Beruflich Dokumente
Kultur Dokumente
ROC L7CR II
Maintenance instructions
1250 0071 04
Safety
Reference................................................................................................................. 5
3
Safety
4
Safety
Reference
Note
Always read the information under Safety before starting to use the rig or starting
maintenance work.
1250 0099 89
5
Safety
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Maintenance instructions
Maintenance instructions
1. General ................................................................................................................... 11
General .................................................................................................................. 11
Safety ................................................................................................................ 11
Target group and objective ............................................................................... 11
Contact details .................................................................................................. 12
Signs for outsourced components ..................................................................... 15
Dismantling and assembly................................................................................ 15
Scrapping .......................................................................................................... 16
Tightening torques for bolted joints.................................................................. 16
Welding............................................................................................................. 17
The following must be observed when welding: ......................................... 17
Electrode recommendations......................................................................... 18
Fault finding...................................................................................................... 18
Battery ................................................................................................................... 19
Environmental considerations regarding batteries............................................ 19
Battery charging................................................................................................ 19
Proceed as follows (24V charger) ................................................................ 20
Proceed as follows (12V charger) ................................................................ 21
Starting with an auxiliary battery...................................................................... 21
Steel cables ............................................................................................................ 22
Scrapping guidelines for steel cables................................................................ 22
Wire break at cable mounting ...................................................................... 23
Occurrence of strand breaks......................................................................... 23
Concentrations of wire breaks...................................................................... 23
Effects of heat .............................................................................................. 23
Occurrence of wire breaks due to operating time. ....................................... 23
Reduced elasticity ........................................................................................ 23
Decrease in cable diameter .......................................................................... 24
Certain number and type of wire breaks ...................................................... 24
Corrosion...................................................................................................... 25
Surface wear................................................................................................. 25
Deformation of the cable.............................................................................. 26
Wire displacement........................................................................................ 26
Strand displacement ..................................................................................... 27
Waviness ...................................................................................................... 27
Cracks........................................................................................................... 27
Kinks ............................................................................................................ 28
Flattening ..................................................................................................... 28
Local cable diameter decrease ..................................................................... 28
Local cable diameter increase ...................................................................... 28
Basket formation .......................................................................................... 29
Tensioning the crawler tracks ................................................................................ 29
Air conditioning..................................................................................................... 30
Safety ................................................................................................................ 30
Environmental issues regarding refrigerant handling....................................... 31
7
Maintenance instructions
2. Transport instructions............................................................................................. 34
Hoisting ................................................................................................................. 34
Single-section boom version............................................................................. 34
Transport................................................................................................................ 36
Before loading the drill rig onto the transport vehicle...................................... 36
Once the drill rig is loaded onto the transport vehicle. ..................................... 37
Towing ................................................................................................................... 38
8
Maintenance instructions
5. Feeder ..................................................................................................................... 72
Cables .................................................................................................................... 72
Feeder cables .................................................................................................... 72
Elongation of cables ......................................................................................... 72
Replacing the haul cable ................................................................................... 73
Replacing the return cable ................................................................................ 76
Replacing the drum cradle haul cable............................................................... 78
Replacing the drum cradle return cable ............................................................ 78
Replacing the slide pieces in the holder ................................................................ 79
Replacing slide rails .............................................................................................. 79
Feed cylinder ......................................................................................................... 81
Dismantling the feed cylinder........................................................................... 81
Tension bushings for spacers ............................................................................ 82
Description ................................................................................................... 82
Dismantling.................................................................................................. 83
Assembly...................................................................................................... 83
7. Radiator .................................................................................................................. 86
Coolant .................................................................................................................. 86
9
Maintenance instructions
10
Maintenance instructions
1. General
1. General
General
Safety
When maintenance work is carried out on the rig, observe the following points:
The maintenance instructions are intended for mechanics and personnel in mainte-
nance and service. The user should have undergone Atlas Copse's training courses for
the equipment concerned.
11
Maintenance instructions
1. General
Contact details
Table: Addresses, phone numbers and fax numbers to Atlas Copco companies
Country Address Phone and fax number
Argentina P.O. Box 192 Suc. 37 Phone: +54 - (0)1 - 912 4421/24
1437 - Buenos Aires Fax: +54 - (0)1 - 912 6622
Australia P.O. Box 6134 Phone: +61 - (0)2 - 9621 9700
Delivery Centre Fax: +61 - (0)2 - 9621 9813
Blacktown NSW 2148
Austria Postfach 108 Phone: +43- (0)1 -76 01 20
A-1111 Wien Fax: +43 - (0)1 - 769 56 72
Bolivia Casilla 8742 Phone: +591 - 2-22 98 62
La Paz Fax: +591 - 2-22 10 36
Brazil P.O. Box 12737 Phone: +55 - (0)11 - 247 88 00
Sao Paulo, SP Fax: +55 - (0)11 - 541 76 71
04744-970
Canada P.O. Box 745 Phone: +1 - 514 631- 5571
Pointe-Claire Dorval Fax: +1 - 514 631-9217
Quebec, H9R 4S8
Chile Casilla 10239 Phone: +56 - (0)2-442 3600
Santiago Fax: +56 - (0)2 - 623 5131
China / Hong 41-1 Huang Jia Wei Phone: +86 - 25 - 5620 115-8
Kong Zhong yang Men Wai Fax: +86 - 25 - 551 5225
210037 Nanjing
CMT S-105 23 Stockholm Phone: +46 - (0)8 - 743 80 00
International Fax: +46 - (0)8 - 702 21 29
Colombia A.A. 95310 Phone: +57 - 1 - 430 4146
Santafé de Bogotá, D.C. Fax: +57 - 1 - 430 6514
Czech Republic Belohorska 159/187 Phone: +420 - (0)2 -205 14 604
169 00 PRAHA 6 Fax: +420 - (0)2- 205 14 614
Brenov
Finland Tuupakankuja 1 Phone: +358 - (0)9 - 296 64 42
SF-01740 Vantaa Fax: +358 - (0)9 - 29 64 21 8
France B.P. 50 Phone: +33 - (0)1 - 30 72 32 22
F-95132 Franconville Fax: +33 - (0)1 - 30 72 32 49
Germany Postfach 10 02 25 Phone: +49 - (0)201 - 217 70
D-46002 Essen Fax: +49 - (0)201 - 217 74 54
Ghana P O B 10071 Phone: +233 - 21 77 45 12
Accra North Fax: +233 - 21 77 61 47
Great Britain P.O. Box 79 Phone: +44 - (0)1442 - 22 21 00
Hemel Hempstead Fax: +44 - (0)1442 - 234467
Herts HP2 7HA
Greece 78, Kifissou Avenue Phone: +30 - (0)1 - 342 6600
GR-182 33 Ag. I. Rentis Fax: +30 - (0)1 - 345 4783
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Maintenance instructions
1. General
13
Maintenance instructions
1. General
14
Maintenance instructions
1. General
CAUTION
• Exercise extreme caution when slinging
and hoisting heavy objects
• Can cause personal injury
• Hoisting must take place at the centre of
gravity
• Only use slings which are intact and
designed for the load they shall carry
• Secure the slings in the lifting eyes,
where available
Before transporting in shafts or the like it may be necessary to fully or partially dis-
mantle the drill rig. Observe the following when dismantling, lifting and assembling:
• 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.
