bearing components may have become damaged in the process. From the safety aspects therefore, the following check points are particularly important (see illustration on opposite page): Tow hook Chain tensioner Track frame attachment Boom support Boom Boom head Drill steel support Feed gear (*) Feed holder with attachment Feed beam * Rock drill and cradle * Feed chain with attachments * For readjustment of chain slack see "Service schedule for Pneumatic Crawler Drills ROC 203PC Printed matter no. ASB 182 00 10 13. Cylinder brackets 14. S link 15. Bellow housing 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

In case checkpoints are not accessible (upright feed), carry out these checks after connection of air supply

19

Topping-up liquids
WARNING
Hazardous air pressure Can cause severe injury l Release pressure in tank before removing any plug

Emergency stop switch (on both control panel) to PUSH MODE + SYSTEM DEPRESSURIZATION

3a
3 Hydraulic oil tank: Check level (a), refill if necessary (b) Recommended oils and lubricants see page 51.

3b

Lubricating oil tank: Top-up with air tool oil Recommended oils and lubricants see page 51.

IVER Type 9 Seria 090 0492 00 lN Volum o. e Max. I. 12 w Test p orking pr.b re a Work ssure bar r(e) 20 (e t Made emp. oc 12 ) 26 0F i Made n by A.C . India

AIR R E CE

3217

5431

00

20

Connecting air supply

1 Wire mesh hose, chain, attachment: Check for attachment and damage

CAUTION
Always secure air hose with wire mesh hose

Air hose: Route air hose through wire mesh hose and connect it to the air inlet

3
3 Compressor: Switch on compressor

Emergency stop switch (On both control panel) to position RELEASE MODE

Air valve to position OPEN

Gauge Return oil filter pressure If needle is in the red area, replace return oil filter according to instructions on page 45

45
21

Functional checks

22

Functional ckecks
NOTE The emergency stops (all) have to be checked before each shift and after each tramming Emergency stops (all) Check that each emergency stop individually closes the inlet valve. All the rig function will then stop. Before checking the next emergency stop the previous emergency stop must be in released mode before restart.

WARNING
Never operate a defective drill rig Can cause severe injury and property l Close the air main valve if the drill rig has failed one or more checkpoints

1 2

Operating controls Check function and for leakages Rock drill cradle Check for frictionless travel without excessive wear between the beam and the cradle (both when drill feeding and rapid feeding) Traction units Check for leakage

22

Hoses, pipes and couplings in the air system Check for leakage and damage

Hoses, pipes and couplings in the hydraulic system Check for leakage and damage

Hydraulic cylinders and double check valves Check for damage, leakage and double check valve function (no creeping)

23

DCT hose and skirts Check for attachment and leakage

Lubricating valve(s): Check that the exhaust air from the rock drill contains oil (both rotation and impact) For setting lubricating valves, see page 47

47

WARNING
Never operate a defective drill rig

10

Call service mechanic if the drill rig has failed one or more checkpoints

24

Manoeuvring
Tramming

WARNING
Tip over hazard Can cause severe injury and property damage l Keep feed in tramming position and boom inside the track limits l Keep oscillation cylinders open l Do not exceed the gradient of 200 lateral and 200 uphill or downhill in direction of tramming l Keep the air bubble inside the limit for tramming l Operate the drill rig from the uphill side

WARNING
Tip over hazard Can cause severe injury and property damage l Keep unauthorized persons out of working area

NOTE The emergency stops (all) have to be checked after each tramming (see 21)

Emergency stop switch (on both control panel) to RELEASE MODE

25

Air valve to position OPEN

CAUTION
Fully lay down the feed beam beneath the hydraulic tank resp. if tramming takes places over a longer distance (in order to reduce the loads onto the boom system) difficult terrain has to be passed (in order to the optimize stability/balance)

Lift feed

Track oscillation shut-off valve to BOTH CYLINDERS OPEN

26

WARNING
Electrical hazard Can cause severe injury and property damage l Keep distance from power lines

Levers Left track (a) and Right track (b) to appropriate position

Max. Max.

