Atlas Copco SMARTROC D65 TIER 4 FINAL Maintenance Manual Download Page 1

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SMARTROC D65 TIER 4 FINAL

Maintenance

Translation of the original instructions

2015-12-17 | No: 713991051.3 en

Summary of Contents for SMARTROC D65 TIER 4 FINAL

Page 1: ...SMARTROC D65 TIER 4 FINAL Maintenance Translation of the original instructions 2015 12 17 No 713991051 3 en...

Page 2: ......

Page 3: ...Reference NOTE Always read the information in the Safety document before starting to use the rig or starting maintenance work...

Page 4: ......

Page 5: ...el cables 23 2 4 Air conditioning 29 2 4 1 Safety 29 2 4 2 Environmental issues when handling refrigerant 29 2 4 3 Changing air filter 29 2 4 4 Diagnostics 30 3 Transport instructions 33 3 1 Hoisting...

Page 6: ...stem Levers 70 5 5 4 System Monitors 72 5 5 5 System administration 73 5 5 6 Loading new software 74 5 5 7 System Engine status 77 5 5 8 System Service Interval 78 5 5 9 System Configuration 79 5 5 10...

Page 7: ...ain 154 9 Dust collector DCT 155 9 1 Filter test dust collector DCT 155 9 2 Adjust the suction capacity 156 9 3 Dust collector DCT filter change 156 10 Radiator 159 10 1 Environmental issues when hand...

Page 8: ...rication 187 13 9 For engine oil and fuel see chapter Diesel engine 188 13 10Draining the fluids 188 13 10 1Draining DEF Diesel Exhaust Fluid 189 13 11Recommended oils and lubricants 189 13 11 1Engine...

Page 9: ...and maintenance 216 14 4 2 Annual maintenance 216 14 4 3 Electric Welding Steam Cleaning and High Pressure Cleaning 216 14 5 Service Winch 216 14 5 1 Cleaning 216 14 5 2 Transmission 217 14 5 3 Diseng...

Page 10: ...SmartROC D65 Tier 4 Final Table of Contents x...

Page 11: ...2 Target group and objective NOTE This chapter General contains general recommendations for maintenance of the drill rig and its peripheral equipment This means that certain sections may not be fully...

Page 12: ...2 HengTai Road Nanjing Economic Technological Development Zone Nanjing Postal code 210038 Phone 86 0 25 85 75 75 00 Fax 86 0 25 85 75 75 30 China 2 No 12 Kun Ming Hu Street Shenyang Economic Technolo...

Page 13: ...ndia Sveanagar Bombay Pune Road Dapodi Pune 411 012 Phone 91 0 20 39 85 24 15 Fax 91 0 20 27 14 59 48 Indonesia P O Box 7021 JKS CCE Jakarta 12075 Phone 62 0 21 780 10 08 Fax 62 0 21 780 18 37 Iran PO...

Page 14: ...Uul District Chinggis Avenue Ulaanbaatar Mongolia Phone 976 0 11 34 49 91 Fax 976 0 11 70 13 02 23 Norway P O Box 334 N 1401 Ski Phone 47 64 86 03 00 00 Fax 47 64 86 03 30 30 Peru Apartado 662 Lima 10...

Page 15: ...ngsao 24180 Phone 66 0 38 56 29 00 Fax 66 0 38 56 29 01 Turkey Istasyon Mah Ibisaga Cad No 6 34940 Tuzla Istanbul Phone 90 0 216 581 05 81 Fax 90 0 216 581 05 82 Ukraine 9 Moskovskiy Avenue Building 3...

Page 16: ...antling hydraulic compressed air and wa ter flushing hoses Immediately plug all hoses nipples and hydraulic oil pipes or seal and protect them from dirt in some other suitable way n Mark hoses pipes a...

Page 17: ...lect and dispose of n Rest oil and oil spill n Oil waste such as filters n Rest fuel and fuel spill n Rest grease and grease spill n Batteries n Discarded refrigerant air conditioning n Chemicals such...

Page 18: ...ma or other illnesses u Welding grinding and other hot work involving paint being heated must only be carried out where sufficient ventilation can be used In addition use personal safety equip ment co...

Page 19: ...rom flammable materials n Always protect hoses cables and electric components n Grind off spatter after welding If possible also grind the surface of the weld smooth and treat it with anti corrosion p...

Page 20: ...m or function 2 2 Battery 2 2 1 Environmental considerations regarding batteries NOTICE Environmental effect Think of the environment u Batteries contain acids and heavy metals For this reason expende...