15
Maintenance instructions
1. General
Scrapping
When the entire drill rig or part of the rig is to be scrapped, local regulations in force
regarding handling, waste management, recycling and destruction must be followed.
Collect and dispose of:
16
Maintenance instructions
1. General
Welding
• Applies to drill rigs equipped with one of the following engines:
- CAT 3176
- CAT6.6
- CAT 3196
- 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.
Figure:
• Grind off rust and paint from the area that is to be welded and carefully prepare the
joint.
17
Maintenance instructions
1. General
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:
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:
Fault finding
Fault finding is a logical sequence of activities to locate a fault, thereby making it
possible to rectify the fault as quickly as possible.
Always try to investigate the location of the fault in order to limit fault finding to a
certain system or function.
18
Maintenance instructions
1. General
Battery
ENVIRONMENTAL DIRECTIONS
Battery charging
WARNING
• Risk of fire and explosion
• May cause serious personal injury and
damage to property
• Flammable hydrogen gas
• Corrosive fluid
• Avoid naked flames and sparks
• Always detach the negative terminal first,
and connect it last
The battery is normally charged by the drill rig's generator. If the battery is fully 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.
19
Maintenance instructions
1. General
Explosive oxyhydrogen gas is produced during charging. A short circuit, naked flame
or spark close to the battery could cause a powerful explosion. Provide adequate ven-
tilation. Always switch off the charger before disconnecting the battery clamps. If the
density of the electrolyte does not change significantly, despite many hours of charg-
ing, the battery has most likely reached the end of its life.
Quick charging, performed correctly, will not damage the battery. Quick charging
should however not be used regularly and is not recommended for older 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:
2. Detach the cable between chassis earth and the negative cable on the battery G1B.
3. Connect the positive cable of the battery charger to the positive terminal of G1A.
4. Connect the negative cable of the battery charger to the negative terminal of G1B.
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.
20
Maintenance instructions
1. General
4. Connect the cable between chassis earth and the negative terminal on G1B.
2. Disconnect the jumper lead between the negative terminal on battery G1A and the
positive terminal on battery G1B.
3. Connect the positive cable of the battery charger to the positive terminal of G1A.
4. Connect the batter charger's negative lead to the negative terminal on G1A.
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.
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.
21
Maintenance instructions
1. General
1. Check that the auxiliary starting batteries (1) have the same voltage as the batter-
ies on the chassis.
1250 0064 41
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.
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
22
Maintenance instructions
1. General
Shorten the cable and reattach it. However, the remaining cable length must be suffi-
cient.
If this is the case, the cable must be scrapped even if the number of wire breaks is less
than the maximum specified in the table.
Effects of heat
Cables exposed to extreme heat must be scrapped. The effects of heat can be estab-
lished through annealing colour.
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.
23
Maintenance instructions
1. General
If the cable has lost elasticity, the following characteristics usually appear:
Reduced elasticity can lead to sudden cable breaks during heavy loads. The cable
should be scrapped.
If the cable's diameter decreases more than 10% in relation to the nominal diameter
of the cable, it must be scrapped.
The cables should be scrapped if the number of wire breaks specified in the table
have been detected
24
Maintenance instructions
1. General
Table:
Number of load-bearing Number of visible wire breaks 2 that require
1
wires in the outer strand scrapping
Machine groups M1 and M2
Cross lay Equal lay
n
Over a length of Over a length of
6d 30d 6d 30d
201 - 220 9 18 4 9
221 - 240 10 19 5 10
d = Cable diameter
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.
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.
25
Maintenance instructions
1. General
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 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.
• 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.
26
Maintenance instructions
1. General
Strand displacement
Strand displacement, which often occurs in conjunction with basket formation, is
when the steel core pushes out between the strands.
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.
d 1 > 4d/3
d 1 = 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.
Figure: Cracks
27
Maintenance instructions
1. General
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.
Figure: Kinks
Flattening
Flattening is deformation caused by mechanical damage.
Figure: Flattening
The area near the end attachments must be inspected especially carefully as it can be
difficult to detect cable diameter decrease at these spots.
28
Maintenance instructions
1. General
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.
2 3
1
A
4
1250 0117 37
29
Maintenance instructions
1. General
N.B.
The clearance (A, see illustration: Crawler track) between the wooden plank and
the crawler track should be between 25 and 50 mm (0.9 and 1.9").
N.B.
The grease nipple should not be filled with grease during normal inspection.
1. Place a wooden plank (2, see illustration: Crawler track) on top of each track.
2. Pack with grease via the nipple (4) to tension the track.
3. If necessary, grease can be removed from the tension cylinder by unscrewing the
nipple (4).
Air conditioning
Safety
WARNING
• Refrigerant under pressure
• Risk of serious personal injury
• Service of refrigerant must always be
carried out by authorised personnel
Note
Do not use the system with too little refrigerant, leakage or any other fault until it is
rectified. Otherwise, there is risk of the compressor breaking down.
30
Maintenance instructions
1. General
ENVIRONMENTAL DIRECTIONS
A B
e b
d
e
a c
31
Maintenance instructions
1. General
• Install the new filters and screw back on the covers (a, b).
Fault finding
No cooling
Check the following points:
Poor cooling
Check the following points:
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
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
32
Maintenance instructions
1. General
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.
33
Maintenance instructions
2. Transport instructions
2. Transport instructions
Hoisting
WARNING
• Hanging load
• May cause serious personal injury and
damage to property
• Do not approach a hanging load
• Only use lifting equipment and lifting
straps with adequate lifting capacity
• Risk of tipping
• Lock the track oscillation cylinders
before the drill rig is raised
Figure: Hoisting
34
Maintenance instructions
2. Transport instructions
Make sure the chassis is not damaged when you position the feed in the transport/
hoisting position.
c
b c
a d
1250 0166 46
• Make sure that none of the hoses, controls or any other components can fasten or
sustain damage when the hoisting slings are tensioned and under load.