9106 1073 21

9106 1073 06

9106 1071 00

When travelling is terminated: Air valve to position CLOSED

27

Towing
WARNING
Hazardous rolling motions Can cause severe injury and property damage l Place wedge blocks underneath both tracks, before de-clutching

Place Wedges or wooden blocks in front and behind both tracks

Emergency stop switch (on both control panel) to RELEASE MODE

Air valve to position OPEN

Left track control to position FORWARD (hold till de-clutching lever operation complete) Left de-clutching lever to position OFF

4 5

97 106 10 3 21

9106 1073 06

28

Right track control to position FORWARD (hold till de-clutching lever operation) Right de-clutching lever to position OFF

9106 1073 21

9106 1073 06

Track oscillation shut-off valve to BOTH CYLINDERS OPEN

Connect Tow bar between drill rig and towing vehicle

10 Remove Wedges

11 Start towing, max towing speed 5 km/h (3 miles/h)

max. 5km/h (3 miles/h)

12 When towing is terminated: Place Wedges or wooden blocks in front and behind both tracks

29

13 Disconnect Tow bar

14 Left & Right de-clutching lever to position ON

9106 1073 21

9106 1073 06

14

14

30

Hoisting
1 Position the boom system so that the crawler is as compact as possible. This will obtain the best possible point of balance and centre of gravity Position a sling under the rear edge of the front wheels, and another sling under the front edge of the rear wheels The sling must be dimensioned for lifting 6 tons with a good safety margin 3 Ensure that rig is not in declutching mode

ROC 203 PC

WARNING
Suspended load Can cause severe injury and property damage l Keep away from a suspended load l Use only lifting device and cargo sling with sufficient hoisting capacity

WARNING
Tip over hazard Can cause severe injury and property damage l Lock oscillation cylinders when the drill rig is being hoisted 4 Before starting to hoist, check carefully that none of the hoses, controls or other components can get caught up or damaged when the slings become tightened and under load

WARNING
Always make sure that nobody is anywhere near a suspended load

31

Drilling
Set-up for drilling
1 Emergency stop switch (on both control panel ) to position RELEASED MODE

Lever Feed speed to RAPID FEED ON

WARNING
Hazardous moving and rotating parts Can cause severe injury l Keep unauthorized persons out of working area l Stay away from the rotating drill string

3 4 5

Run-up the rockdrill Insert a drillrod Mount a drillbit

Position the feed

Track oscillation shut-off valve to BOTH CYLINDERS CLOSED

32

CAUTION
Use Boom lift to lift the tracks Using Feed extension puts excessive load onto the boom head

Achieve a stable 3-point set-up Lever Boom lift (a) to DOWN

Lever Feed speed to RAPID FEED OFF

33

Collaring & drilling down the first rod

d
a) Lever Rotation to DRILLROTATION b) Lever Impact / Flushing air to MAX. FLUSHING AIR (for DTH) or c) Lever Flushing Air to max Flushing Air (for TH) d) Switch DCT* to ON

a c b

Lever Feed to DRILLFEED

When the bit reaches the ground: Lever Impact to REDUCED IMPACT

When solid rock is reached (min. 20 cm / 8"): Lever Impact to FULL IMPACT

* optional

34

Adjust Feed pressure in order to obtain the optimum rotation torque:

Feed pressure too low: - metallic noise from couplings - couplings heat up (and suffer increased wear) - energy is lost - excessive shank adapter and threads wear

Feed pressure too high: - hole deviation - threads get too tight - drill bit wear

When coupling is ~ 25 cm (10") above drill steel support: Open Drill steel support halves

Lever Rotation to NEUTRAL Lever Feed to REDUCED DRILL FEED

When the couplings create a metallic noise: All levers to NEUTRAL

Switch DCT * to CLEANING

* optional

35

Adding rods
1 Lever Rotation to REVERSE Shank adapter / adapter rotates out of coupling

Lever Rotation to NEUTRAL

Lever Feed speed to RAPID FEED ON

Lever Feed to REVERSE FEED until rock drill reaches the stop

Lever Feed speed to RAPID FEED OFF

Insert another rod

36

In order to couple shank adapter to new rod and new rod to old rod: Lever Rotation to SLOW DRILL ROTATION Lever Feed to DRILLFEED

Lever Flushing to MAX. FLUSHING AIR a) for TH b) for DTH Lever Rotation to DRILL ROTATION Lever Impact to REDUCED IMPACT Switch DCT * to ON

When the coupling has passed the drill steel support: Close Drill steel support halves

10 Lever Impact to FULL IMPACT

11 Adjust Feed pressure in order to obtain the optimum rotation torque (see page 35) * optional

37

Withdrawing the drill string

1 Lever Rotation to NEUTRAL Lever Feed to REDUCED DRILL FEED

In order to loosen the couplings: Keep lever Impact in FULL IMPACT for another 3 - 6 sec