Page 21: ...the charging current required to bring a battery up to a certain voltage changes with age n The batteries must not be loaded unevenly n Series coupling maintains the same capacity but increases the v...

Page 22: ...Repeat steps 3 8 on G1B After charging 1 Turn off the battery charger 2 Reconnect the jumper lead between the negative terminal on battery G1A and the positive terminal on battery G1B 3 Connect the c...

Page 23: ...ating time n Reduced elasticity n Decreased cable diameter n Certain number and type of wire breaks n Corrosion n Surface wear n Deformation of the cable n Permanent extension of the cable Wire break...

Page 24: ...ore quickly than during normal wear of the individual cable strands Reduced elasticity can lead to sudden cable breaks during heavy loads The cable should be scrapped Decrease in cable diameter Decrea...

Page 25: ...n the strands n 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...

Page 26: ...hich often occurs in conjunction with basket formation is when the steel core pushes out between the strands Cables with strand displacement must be scrapped Waviness Waviness is a deformation that gi...

Page 27: ...ion 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 cas...

Page 28: ...ease Local cable diameter increase This means repeated thickening of the cable over a long stretch At the thicker spots the core pushes out of the cable and causes unevenness of the outer strands Cabl...

Page 29: ...o little refrigerant leakage or any other fault until it is rectified Otherwise there is risk of the compressor breaking down 2 4 2 Environmental issues when handling refrigerant NOTICE Environmental...

Page 30: ...eck the following points n Fresh air fan and V belt tension n That the air does not evade the evaporator in the unit n That the evaporator and condenser are not clogged by rubbish and the filter in th...

Page 31: ...s when the speed increases or decreases there is probably nothing wrong with the compressor itself The difference between the pressure on the suction side and the pressure side also affects the level...

Page 32: ...SmartROC D65 Tier 4 Final 2 General 32...

Page 33: ...lifting straps with adequate lifting capacity u Risk of dumping u Lock the track oscillation cylinders before the drill rig is raised Hoisting Make sure the chassis is not damaged when you position th...

Page 34: ...er load n Place the hoisting slings under both crawler tracks at points A and B as shown in the il lustration Hoisting 3 2 Transport WARNING Serious injury Risk of dumping u May cause serious personal...

Page 35: ...transport posi tion and firmly down on its jack A 3 2 2 Once the drill rig is loaded onto the transport vehicle n Lower the hydraulic jack extra equipment n Track oscillation cylinders to LOCKED posit...

Page 36: ...hine is towed with low oil level in the traction gears u Make sure that there is sufficient oil in the traction gears before disengagement takes place NOTICE Risk of damage The traction gears may be d...

Page 37: ...cover plate B Screw the screws in evenly so that the cover plate B is pressed away from the cover for the traction gear 3 Remove the cover plate B O ring D and cylinder barrel E 4 Screw an 80 mm M8 sc...

Page 38: ...SmartROC D65 Tier 4 Final 3 Transport instructions 38...

Page 39: ...S 4 1 Display application and CCI module Display Application CCI module 4 1 1 Connections Contact Function X1 Power supply module X2 CAN network 2 X3 X4 CAN network 1 X5 Address plug X6 COM2 X7 USB CO...

Page 40: ...fferent addresses 4 1 3 LED functions Module status D16 n LED colour is green n When the system starts the LED flashes twice per second n When CAN communication is in progress the LED will flash once...

Page 41: ...tion X1 Power supply module X3 X4 CAN network X5 Address plug X6 X9 Resolver inputs X10 Encoder input X11 X12 Analogue inputs Table 6 Functions of connections 4 2 2 Pin configurations Contact Type Pin...

Page 42: ...Six pin conin verse male contact Ref Ref Sine sig nal Sine GND Cosine signal Cosine GND X10 Six pin conin verse male contact 15V 15V Signal A GND Signal B GND X11 X12 Five pin M12 male contact GND 15V...

Page 43: ...S 43 4 3 I O module I O module 4 3 1 Connections Contact Function X1 X19 CAN in X1 CAN out X19 X2 X3 X4 X20 X21 X22 Analogue inputs X5 X23 DI DO NPN Encoder X7 X8 X9 X10 X14 X15 X16 X24 DI DO PWM X11...

Page 44: ...s per contact but only one output can be activated at a time Output current is between 50mA and 2 0A The amplitude is adjustable from 0 to 500mA in steps of 50mA X11 X12 X17 X18 Five pin M12 female co...