• Place the hoisting slings under both crawler tracks at points A and B as shown in
the illustration Hoisting.
35
Maintenance instructions
2. Transport instructions
Transport
WARNING
• Risk of tipping
• May cause serious personal injury and
damage to property
• Lock the track oscillation cylinders
before the drill rig is raised
• Transportation equipment must be
adapted for the dimensions and weight of
the drill rig
36
Maintenance instructions
2. Transport instructions
c
b c
a d
1250 0166 46
37
Maintenance instructions
2. Transport instructions
Towing
WARNING
• Danger of moving parts
• May cause serious personal injury and
damage to property
• Place a wedge under both of the track
frames, before dismantling the traction
gears
1250 0131 32
Figure:
1250 0131 33
Figure:
38
Maintenance instructions
2. Transport instructions
1250 0131 34
Figure:
4. When the cover plate is in place, the drill rig is ready for towing.
1250 0131 35
Figure:
39
Maintenance instructions
3. Drilling system
3. Drilling system
WARNING
• Danger of serious equipment damage
• An incorrectly adjusted damper pressure
can cause serious damage to equipment
• Adjustment of damper pressure should
only be carried out by trained staff
200
100 300
2
0 400
bar
x 100 kPa
100 150
50 200
3 QDS-O 8a
0
bar
x 100 kPa
250
8b
100 150
4
50 200
0 bar 250
QDS-I
5
100 150
50 200
bar 250
QDS-A
QDS-J
8
6 10
2
0 bar 16
12
14
6
20
1250 0167 37
10 30
0
bar
40 7
40
60
20
80
The rock drill's damper circuit is supplied with oil via a constant flow valve inte-
grated into the logic block for percussion. The desired flow value through the damper
circuit is equivalent to the pressure when the damper piston is unloaded, i.e. the rock
drill's percussion rod is in its front position. Damper pressure adjustment must always
be made without pipes connected to the adapter and with the rock drill in vertical
position. Damper pressure must only be adjusted once the hydraulic oil has reached
working temperature, normally 40ºC (104ºF).
40
Maintenance instructions
3. Drilling system
1. Connect a pressure gauge between the damper pressure connection and the
damper pressure hose on the rock drill.
3. Make sure the rock drill's percussion rod/shank adapter is in its front end position.
5. Undo the lock screw (8b) and adjust the damper pressure by turning the knob (8a)
clockwise to lower the pressure or anticlockwise to increase it. The pressure
shown on the rock drill pressure gauge should read 35 bar and in the cab it should
read 45 bar.
For detailed information on rock drill pressure settings, refer to separate instruc-
tions “How to use the COP XXXX” for the relevant rock drill.
Note
The percussion should stop automatically if the damper pressure exceeds 120 bar,
falls below 45 bar or if drill feed is not activated.
Incorrect damper pressure can lead to damage to the rock drill, drill rig and drill
string. Damper pressure should only be adjusted by trained Atlas Copco personnel.
DPCI system
Function
The DPCI system controls the percussion function by sensing the damper pressure
during drilling. Depending on the damper pressure, activation of percussion may be
permitted, stopped or switched between high and low percussion pressure. This is
takes place by means of a number of sequence valves, so-called QDS valves, in the
rig's pilot-hydraulic system.
• QDS-I prevents the activation of percussion if the damper pressure is below 45 bar
or stops percussion if the damper pressure falls below 45 bar in the event of hose
ruptures or valve malfunctions for example.
• QDS-J switches off percussion if the damper pressure exceeds 120 bar, in the
event of the feed pressure being abnormally high or if a mechanical fault arises in
the damper for example.
• QDS-A. Permits high percussion pressure when the damper pressure exceeds 50
bar.
• QDS-O. Permits percussion activation when a certain drill feed pressure has been
reached or switches off percussion with reverse feed and hollows in the rock.
41
Maintenance instructions
3. Drilling system
Adjustment
CAUTION
• Incorrect settings can lead to damage to
the rock drill, drill rig and drill string
• Settings should only be made by Atlas
Copco service technicians
The DPCI system can either be adjusted in the workshop or at the drilling site.
Adjustment in the workshop generally produces more precise values for the settings.
Adjustment at the drilling site produces settings which are well adapted to the rock
conditions and the other settings of the rig.
In general it is important that both QDS-I and QDS-O have values set as high as pos-
sible without making percussion difficult to start.
Table: Guide values for QDS valves (optimum values can be higher)
QDS-I QDS-J QDS-A QDS-O (feed pressure)
45 bar 120 bar 50 bar 50-55 bar
(2-5 bar under low feed
pressure)
42
Maintenance instructions
3. Drilling system
200
100 300
2
0 400
bar
x 100 kPa
100 150
50 200
3 QDS-O
8a
0
bar
x 100 kPa
250
8b
100 150
4
50 200
0 bar 250
QDS-I
5
100 150
50 200
bar 250
QDS-A
QDS-
8
6 10
4
2
0 bar 16
12
14
6
20
1250 0167 37
10 30
0
bar
40 7
40
60
20
80
2. Disconnect QDS-O by turning its adjusting screw anticlockwise 3-4 turns. If this
is not done then percussion will be switched off due to too low feed pressure dur-
ing setting of QDS-I.
3. Start drilling with low percussion pressure and collaring feed pressure.
4. Lower the feed pressure slowly to 0 while observing the damper pressure gauge
(2).
5. When the damper pressure falls below 45 bar, due to the lower feed pressure, per-
cussion will be switched off automatically.
7. Verify that percussion cannot be activated without the drill bit being pressed
against the ground as well as that percussion can be activated when the bit is
pressed against the ground with collaring feed pressure.
43
Maintenance instructions
3. Drilling system
8. Re-adjust QDS-O by turning its adjusting screw clockwise as many turns as it was
turned anticlockwise in step 1, or in accordance with instructions.
9. Test the function by accessing the engine display and increasing the value for per-
cussion stop by 0.5 m. In practice, the automatic percussion stop is then deacti-
vated. Note down the original value!
1250 0167 96
When the rock drill cradle stops against the mechanical end stop the percussion
must be switched off immediately. If not, the setting for QDS-I must be raised.
10. Reset the value for percussion stop to its original value.
NOTE: The QDS-I setting must be the highest possible without making it difficult
to start percussion. This means that high percussion pressure and damper pressure
during collaring require a higher QDS-I setting.
NOTE: Drilling with too low percussion pressure can cause damage to COPROD
sections and the rock drill.
2. Adjust QDS-O clockwise until percussion is switched off and then anticlockwise
until it restarts.