... 3 - 6 sec:
3 Lever Impact to NEUTRAL Lever Feed to NEUTRAL Keep switch DCT * in ON lever Flushing air in MAX .FLUSHING AIR a) for TH b) for DTH

a b

Lever Feed speed to RAPID FEED ON

Lever Feed to RAPID REVERSE FEED until the coupling has passed the drill steel support

* optional

38

Lever Feed to NEUTRAL

Make sure that the drill steel support halves are closed

Lever Flushing to NEUTRAL a) for TH a) for DTH Switch DCT * to CLEANING for approx. 20 sec

a b

... 20 sec:
9 Switch DCT * to OFF

10 In order to separate the shank adapter from the drill string: Lever Rotation to REVERSE until the shank adapter has rotated out of the coupling

* optional

39

11 Lever Rotation to NEUTRAL

12 In order to raise the rock drill a few centimeters: Lever Feed to RAPID REVERSE

13 Lever Feed to NEUTRAL

14 Rotate top rod out of coupling by hand

15 Put the rod on a suitable place

40

16 Lever Feed to RAPID FEED until the shank adapter reaches the coupling

17 Lever Feed to NEUTRAL Lever Rotation to DRILLROTATION until the shank adapter has safely gripped the drill string Do not tighten the thread !

18 Lever Feed to RAPID REVERSE FEED

19 Lever Feed to NEUTRAL

20 Continue with step 10 until there is only one rod left in the drill string

39

21 Check the drill bit Replace resp. grind if required

41

When the drill string gets stuck during withdrawing ...

NOTE For TH / DTH you may try with flushing air alone for the start

Lever Rotation to DRILLROTATION and Lever Flushing air to MAX. FLUSHING AIR a) for TH a) for DTH

a b

If this tightens the couplings too much: Arrest coupling on drill steel support

Lever Feed speed to RAPID FEED OFF

For a few seconds: Lever Feed to REDUCED FEED PRESSURE Lever Impact to REDUCED IMPACT

Lever Feed to NEUTRAL Lever Impact to NEUTRAL

42

Reconnection of the feed swing cylinder

To simplify certain types of drilling work, it is possible to reconnect the feed swing cylinder so that the boom system can operate outside the confines of the track frames

2 1

CAUTION
Operating the feed within sector 2 causes reduced stability of the crawler. Strictly follow the procedures given below in order to prevent accidents

Emergency stop switch (on both control panel) to RELEASE MODE

Air valve to position OPEN

Position the feed beam horizontally above the control panel

43

Track oscillation shut-off valve to BOTH CYLINDERS CLOSED

a
5 Remove a) Screws b) Lock Plate c) Pin

Make sure the other reception hole is free from dirt and corrosion

7) Match (align) the cylinder rod end eye to another eye of boom head by: a) operating feed swing cylinder & b) Rotate the feed slowly by hand

7a

CAUTION
During the rotating the feed beam take care it should not collide on DCT.

7b

8b
8 Tap the cylinder pin (8a) in position & tighten with screws (8b) on lock plate (8c)

8c

8a 44

Settings and maintenance by the operator

Replacing the oilfilter cartridge
When the needle of return oil pressure gauge is in the red field, the filter cartridge needs to be replaced 1 Emergency stop switch (on both control panel) to PUSH MODE SYSTEM DEPRESSURIZATION In order to release residual pressure in the hydraulic system: Operate a Track control (or any of the positioning controls)

Clean the filter cap

4a 4b
4 a) Remove the filter cap screws b) Remove the filter cap

Remove the old filter cartridge

Insert a new filter cartridge

Mount the filter cap

45

Cleaning the strainer

1 Emergency stop switch (on both control panel) to position PUSH MODE SYSTEM DEPRESSURIZATION

4
2 Drain the oil by removing the drain plug

Remove return line filter assembly by removing screws

Remove strainer

5
6 Clean up the strainer

6 2
7 Assemble strainer, return line filter assly., drain plug

Tensioning the crawler tracks

1 Make sure the crawler drill is standing on more or less horizontal ground

A = 25 - 50 mm !
2 Place a wooden plank on the crawler track Check that the slack is between 25 - 50 mm

A > 50 mm ?
4 If the slack exceeds 50 mm, press in grease through the nipple

46

Setting the lubricating valves

Undo the wing nut

Increase (+) or decrease (-) the oil dosage by turning the adjustment screw

Tighten the wing nut

47

Technical data *
Masses
ROC 203 PC-00 Optional Equipment Dust collector DCT 60-E Assembly kit DCT 2500 kg 5520 lbs