Page 45: ...ound PNP input Input voltage low No signal on input Voltage on input Input active Does not arise if the port is initial ised as input Does not arise if the port is initial ised as input NPN output Not...

Page 46: ...6 4 4 Operator panel 4 4 1 Connections Operator panel Contact Function X1 Supply voltage X3 CAN network end plug X4 CAN network to display D501 X5 Address plug D569 Aim Device A Emergency stop NOT CAN...

Page 47: ...nput output contacts Table 9 Functions of connections 4 5 2 Pin configurations X1 X6 Contact Type Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 X1 Four pin M12 male contact 24V supply voltage 24V supply voltage GND G...

Page 48: ...OUT 4 26 Din 4 LED OUT 25 8 Ain 4 LED OUT 3 27 Din 5 LED FEED 8 GND LED OUT 4 28 Din 6 Kbd IN 1 10 Ain 5 LED OUT 9 29 GND Kbd IN 2 11 POT FEED LED OUT 4 30 Din 7 Kbd IN 3 12 Ain 6 LED OUT 3 31 Din 8...

Page 49: ...he RCS system is based on CAN technology CAN Con troller Area Network The number of electronic modules varies from rig to rig depending on the options it has been equipped with n Lever modules 500 1 5...

Page 50: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 50 Rig Layout Feeder Layout...

Page 51: ...TE The service menus in these instructions are intended for service personnel that have completed Atlas Copco s training for the drilling system Incorrect handling can lead to the system becoming inop...

Page 52: ...menu F3 Performance log Direct selection menu F4 Direct selection menu F5 Main menu System System Modules Status View System Modules System layout System Modules Rig Layout System Modules Feeder Layou...

Page 53: ...ensors Drilling Sensors Calibration Drilling Actuations Drilling Parameters Drilling Parameters Feed Speed Drilling Parameters Feed pressure Drilling Parameters Feed pressure Calibration Drilling Para...

Page 54: ...parameters Feed Speed RHS Auto RHS parameters Rotation RHS Auto RHS parameters Times Table 10 Menu structure 5 3 Settings 5 3 1 General and specific settings The speed of the hydraulic cylinders is se...

Page 55: ...options from which the desired type of drill bit can be selected Table 11 Symbols 5 3 2 Parameters Example of Parameters The parameter menus are used for settings of different values n Highlight the...

Page 56: ...at a certain function is actuated from the I O module outputs n Highlight the desired function using the cursor keys and press ENTER n Specify the desired actuation value The value may be in milliamps...

Page 57: ...ction menu F1 NOTE GPS is covered separately in the chapter entitled Options The following is an explanation of the symbols shown in direct selection menu F1 Symbol Name Explanation Tank pressure Show...

Page 58: ...entered Drilling will be stopped automatically once this hole depth has been reached Rod indication Shows the number of drill steel in the hole Hole number Current hole number in the drill plan if us...

Page 59: ...ee rods n Extra flushing Extra blow cleaning of the borehole when half of the rod is drilled The number indicates for how many rods blow cleaning should apply For example number 3 indicates that the b...

Page 60: ...ing air being on Used for example when you have a new down the hole drill n Ignore chair switch Normally you have to sit in the seat to operate the positioning levers If the box is checked you can lea...

Page 61: ...e carousel rotates anticlockwise n Automatic Switching Jaw Drill Support Automatic function switching for Lever 36 on the left hand operator s panel In manual mode Button 3 must be used n Try Rod Add...

Page 62: ...sel consumption Resettable counter for showing diesel consumption since last reset Diesel engine hours Counter for diesel engine hours Resettable upper total number of hours below Percussion hours Cou...

Page 63: ...value is an adjustable field where the desired tilt angle can be set In order to change the setting this field must be highlighted and the field activated by pressing the enter button on the display s...

Page 64: ...menu F5 Direct selection menu F5 activated by pressing the button Fn and then button F1 on the display The Fn button is active for 3 seconds after each press This menu shows the values for the diesel...

Page 65: ...DEF gauge Shows the level of DEF Diesel Exhaust Fluid in the tank Engine load Displays the instantaneous load the diesel engine is exerted to in percent Oil pressure Displays the engine oil pressure...

Page 66: ...to the injectors Forced regeneration Start forced regeneration Block regeneration Block automatic regeneration Max time left before regenera tion Shows maximum time remaining until automatic regenerat...