3. Reverse the rock drill. Percussion should be switched off immediately without idle
stroke.
44
Maintenance instructions
3. Drilling system
4. Start drilling again and check that percussion starts without problems. Otherwise
QDS-O may need to be lowered slightly.
NOTE: The QDS-O setting must be the highest possible without making it difficult
to start percussion. This means that high feed pressure during collaring requires a
higher QDS-O setting.
2. Start drilling. Perform a thorough collaring and then activate high percussion pres-
sure.
3. Lower the feed pressure slowly while observing the damper pressure gauge (2).
4. When damper pressure falls below 50 bar the percussion pressure shall change to
low percussion pressure.
2. Start drilling. Perform a thorough collaring and then activate high percussion pres-
sure.
3. Increase the feed pressure slowly to maximum while observing the damper pres-
sure gauge (2).
4. When the damper pressure exceeds 120 bar percussion shall be switched off auto-
matically.
NOTE: This setting procedure involves an increased risk of jamming during setting
due to the increased feed pressure.
NOTE: In softer rock conditions it may be difficult to force damper pressure suffi-
ciently high. The setting can be made by temporarily setting the damper pressure reg-
ulator at 120 bar.
45
Maintenance instructions
3. Drilling system
2. Start the diesel engine, run it to 1500 rpm and select drill position on the switch,
Drilling/Tramming/Preheating.
3. Adjust damper pressure to 45 bar, read off on the damper pressure gauge in the cab
(2).
4. Activate forward drill feed. This is necessary to enable the start of percussion on
COPROD rigs (QDS-O). When the rock drill reaches its lower end position, per-
cussion is prohibited by limit sensor B121. This can be avoided by increasing the
value for percussion stop by 0.5 m in the engine display. Note down the original
value!
5. Activate low percussion pressure. Check that low percussion pressure shows on
the percussion pressure gauge in the cab (1).
6. Adjust QDS-I slowly forward and back to find the change-over point where the
percussion pressure disappears from the pressure gauge. Clockwise raises the
change-over point and anticlockwise lowers it. Following which, slowly screw
anticlockwise until the percussion pressure is visible again on the pressure gauge.
7. Check: Increase and decrease damper pressure several times to make sure that per-
cussion is switched off when the damper pressure falls below 45 bar.
8. Deactivate percussion and feed, and switch off the diesel engine.
9. Tighten the lock nut on QDS-I, reset the value for percussion stop to its original
value and reconnect the percussion's pressure hose.
2. Start the diesel engine, run it to 1500 rpm and select drill position on the switch,
Drilling/Tramming/Preheating.
3. Adjust the damper pressure to approx. 50 bar in order to disengage QDS-I (permit
percussion activation without the drill bit being pressed against the ground).
46
Maintenance instructions
3. Drilling system
5. Activate low percussion pressure. Check the pressure on the percussion pressure
gauge in the cab (1).
6. Adjust the low drill feed pressure to 2-5 bar lower than the normal setting, e.g. 45
bar.
7. Adjust QDS-O slowly forward and back to find the change-over point where the
percussion pressure disappears from the pressure gauge. Clockwise raises the
change-over point and anticlockwise lowers it.
8. Check: Increase and decrease collaring feed pressure to make sure that percussion
is switched off at the set value.
9. Deactivate percussion and feed, and switch off the diesel engine.
10. Tighten the lock nut on QDS-O without changing the setting, reset the value for
percussion stop to its original value and reconnect the percussion's pressure hose.
2. Start the diesel engine, run it to 1500 rpm and select drill position on the switch,
Drilling/Tramming/Preheating.
3. Adjust damper pressure to 50 bar, read off on the damper pressure gauge in the cab
(2).
4. Activate forward drill feed. This is necessary to enable the start of percussion on
COPROD rigs (QDS-O). When the rock drill reaches its lower end position, per-
cussion is prohibited by limit sensor B121. This can be avoided by increasing the
value for percussion stop by 0.5 m in the engine display. Note down the original
value!
6. Activate high percussion pressure. Check that high percussion pressure shows on
the percussion pressure gauge in the cab (1).
47
Maintenance instructions
3. Drilling system
7. Adjust QDS-A slowly forward and back to find the change-over point where the
percussion pressure switches between high and low. Clockwise raises the change-
over point and anticlockwise lowers it. Following which, slowly screw clockwise
until the percussion pressure switches to low.
8. Check: Increase and decrease damper pressure several times to make sure that the
percussion pressure changes when the damper pressure passes 50 bar.
9. Deactivate percussion, feed and rotation, and switch off the diesel engine.
10. Tighten the lock nut on QDS-A, reset the value for percussion stop to its original
value and reconnect the percussion's pressure hose.
2. Start the diesel engine, run it to 1500 rpm and select drill position on the switch,
Drilling/Tramming/Preheating.
3. Adjust damper pressure to 120 bar, read off on the damper pressure gauge in the
cab (2).
4. Activate forward drill feed. This is necessary to enable the start of percussion on
COPROD rigs (QDS-O). When the rock drill reaches its lower end position, per-
cussion is prohibited by limit sensor B121. This can be avoided by increasing the
value for percussion stop by 0.5 m in the engine display. Note down the original
value!
5. Activate low percussion pressure. Check that low percussion pressure shows on
the percussion pressure gauge in the cab (1).
6. Adjust QDS-J slowly forward and back to find the change-over point where the
percussion pressure disappears from the pressure gauge. Clockwise raises the
change-over point and anticlockwise lowers it. Following which, slowly screw
clockwise until the percussion pressure disappears.
7. Check: Increase and decrease damper pressure several times to make sure that per-
cussion is switched off when the damper pressure exceeds 120 bar.
8. Deactivate percussion and feed, and switch off the diesel engine.
9. Tighten the lock nut on QDS-J without changing the setting, reset the value for
percussion stop to its original value and reconnect the percussion's pressure hose.
48
Maintenance instructions
3. Drilling system
200
2
100 300
0 400
bar
x 100 kPa
100 150
50 200
3
0 250
bar
x 100 kPa
100 150
4
50 200
0 bar 250
5
100 150
50 200
bar 250
6
6 10
4 12
2 14
0 bar 16
20
10 30
0
bar
40 7
40
60
1250 0127 74
20
80
Note
Valves Percussion pressure (7 and 8) are located inside the cab (on the right-hand
side).
49
Maintenance instructions
3. Drilling system
2
2b
3 1
3b 1b
4
4b
5
5b
6
6b
7
7b
Note
Pressure ex works is 120 bar (factory setting).
The switch on the drill lever must be in position LOW PERCUSSION PRESSURE.