85 kg 110 kg

187 lbs 242 lbs

Performance
Max. travel speeds (w/o compressor on level ground) Max. towing speed Tractive force Tramming (w/o compressor) Tramming with compressor (max. 3500kg.) Max. longitudinal inclination for drilling Max. lateral inclination Tramming Drilling Drilling with reconnected feed swing cylinder Average ground pressure Ground clearance Track oscillation Max. ambient temperature Max. operating air pressure Sound level 2.5 km/h 5 km/h 18.8 kN 20 15 20 20 15 10 0.04 N/mm2 295 mm 12 45C 12 bar 126 dB(A) 1.55 miles/h 3.1 miles/h 4225 lbf 20 15 20 20 15 10 5.8 psi 11.63" 12 113F 171.5 psi 126dB(A)

Hydraulic system
Max. operating pressure Air motor Type Performance max. Torque max. Rotation speed max. Pump Type Pressure max. Traction motor Type Displacement per revolution Filter (Filtration degree) Gerotor motor 160cc 25 m nominal 25 m nominal Gear pump max. 210 bar 3000 psi Piston motor 7.5 kW (at 6 bar) 69 Nm 1100 rpm 10 hp 51 lbf.ft. 1100 rpm 210 bar 3045 psi

* Specifications are subject to change without prior notice

48

Component specifications
Pneumatic chain feed 1) Mass excl. rock drill Total length Travel length Travel speed max. Feed force max. Air consumption during drilling max. 2) BMM 35K 859-00 (Five start) Mass excl. rock drill Total length Travel length Travel speed max. Feed force max. Air consumption during drilling max. Pneumatic chain feed 1) Down-The-Hole 300 kg 5430 mm 3940 mm 0.3 m/s 12 kN 9 l/s 661 lbs 17" 9.8" 12 11" 11.8"/s 2700 lbf 19 cfm Top Hammer 300 kg 5430 mm 3940 mm 0.3 m/s 8 kN 9 l/s 661 lbs 17" 9.8" 12 11" 11.8"/s 1800lbf 19 cfm BMM 35K 157-00 (Single start)

BMM 35K 257-01 (Single start) Mass excl. rotation unit Total length Travel length Travel speed max. Feed force max. Air consumption during drilling max. at 6 bar 295 kg 5430 mm 4009 mm 0.3 m/s 8 kN 9 l/s 650 lbs 17' 9.8" 13 1.8" 11.8" / s 1800 lbf 19 cfm

2)

BMM 35K 859-01 (Five start) Mass excl. rotation unit Total length Travel length Travel speed max. Feed force max. Air consumption during drilling max. at 6 bar 295 kg 5430mm 4009 mm 0.3 m/s 12 kN 9 l/s 650 lbs 17' 9.8" 13 1.8" 11.8" / s 2700 lbf 19 cfm

49

Pneumatic rock drill Hole Dia Weight Length Piston Dia Stroke Impact rate at 6 bar Rotation speed

BBC 120 (TH) 48-76 mm 69 kg. 780 mm 120 mm 65 mm 2100 blows / min 180 rpm 212 l/s 58 l/min. 45 l/min. 2"-3" 152 lbs 2' 6.7" 4.72" 2.56" 2100 blows / min 180 rpm 448 cfm 263.6 lmp.gal/min 15.3 US gal/min 204.5 lmp.gal/min 11.9 US gal/min

Air Consumption at 6 bar Flushing: Water Air Hose connections: Impact mechanism Rotation Flushing water Rotation unit Weight Length Torque max. at 6 bar Spindle speed range Down The Hole Hammer External diameter Length without drill bit Mass without drill bit Working pressure max. Hole size range Connecting threading size (male) Down The Hole Hammer External diameter Length w/o drill bit Mass w/o drill bit Working pressure max. Hole size range Connecting threading size (male) COP 44 COP 42 BBR4 (DTH)

38 mm 10 mm 19 mm

1 1/2" 3/8" 3/4"

83 kg 850 mm 900 Nm 0 to 70 rpm.

183 lbs 2' 9.5" 662 lbs.ft. 0 to 70 rpm.

96 mm 960 mm 35 kg. 6-25 bar 105-127 mm -

3.7" 3 2" 77 lbs 85.7 psi 4"-5" 2 3/8" API Reg.

98 mm 1036 mm 38 kg. 6 - 25 bar 110 - 130 mm -

3.85" 3' 4.8" 83.6 lbs 85- 365 psi 4.3"- 5.1' 2 3/8" API Reg.