Page 67: ...Layout 3 Rig Layout 4 Feeder Layout Status View The status of all the modules can be checked in this menu n D500 1 Left lever module n D500 2 Right lever module n D501 Operator s display n D569 Aim n...

Page 68: ...5 RCS drilling system 68 n D102 I O module n D103 I O module Select the module using the arrow keys and open it with Enter to see the message that the system has written for the module These figures a...

Page 69: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 69 Rig Layout Feeder Layout...

Page 70: ...e 0 127 units If a lever is replaced or if the lever gives an actuation value lower than 115 or higher than 127 units all the levers must be recalibrated see Calibration levers below The function of t...

Page 71: ...e levers have been calibrated n Calibration mode With calibration mode activated none of the functions will be ac tuated and it will only be the lever movements that will be shown as a reading on the...

Page 72: ...here This means it is easier to locate the source of the fault so that it can be rectified more quickly The monitors in the top box turn off the diesel engine n Emergency stop tripped n Hydraulic Oil...

Page 73: ...ware to a later version The information is saved on a USB memory stick NOTE Only use USB memory sticks from Atlas Copco Save parameters Parameters are saved on a USB memory stick Load parameters Param...

Page 74: ...o Save parameters or to Load parameters and press Enter NOTE A text box will appear on the screen and when the operation is complete OK will be displayed 3 Remove the USB memory stick 5 5 6 Loading ne...

Page 75: ...cabin 2 Insert the USB memory stick with the new software into the USB socket USB Socket 3 Start the RCS system NOTE The system now reads the new software and displays the Load ready message on the s...

Page 76: ...ed Many settings are made by changing an existing numerical value e g setting the date and time in the Administration menu Date and time in the Administration menu 1 Move the cursor to the current num...

Page 77: ...ear text in the diesel engine manufacturer s manual n 100 Engine Coolant Temp Sensor n 103 Intake Manifold Temp Sensor n 101A Engine Oil Temp Sensor Mid n 101B Engine Oil Temp Sensor End n 200 Turbo O...

Page 78: ...tROC D65 Tier 4 Final 5 RCS drilling system 78 5 5 8 System Service Interval Service Interval n Time To Service n Service Interval n Service Done n Distance to grinding n Grinding interval n Grinding...

Page 79: ...see how the rig is equipped Configuration file An approved configuration file means that the rig s software is con sistent with the equipment on the rig n Engine type n Boom type n Feeder type n Rod H...

Page 80: ...e on the rig Certain rig options can be activated or deactivated by checking the box to the right and pressing Enter n Laser plane n Angle Indication n Hole navigation n Electr Compass n Automatic pos...

Page 81: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 81 5 6 Logging 5 6 1 Logging Menu Logging n Event Log n Save n MWD n Trace Log n Signal Log n Aux Temp...

Page 82: ...ing system 82 Logging Event Log Event Log Save Event Log by inserting a USB memory stick into the USB socket on the right hand pillar behind the display and select the button at the bottom of the disp...

Page 83: ...Statistics Save statistics from the rig Can be saved as text or spreadsheet depend ing on what it is going to be used for n Blast log Used when the log from the round is to be exported to ROC Manager...

Page 84: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 84 Logging MWD MWD n MWD Logging Off or On n Sample distance The interval with which MWD is saved...

Page 85: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 85 Logging Trace Log Trace Log Only used after contact with staff from Atlas Copco...

Page 86: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 86 Logging Signal Log Signal Log...

Page 87: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 87 Logging Auxiliary Temperature Logging Aux Temp n Threshold n Resolution...

Page 88: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 88 5 7 Positioning 5 7 1 Positioning menu Positioning n Sensors n Actuations n Parameters...

Page 89: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 89 Positioning sensor Positioning sensor n Adjustable sensors are l Feed swing l Feed dump l Boom swing l Aim device...

Page 90: ...rument can be reset in the Calibration menu n Be sure to adjust the cabin s aim device directly forward 90 towards the cabin wind screen n Adjust the boom straight forward so that it is parallel with...

Page 91: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 91 Positioning Actuations Actuations n Boom lift n Boom swing n Feed dump n Feed swing n Feed extend...

Page 92: ...system 92 Positioning Parameters Parameters n Valve Parameters The parameters used when the positioning cylinders are operated manually n Auto Parameters The parameters used when the Semi automatic bo...

Page 93: ...ng Parameters Valve Parameters Valve Parameters n Boom lift n Boom swing n Feed dump n Feed swing n Feed extend n Cylinder in l Lowest valve current l Highest valve current n Cylinder out l Lowest val...