1. Slacken lock nut (6b, see illustration: Control panel for pressure).
2. Turn the adjusting screw (6, see illustration: Control panel for pressure) clockwise
to increase the low percussion pressure.
3. Turn the adjusting screw (6, see illustration: Control panel for pressure) anticlock-
wise to decrease the low percussion pressure.
4. Tighten the lock nut (6b, see illustration: Control panel for pressure).
Note
Pressure ex works is 200 bar (factory setting).
50
Maintenance instructions
3. Drilling system
The switch on the drill lever must be in position HIGH PERCUSSION PRESSURE.
1. Slacken lock nut (7b, see illustration: Control panel for pressure).
2. Turn the adjusting screw (7, see illustration: Control panel for pressure) clockwise
to increase the high percussion pressure.
3. Turn the adjusting screw (7, see illustration: Control panel for pressure) anticlock-
wise to decrease the high percussion pressure.
4. Tighten the lock nut (7b, see illustration: Control panel for pressure).
S167
a
S111 f
d b e
S100
c
1250 0166 47
S451
S400 S181
51
Maintenance instructions
3. Drilling system
The mode to use depends on the rock conditions. When drilling in loose rock forma-
tions, long percussion will contain more energy than can be absorbed by the rock. In
this case, it may be better to use short percussion only.
Valves Drill feed pressure (2 and 3) are located inside the cab (on right-hand side).
2
2b
3 1
3b 1b
4
4b
5
5b
6
6b
7
7b
Drill feed pressure can be checked on pressure gauge Drill feed pressure (3)
52
Maintenance instructions
3. Drilling system
200
2
100 300
0 400
bar
x 100 kPa
100 150
50 200
3
0 250
bar
x 100 kPa
100 150
4
50 200
0 bar 250
5
100 150
50 200
bar 250
6
6 10
4 12
2 14
0 bar 16
20
10 30
0
bar
40 7
40
60
1250 0127 74
20
80
Select low or high drill feed pressure using the drilling lever.
2
1
4
3 6
5
53
Maintenance instructions
3. Drilling system
The drilling lever must be in position (a), feed and rotation clockwise, as well as
reduced percussion pressure, button (5). The indicator lamp (2) should then flash and
indicator lamp (5) should illuminate.
See illustration “Control panel for pressure” for the location of adjusting screws.
The drilling lever must be in position (a), feed and rotation clockwise, as well as full
percussion pressure, button (6). The indicator lamp (2) and indicator lamp (5) should
illuminate.
See illustration “Control panel for pressure” for the location of adjusting screws.
54
Maintenance instructions
3. Drilling system
2
2b
3 1
3b 1b
4
4b
5
5b
6
6b
7
7b
• Loosen the knob (1b, see illustration: 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 (1b).
Note
Rotation speed can be set without drilling taking place.
The hydraulic oil should have a normal working temperature of 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 with the diesel engine running at maximum revs.
55
Maintenance instructions
3. Drilling system
- 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.
• 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.
• 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.
The friction can vary due to the degree of wear and adjustment of the slide pieces, as
well as whether or not these are lubricated. There is also a difference between thread-
ing and unthreading with or without a drill rod due to the difference in weight. The
setting must be adjusted to the higher load, for example: threading a drill rod in the
rod grippers and unthreading a rod in the rod grippers.
56
Maintenance instructions
3. Drilling system
2
2b
3 1
3b 1b
4
4b
5
5b
6
6b
7
7b
The drilling lever must be in rapid feed/jointing position. Change with button 3.
Lamp 1 should be off.
2
1
4
3 6
5
Threading
1. Undo the lock nut (4b) on the adjustment valve (4) for pipe threading.
57
Maintenance instructions
3. Drilling system
3. Turn the adjustment valve (4) for pipe coupling pressure clockwise/anticlockwise
to increase/decrease the feed pressure and feed speed. In general, the setting
should be the lowest possible for the cradle to move smoothly on the feed beam
with a pipe in drill centre and the grippers in guide position.
Unthreading
1. Undo the lock nut (5b) on the adjustment valve (5) for pipe unthreading.
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.
Adjustment
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 40ºC
(104ºF). In order to be able to make a good setting, the rock should be reasonably
homogenous so that a stable rotation pressure is obtained.
58
Maintenance instructions
3. Drilling system
3
3b
1
4
4b 1b
5
5b
6
6b
7
7b
8
8b 2
1250 0131 65
2b
1. Undo the lock nut (2b) and turn the adjuster screw (2) clockwise to its end position
in order to disengage the function. Oil can trickle out around the adjuster screw
while it is being adjusted.
2. Start drilling and set in a suitable feed pressure, percussion pressure and rotation
speed according to the rock drill's “How to use” instructions. See also the chapter
on pressure setting in this manual.
59
Maintenance instructions
3. Drilling system
3. Once an even and stable rotation pressure is achieved (pressure gauge 4), the
RPCF valve adjuster screw must be turned anticlockwise until the feed pressure
(pressure gauge 3) starts to drop.
200
2
100 300
0 400
bar
x 100 kPa
100 150
50 200
3
0 250
bar
x 100 kPa
100 150
4
50 200
0 bar 250
5
100 150
50 200
bar 250
6
6 10
4 12
2 14
0 bar 16
20
10 30
0
bar
40 7
40
60
1250 0127 74
20
80
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.
60
Maintenance instructions
3. Drilling system
1 3
2 4
Figure:
1 Regulator knob
2 Locking the regulator knob
3 Pressure gauge, compressor pressure
4 Temperature switch
Set the compressor discharge pressure according to the table above by turning the
regulator knob (1) clockwise/anticlockwise to increase/decrease the discharge pres-
sure. The pressure can be read on the pressure gauge (3).
In good rock conditions, the compressor can occasionally be run at a lower pressure
with maintained flushing air function. This will help to lower fuel consumption.
61
Maintenance instructions
3. Drilling system
Flushing air
Adjusting reduced flushing air
1250 0167 97
FLUSH AIR
1 a
FULL REDUCED
Y115 Y116
b
2
c
3
Flushing air is regulated with two solenoid valves, Y115 (1) and Y116 (2). When full
flushing air is activated, both valves will be open and when reduced flushing air is
activated, only Y116 will be open.
On occasions when low flushing air pressure and flow are required, e.g. when collar-
ing, the flushing air can be run at reduced rate by setting switch S100 to position (b).
In this case, only Y116 is active and flushing air flow can then be set by opening or
closing the valve (3) until the desired flow is attained.
While the system is being run with full flushing air, the compressor discharge pres-
sure will limit the flushing air pressure. Full flushing air is consequently adjusted by
adjusting the compressor discharge pressure.