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Recommended hydraulic oils and lubricants

Lubricating point Hydraulic oil tank Recommendation Use mineral-based hydraulic oils with good anti-wear, anti-rust, anti-oxidation and foam inhibiting properties and with good air and water separation characteristics. Choose an oil with viscosity grade (VG) and viscosity index (VI) in accordance with the table below. An oil with a high viscosity index is less sensitive to the effects of temperature: Hydraulic oil temperature in tank C (F) Viscosity Viscosity Normal operating temp. Min. starting temp. Max. temp grade VG index VI (viscosity 25-50 mm2/s (cST)) (viscosity min. (ISO 3448) 1000 mm2 /s (cST)) + 45 to + 60 (113 to 140) -5 (23) 75 (167) ISO VG 68 min. 100 + 35 to + 50 (95 to 122) -10 (14) 65 (149) ISO VG 46 min. 100 + 25 to + 40 (77 to 104) -15 (5) 55 (131) ISO VG 32 min. 100 + 10 to + 25 (50 to 77) -25 (13) 45 (113) ISO VG 15 min. 100 NB: When operating in extremely low temperature, installation of additional heating equipment is recommended. If the oil temperature exceeds +60 C (140 F) during long periods, a tropical oil cooler should be installed.
l l

Lubricating oil tank Feed chains

Mineral-based air-tool oils Ambient temperature C (F) -30 to 0 (22 to 32) -10 to + 20 (14 to 68) + 10 to + 50 (50 to 122) Viscosity grade (ISO 3448) VG 32 - 68 VG 68 - 100 VG 100 - 150

or
l

Transmission oils of hypoid type SAE HD 80W/90 Valid for ambient temperatures -30 to + 50 C (22 to 122 F) Specification: MIL-L-2105C, EP tests L27 and L42 Operating temp. C (F) Max. 100 (212) Max. 140 (284)

Grease nipples Feed beam

l l l

Universal grease NLGI 2 lithium/molybdenum additive Synthetic sodium or calcium grease

Traction gears Feed gear Air motro (Power pack)

Use mineral-based transmission oils (for cars) that conform to quality SAE HD 80W/90 and to the norm MIL-L-2105C Use mineral-based engine oils that conform to quality SAE20 W / 40

Volumes
Lubricating oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic oil system, total . . . . . . . . . . . . . . . . . . . . . . Hydraulic oil tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Traction unit, planetary gear (each) . . . . . . . . . . . . . . Feed gear (single boom version) . . . . . . . . . . . . . . . . Air motor power pack. . . . . . . . . . . . . . . . . . . . . . . . . . 12 l 85 l 80 l 0.25 l 1l 1.2 l 2.69 Imp.gal 18.7 Imp.gal 18 Imp.gal 0.055 Imp.gal 0.22 Imp.gal 0.26 Imp.gal 3.17 US.gal 22.5 US.gal 21 US.gal 0.066 US.gal 0.26 US.gal 0.31 US.gal

Tightening torques
Size M 10 M 12 M 16 M 20 Wrench size 17 mm 19 mm 24 mm 30 mm Tightening torque in Nm (lbf.ft.) 8.8 12.9 49 (36) 69 (51) 86 (63) 120 (89) 210 (156) 295 (218) 410 (303) 580 (428)

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Transport dimensions
Height Without DCT ........ 1595 mm With DCT 60-E ............................. 3265 mm Width Across tracks.................................. 1950 mm Incl. DCT 60-E in transport pos.... 2150 mm Incl. DCT 60-E in working pos...... 2635 mm Length 5500mm Track chain width........................................ 200 mm 6 4.7" 7 1" 8 8" 18'1" 7.8" 5 2.8" 10 8.5"

ATLAS COPCO

ROC

-203

ROC

Track oscillation

52

Coverage area (Boom swing)

72
35

37

Manoeuvring possibilities
Max. and Min. height position as well as feed extension

800

ATLAS COPCO

RO C-2 03

425

1484

ROC

2672

53

Feed swing after reconnection of feed swing cylinder

Feed swing angle at two positions of feed swing cylinders

54

68

13

Documentations Feedback
Dear Operator, if you find any deficiency in this manual (a procedure insufficiently or not described, a safety risk not referred to etc.), please take a copy of this page, fill it in and send it to:

Atlas Copco Rock Drills AB attn.: Tekn. Dok S-701 91 rebro Sweden
Feedback E-mail: rde.techdoc@atlascopco.com Printed matter no.: AIB 181 00 10 Affected page(s): ....................... Description of deficiency:

Add pages if necessary

TUESDAY

DECEMBER

31

Signature
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