Page 94: ...itioning Parameters Auto Parameters Auto Parameters n Feed dump n Feed swing n Cylinder in l Lowest valve current l Highest valve current n Cylinder out l Lowest valve current l Highest valve current...

Page 95: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 95 5 8 Drilling 5 8 1 Menu Drilling Drilling n Sensors n Actuations n Parameters n DCT...

Page 96: ...r Sensors n Rotation pressure n Percussion n Feed pressure n Pump pressure HECL n Oil level HECL n Laser Sensor n Water Level WM Tank Drilling Sensor Calibration Calibration of the sensors involved in...

Page 97: ...stem 97 n Ensure that the system is depressurised n Select the Set to zero by the relevant pressure sensor n Press Enter to Set to zero the sensor The pressure sensor is then reset and automat ically...

Page 98: ...Actuations n Feed speed n Rapid feed n Feed pressure n Rotation Speed n Rotation pressure threading n Air flow reduced n Air flow full n Lubrication n Thread greasing spray air valve n Thread greasing...

Page 99: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 99 Drilling parameters Parameters n Feed speed n Feed pressure n Rotation n Lubrication n Timers n Drill bit n Others...

Page 100: ...Speed Feed speed n Min current drill feed n Max current drill feed n Min current rapid feed n Max current rapid feed n Min speed braking forward n Min speed braking backward n Speed calibration n Max...

Page 101: ...inal 5 RCS drilling system 101 Drilling Parameters Feed Pressure Feed pressure n Feed pressure collaring n Feed pressure drilling n Max feed pressure drilling n Min feed pressure drilling n Pressure i...

Page 102: ...ation Calibration n Calibration of feed pressure Operate the cradle down to mechanical stop Select Start calibration The system will now automatically read the different pressures for the different cu...

Page 103: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 103 Drilling Parameters Rotation Rotation n Rotation speed drilling n Rotation pressure jamming n Pressure decrease free...

Page 104: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 104 Drilling Parameters Rotation Calibration Calibration Clamp the adapter in the break table and start the calibration...

Page 105: ...ng Parameters Lubrication Oil Lubrication n Frequency lubrication HECL pump n Min HECL Pressure n Time Before HECL Guarding n Timeout HECL Pressure n Thread Greasing Spray Pulse Duration n Thread Grea...

Page 106: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 106 Drilling Parameters Times Timers n Min collaring time n Air flushing time n Half rod flushing time n Extra flushing time...

Page 107: ...RCS drilling system 107 Drilling Parameters Drill Bit Drill bit n Feed pressure drilling n Max speed automatic collaring n Speed drilling forward n Speed drilling backward n Rotation speed drilling n...

Page 108: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 108 Drilling Parameters Miscellaneous Others n Min air pressure n Air pressure drill out n Initial collar length n M4 offset...

Page 109: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 109 Drilling DCT DCT n Parameters n Actuations...

Page 110: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 110 Drilling DCT Parameters Parameters n Time clean pulse n Pause time n Number of after clean pulses...

Page 111: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 111 Drilling DCT Actuations Actuations n DCT Fan n DCT Flap n Filter clean A n Filter clean B n Filter clean C n Filter clean D...

Page 112: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 112 5 9 Rig 5 9 1 Rig menu Rig menu n Sensors n Actuations n Parameters...

Page 113: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 113 Rig sensor Rig sensor n Power Pack n Wagon Frame...

Page 114: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 114 Rig sensor drive unit n Start Key Ignition n Start Key Start n Fuel Meter Shows the volume in litres in the fuel tank...

Page 115: ...emp Shows the temperature of the hydraulic oil n Hyd Filter pressure Shows hydraulic filter pressure n Compressor Temp High Stage Shows the compressor temperature in the high pressure stage n Compress...

Page 116: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 116 n Calibrate by selecting and setting the boxes to zero Rig actuations Actuations...

Page 117: ...Wagon Frame n Cooling Fan Rig actuations drive unit n ECM Enabled n Start Engine On n Enable diesel filler pump n Load Compressor n Loading Valve High Pressure n Hydraulic oil heat n Reverse Warning n...

Page 118: ...high speed n Hydraulic Jack In n Hydraulic Jack Out n Track oscillation lock n Left Track Oscillation Fwd n Left Track Oscillation Bwd n Right Track Oscillation Fwd n Right Track Oscillation Bwd n Le...