Anti-jamming protection
The drill rig is equipped with two types of anti-jamming protection.
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.
62
Maintenance instructions
3. Drilling system
b
1250 0167 98
c
Figure: Rod/pipe handling panel with switch S100
2. Drill almost down to the greatest depth that will be drilled at the current position.
Make sure that full flushing air is activated. Switch S100, position a.
63
Maintenance instructions
3. Drilling system
3. Turn the flow switch adjuster screw (1) anticlockwise until the rock drill starts to
reverse. The higher the numerical value on the adjuster screw graduation, the
more sensitive the flow switch is. Factory setting is 30 mbar.
4. Screw back the adjuster screw until the rock drill starts moving down again.
5. Drill another hole to check that the anti-jamming protection is not activated inad-
vertently due to the setting being too sensitive. If this is the case, screw back the
adjuster screw a little more.
When changing drill bit or drill steel dimension, or when changing the drill depth, it
may be necessary to readjust the flow switch to maintain satisfactory anti-jamming
protection.
Note
Factory setting is 80 bar.
64
Maintenance instructions
3. Drilling system
3
3b
1
4
4b 1b
5
5b
6
6b
7
7b
8
8b 2
1250 0131 65
2b
WARNING
• Risk of serious personal injury
• During the procedure the rock drill will
reverse automatically
• Make sure that no personnel are within
the rock drill's area of movement
1. Turn the rotation speed adjusting knob (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.
65
Maintenance instructions
3. Drilling system
5. Slowly screw the adjusting knob clockwise while observing the rotation pressure
gauge. When the pressure exceeds the rotation pressure switch setting, the feed
direction will reverse. This can be seen by the pressure gauge reading falling to 0
and the rock drill attempting to pull loose from the drill-steel support.
6. Screw the adjuster knob anticlockwise to lower the rotation pressure and allow the
feed to start going down once 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.
Lubrication settings
Lubrication settings are made in the display for the engine and directional instru-
ments. See Operator's instructions.
If the lubricating oil tank has run dry, the system may need to be bled in order to pre-
vent air pockets forming in the lines and the pump.
66
Maintenance instructions
3. Drilling system
This can be done by pumping the lubricating oil through the hoses. Set the pulse relay
to the maximum number of pulses/minute to reduce the time it takes to bleed the sys-
tem.
The diesel engine must be running when bleeding HECL since the pump is hydrauli-
cally driven. This is not necessary when bleeding ECL since the pump is electrically
driven.
1. Detach the ECL hose from the rock drill and the HECL hose from its connection
on the flushing air line.
2. Undo the plug on the bleed hose leading from the ECL pressure gauge in the cab.
The hose is sticking out through the open bottom of the pressure gauge panel.
3. Open the bleed plugs on the ECL and HECL pumps (A).
4. Start the diesel engine and set the Drilling/Tramming/Preheating knob (S130) to
drilling.
6. Activate ECL and HECL by pressing the percussion button to the left for 0.5 sec-
onds.
7. First tighten the bleed plugs on the pumps and then the pressure gauge bleed plug
once pure oil runs out without air bubbles.
8. Refit the ECL and HECL hoses once pure oil without air bubbles runs out of them.
The ECL hose has a narrow inner capillary tube and is therefore quicker to bleed
than the HECL hose.
67
Maintenance instructions
4. Hydraulic systems
4. Hydraulic systems
ENVIRONMENTAL DIRECTIONS
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.
68
Maintenance instructions
4. Hydraulic systems
• Always plug hydraulic connections immediately after they have been detached.
• Use clean protective plugs.
• Hydraulic components like hoses, valves, motors, etc. must always be stored with
suitable protective plugs fitted in place.
• Spare parts for hydraulic components must always be kept in sealed plastic bags.
• Change filter cartridges as soon as the filters show signs of clogging.
• Suitable premises for hydraulic repairs arranged at the workplace. Repairs can be
carried out by your own specially trained personnel, the manufacturer's techni-
cians or Atlas Copco personnel.
• Components sent to the manufacturer's local agent for repair.
• Component repairs carried out by Atlas Copco. Repair instructions are available
for the most important and most complicated hydraulic components.
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, that are only used in the
hydraulic workshop.
• Have a ventilation system that does not admit dust into the premises.
• Have well-trained mechanics.
69
Maintenance instructions
4. Hydraulic systems
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 replaced in accordance with 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 replaced immediately.
Note
The filter cartridges cannot be cleaned but must be replaced when they are clogged.
1. Clean on and around the filter cap and unscrew the nuts (A).
A
B
D
1250 0097 64
2. Lift off the cap (B) and change the O-ring (C) if it is damaged.
4. Detach the overflow valve (E) by pressing down and turning the handle anticlock-
wise.
70
Maintenance instructions
4. Hydraulic systems
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.
71
Maintenance instructions
5. Feeder
5. Feeder
Cables
Feeder cables
Min 10 mm
A B
Elongation of cables
Tools: U-wrench 36 mm, U-wrench 19 mm, U-wrench 16 mm
Note
The cables must not rotate during elongation and slackening. Counterhold the turn-
ing with a 19 mm wrench on the flat part of the cable end.
72
Maintenance instructions
5. Feeder
3. Adjust the cable ends A and B so that the measurement between the drum cradle
and stop lug is obtained in accordance with the figure above. If the distance needs
to be increased then cable B is slackened and cable A is elongated. Cable C may
also require slackening in order to increase the distance. To reduce the distance,
cable A is slackened and cable B is elongated.
4. Tension cable A.
5. Run the drill cradle to stop in the lower end position. Load the cylinder (150 bar
feed pressure) and check that cable B does not slacken during loading. If the cable
slackens the cradle is run up to upper end position and cable A is tensioned further.
6. The drum cradle haul cable is adjusted so that the slack is greater than that of the
hydraulic hoses.
7. The drum cradle return cable is adjusted so that it is not tensioned more that the
drill cradle return cable.
Other tools: slide hammer, 18 and 12 mm sockets or block wrenches, 185 mm spacer
or straps (in the event of cable breakage).
The haul cable is threaded at one end and has an eyelet in the other end.
2. Run the hydraulic cylinder until the pulley wheel assembly is in the hole on the
left-hand side of the feeder (C).
73
Maintenance instructions
5. Feeder
3. Insert a 185 mm long spacer block between the cradles when the hose drum is in
its top position.
4. If the cable shall be replaced due to breakage then the cradles need to be pulled
apart with straps to facilitate fitting the new cable, see the illustration to the right.
The drill cradle must be pulled with the strap in the feed direction.
Figure: Straps
5. Undo the cable's threaded end. Remove pulley wheel C by removing the wheel
axle's stop washer, and screw the slide hammer into the centre hole. Then pull the
axle out and loosen the wheel via hole B. In addition, remove pulley wheel D in
the same way. First pull out the lubricating hose and remove the grease nipple
located in the centre hole (F) of the pulley wheel.
7. Go to the cable mounting on the cradle and undo the eight bolts holding plate A, in
which the other end of the cable is mounted. Turn the plate and pull it out in the
direction of the cable. Undo the bolt holding the cable's eyelet B and undo the
cable from the plate.
74
Maintenance instructions
5. Feeder
Secure the new cable's eyelet in the plate. Then move the plate back to the correct
position and screw in the eight bolts.
8. Move the threaded end of the cable back to where the front wheel should be
located (A in the illustration below) and up through the hole (B in the illustration
below)
9. Secure the stop nut, washers and spacer sleeve, then insert the threaded end of the
cable in the hole (see illustration of pulley wheel assembly, A).
Refit the pulley wheel (see illustration of pulley wheel assembly, B) and screw in
the first nut and lock nut on the end of the cable.
10. Tension the cable and remove the spacer or strap. Check that the cables are cor-
rectly tensioned in accordance with the instructions.
75
Maintenance instructions
5. Feeder
The return cable is threaded at one end and has an eyelet in the other end.
2. Run the rock drill cradle forward/down until the drum cradle is almost in end posi-
tion in accordance with the illustration, Drum cradle.
4. Pull out the threaded end of the cable through hole B in the illustration, Drum cra-
dle.
5. Undo the eight bolts holding the mounting for the cable's mounting eyelet on the
cradle. Then undo the eyelet from the plate.
76
Maintenance instructions
5. Feeder
6. Then run the cradle to the lower end position so that the wheel axle A is visible
through the hole in accordance with the illustration, Wheel axle.
7. Loosen the wheel by first unscrewing the axle's lock washer and then pull out the
axle with the slide hammer.
8. Now pull the cable's threaded end until the eyelet comes out through the hole (B in
the illustration, Drum cradle).
9. Insert the new cable with the eyelet end first and push it until it comes out from the
beam at the upper pulley wheel. Route the cable around the pulley wheel and
secure the eyelet in the plate. Screw in the plate using the eight bolts.
77
Maintenance instructions
5. Feeder
10. Run the cradle into position in accordance with the illustration, Drum cradle.
Secure the stop nut with washers on the threaded end of the cable, insert the end of
the cable into the mounting hole and secure the washers, nut and lock nut.
1. Undo the nuts on the two threaded ends of the haul cable.
The drum cradle return cable is threaded at one end and has an eyelet in the other end.
3. Unscrew the protective cover over the hole for the cable eyelet mounting. Then
unscrew the bolt from the eyelet.
78
Maintenance instructions
5. Feeder
4. Pull the cable out from the beam from the rear pulley wheel.
5. Guide the eyelet section of the new cable into the mounting and screw in the eye-
let.
6. Secure the stop nut and stop washer on the threaded section. Then secure the
threaded section of the cable in the drum cradle and tighten the nut and the stop
nut.
D
A
C
B
1250 0064 90
1. Prise off the slide pieces C from the holder using a screwdriver and remove the
keys D.
2. Slide a new slide piece into the holder track and fit the new keys.
3. Make sure the holders are refitted correctly in the cradle and are adjusted accord-
ing to the directions.
79
Maintenance instructions
5. Feeder
A
1250 0020 11
2. Remove the old slide rails A by prising the lower edges of the bars outwards using
a screwdriver.
4. Fit the new slide rails. The larger edge on the slide rail must be facing upwards.
The rails should be pressed in place by hand.
5. Refit the rock drill cradles, intermediate drill-steel support and water-hose drum.
Adjust the holders on the cradles as described in the instructions.
Note
Always replace the slide pieces when replacing slide rails!
80
Maintenance instructions
5. Feeder
Feed cylinder
WARNING
• Hazardous hydraulic oil and water
pressure
• Risk of personal injury
• Ensure that the system is depressurised
before work
• Never replace high-pressure hoses with
hoses of lower quality than the original or
with hoses with detachable couplings
1. Run the rock drill cradle to about half the feeder length.
2. Relieve the tension on the haul and return ropes, bolt A and nut B.
3. Remove the hose drum by undoing the 4 bolts in the centre of it and lifting off the
entire drum.
81
Maintenance instructions
5. Feeder
C
E
SP
D
G H
N
F
A
K
M
L I
1250 0020 87
6. Remove bolt A completely. Remove also end piece G and the end plate H.
7. The cylinder and fork can now be pulled backwards out of the beam.
Note
Avoid dismantling the spacer L. If it must be dismantled, measure SP first so that
the spacer can be refitted in the same position.
Measurement SP = 492 mm
Description
The spacer at the front end of the cylinder is kept in place with a tension bushing. In
order for the feed to function properly, the measurement SP on the spacer must be
correct. The measurement varies depending on the feed length and type of feed.
82
Maintenance instructions
5. Feeder
1250 0065 30
Dismantling
1. Remove the plastic plugs M from their holes.
3. Fit the bolts into the threaded holes and pull them alternately until the bushing
parts.
Assembly
1. Assemble the bushing as illustrated but do not tighten the bolts.
2. Fit the spacer and bushing into the sleeve and make measurement SP is the same
as before.
83
Maintenance instructions
6. Dust collector (DCT)
To check the filters in the dust collector. Unscrew the plugs (a) and connect a pres-
sure drop gauge to the two holes.
Measure the pressure drop while air flushing is activated. If the drop is greater than
an 800 mm (wg) column of water, all the filters should be changed.
Use a spanner to unscrew the filters. Turn the nut on the underside of the filter anti-
clockwise.
84
Maintenance instructions
6. Dust collector (DCT)
1250 0116 41
b
Figure: Dust collector.
85
Maintenance instructions
7. Radiator
7. Radiator
Coolant
WARNING
• Danger of scalding and pressure
• Can cause serious personal injury
• Release the pressure in the radiator
before removing the radiator cap
The drill rig has two radiators. The left-hand radiator is for the compressor oil and the
right-hand radiator is for engine coolant.
86
Maintenance instructions
8. Diesel engine
8. Diesel engine
Safety
WARNING
• Danger of rotating parts
• Hot engine and components
• Can cause serious personal injury
• Maintenance work on the drill rig must
only be carried out when the engine is
switched off
ENVIRONMENTAL DIRECTIONS
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Maintenance instructions
8. Diesel engine
N.B.
Top up (3) if the oil level is below or level with the lower mark on the dipstick (see
table “Recommended hydraulic oil and lubricants”).
1. Check that the oil level is between the upper and lower marks on the dipstick (1).
2
1250 0167 38
1
Figure: Diesel engine
1. Dipstick
2. Filling up
2. Top up (2) if the oil level is below or level with the lower mark on the dipstick (see
table “Recommended hydraulic oil and lubricants”).
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Maintenance instructions
8. Diesel engine
The intervals specified in the maintenance schedule for changing and cleaning the
main air filter cartridge are given only as guidelines. The actual interval can vary
between different workplaces and applications.
RCS
ESC
The filter cartridges, therefore, do not require service until the indicators warn other-
wise. The cartridges should, however, be checked for damage to the filter material at
the specified intervals.
If correct cleaning of the main cartridge cannot be ensured, a new cartridge should be
installed on each service occasion.
Table: Example
Hours 0 250 500 750 1000
Main cartridge service New Cleaning/ Cleaning/ Cleaning/ Changi
Changing Changing Changing ng
Safety cartridge service New Changi
ng
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Maintenance instructions
8. Diesel engine
1
2
3
4
1250 0026 14
3. Clean inside the filter housing and lid with a clean, dry rag.
Note
NOTE! If the safety cartridge has also been removed for changing, the filter hous-
ing air outlet must be completely covered with adhesive tape before cleaning the
filter housing.
4. Check that the evacuation valve (4) is not damaged. Change it if necessary.
5. Remove any adhesive tape there may be on filter housing air outlet.
Note
Never run the engine without the air filters in place.
Never clean filters by tapping them or tapping them against the ground. This can
damage the sealing surfaces and deform the filter cartridge.
Never clean filters in water or cleaning agent.
Never use a damaged filter cartridge!
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Maintenance instructions
8. Diesel engine
6
1250 0026 25
To ensure filter clogging is detected, the function of the filter switches (6) must be
checked regularly. This is done by gradually blocking the air intakes, one at a time.
The filter switches should trip and the filter warning light come on. If the lamp does
not light, start by checking the cable connections. If there are no problems with the
connections, the switch is faulty and must be changed.
Fuel system
Filter
The diesel engine has two fuel filters: diesel filter and prefilter. The prefilter has a
removable insert that must be cleaned once a month. If the prefilter insert is damaged,
change it.
Prefilter
The prefilter is mounted on the left of the engine.
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Maintenance instructions
8. Diesel engine
a
c
b
Figure: Prefilter
Draining
• Drain the water from the prefilter container daily by closing the fuel cock (a) and
opening the drain cock (b).
• Remove the filter bowl (d) and clean it with pure diesel fuel.
• Remove the fuel filter (c) and clean the sealing surface on the base of the filter.
Make sure all the remnants of the gasket have been removed.
• Apply pure diesel oil to the new fuel filter gasket.
• Screw on the new fuel filter on the base of the filter until the gasket makes contact
with the filter base. Use the twist marks to aid tightening. Tighten the filter a fur-
ther three quarters of a turn by hand. Do not tighten the filter too hard.
• Screw the clean filter bowl (c) back in place.
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Maintenance instructions
8. Diesel engine
Fine filter
1. Close the fuel cock to the prefilter. See previous section on prefilter.
CAT
a
Figure: Fine filter.
2. Unscrew the fuel filter (a) with a suitable tool and detach it.
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Maintenance instructions
8. Diesel engine
ENVIRONMENTAL DIRECTIONS
1. Undo the front protective plate on the underside of the drill rig.
2. Undo the bottom plug by holding the nut with a 22 mm ring spanner and unscrew-
ing with an 8 mm Allen key. Allow the water to drain.
3. Use track oscillation to tilt the drill rig so that the tank drains completely.
94
Maintenance instructions
8. Diesel engine
Belts
Tension gauge
Check the belt tension with a tension gauge.
2. Place the guide (3) on the belt (2) between the two belt pulleys, making sure the
stop fits laterally.
3. Press the button (4) at right angles to the belt (2) so that the spring can be felt or
heard to release.
4. Carefully lift up the gauge without changing the position of arm (1).
5. Read off the value at the intersection (arrow) of the scale (5) and the arm (1).
95
Maintenance instructions
8. Diesel engine
2
1
3
1250 0001 93
Figure: Generator.
3. Relieve the tension of the belts by screwing the upper adjuster arm nut away from
the stop (2).
4. Loosen and pull out the four bolts in the shaft coupling until there is some clear-
ance (4).
1250 0105 03
4
Figure: Undo the bolts.
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Maintenance instructions
8. Diesel engine
5. Change belts by inserting them through the clearance between the coupling rubber
and the shaft flange.
6. Screw back the coupling rubber and tighten the bolts (185Nm).
7. Tension the belts by screwing the top adjuster arm nut towards the stop (2).
8. Once the belts are sufficiently taut (use the tension gauge), the adjuster arm must
be locked by screwing the lower adjuster arm nut against the stop (3).
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Maintenance instructions
9. Oils and fuel
ENVIRONMENTAL DIRECTIONS
Refuelling
Switch off the engine before topping up the fuel. Do not handle fuel in the vicinity of
hot surfaces, sparks or naked flames.
Figure: Refuelling.
1 Location of fuel filler orifice.
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Maintenance instructions
9. Oils and fuel
Use fuel with specifications complying with the engine manufacturer's recommenda-
tions.
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Maintenance instructions
9. Oils and fuel
ENVIRONMENTAL DIRECTIONS
Compressor oil
WARNING
• Danger of rotating parts
• Hot engine and components
• Can cause serious personal injury
• Maintenance work on the drill rig must
only be carried out when the engine is not
running
100
Maintenance instructions
9. Oils and fuel
The compressor oil level can be read in the sight glass on the front of the air tank.
2
1250 0168 18
1. Check that the engine is not running and that the sight glass (2) is half full.
2. Depressurise the system by opening the extra outlet valve located on the right-
hand side of the drill rig.
3. Top up (1, see illustration: Compressor tank) if necessary. Unscrew the filler plug
when topping up (see table “Recommended hydraulic oil and lubricants”.
Oil sampling
An oil sample gives a good indication of how well the hydraulic system has been
maintained.
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Maintenance instructions
9. Oils and fuel
Hydraulic oil
CAUTION
• Protect your eyes from hydraulic oil
Note
Do not fill up with too much hydraulic oil as it might then clog the ventilation filter.
The hydraulic oil level can be read in the sight glass on the front of the hydraulic oil
reservoir. The lower sight glass (2) should be full and the upper sight glass (1) should
be half full.
1
2
102