Page 119: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 119 Rig actuations cooling fan n Cooling fan engine n Cooling fan hyd oil compr...

Page 120: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 120 Rig parameters Parameters n Tramming...

Page 121: ...k Forward l Lowest valve current l Highest valve current n Right Track Forward l Lowest valve current l Highest valve current n Left Track Reverse l Lowest valve current l Highest valve current n Righ...

Page 122: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 122 5 10 RHS 5 10 1 RHS menu RHS n Sensors n Actuations n Parameters n Cradle positions n Auto RHS Parameters...

Page 123: ...this menu The sensor module location connector and marking are shown to facilitate fault finding where appropriate n Cradle Position pulses n Upper Calibration Sensor n Lower Calibration Sensor n Arm...

Page 124: ...t n Activate learn mode calibr sensor n Distance to upper calibration sensor n Distance to lower calibration sensor n Operate the cradle to mechanical stop n Set to zero by checking the boxes Set to z...

Page 125: ...ired value n Function l Grippers in Guide Position l Grippers open l Magazine outlet open l Rotate Gripper Towards Drill Centre l Rotate Gripper Towards Magazine l Arm to drill centre l Arm to magazin...

Page 126: ...ght Digital Lever n Actuate desired value n Function l Lower Drill Support Closed l Lower Drill Support Open l Upper Drill Support Closed l Upper Drill Support Open l Suction Hood Up l Suction Hood Do...

Page 127: ...k table n Actuate desired value n Function l Breaking cylinder CW l Breaking cylinder CCW l Break out jaws lower open l Break out jaws lower closed l Break out jaws upper open l Break out jaws upper c...

Page 128: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 128 RHS Parameters Parameters RHS n Drill Rod Drill Tube Parameters Threading n Feed speed threading...

Page 129: ...eed speed unthreading n Feed pressure forward RHS n Feed pressure backward RHS n Feed pressure threading n Feed pressure unthreading n Rotation speed threading n Rotation speed unthreading Parameters...

Page 130: ...nel n M2 Position for breaking of adapter rod applies when automatic rod handling is ac tivated on the right hand control panel n M3 Rapid feed stop forward n M4 Position for breaking rod rod Requires...

Page 131: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 131 RHS Auto RHS parameters Auto RHS Parameters n Feed speed n Rotation n Timers n Others Not used...

Page 132: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 132 RHS Auto RHS parameters Feed speed Feed speed n Feed Speed Asyncronous Threading Unthreading...

Page 133: ...ers Rotation Rotation n Max Rotation Pressure Threading Adapter Rod Y155 n Max Rotation Pressure Threading Rod Rod Y155 n Threshold Value For Threading Completed Adapter Rod n Threshold Value For Thre...

Page 134: ...SmartROC D65 Tier 4 Final 5 RCS drilling system 134 RHS Auto RHS parameters Times Timers n Rotation Time For Loosening Adapter Rod Joint...

Page 135: ...sidue and spillage Treat in accordance with local regulations in force u Use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products wherever possible Contact your local Atlas Cop...

Page 136: ...immediately after they have been detached n Use clean protective plugs n Hydraulic components such as hoses valves motors must always be kept with suit able protective plugs fitted n Spare parts for h...

Page 137: ...ust into the premises n Have well trained mechanics 6 6 Filter 6 6 1 Return oil filter General The return oil filter cleans the oil before it returns to the tank There are two return oil filters conne...

Page 138: ...ilter canister by the handle 4 Detach the overflow valve E by pressing down and turning the handle anticlockwise 5 Take out the filter cartridges D and replace with new ones 6 Refit the overflow valve...

Page 139: ...ance schedule and also if it is severely fouled NOTE If the breather filter becomes covered in oil it will be ruined This can happen if the tank is overfilled The filter must then be changed Changing...

Page 140: ...SmartROC D65 Tier 4 Final 6 Hydraulic systems 140...

Page 141: ...that the feeder chain has the correct tension A poorly tensioned chain leads to increased wear on both the chain and associated components When the feeder chain is correctly tensioned it should come...

Page 142: ...The distance A must be at least 280 mm 7 2 Tension of hoses on the hose drum 1 Move the rotation unit halfway down on the feeder 2 Fit a chain pulley block between the hose drum cradle and the top of...

Page 143: ...heel and climbing chain cover The climbing chain s gear 2 is lubricated by means of filling 2 to 3 pump strokes of grease in the grease nipple 3 on the gear s shaft If the climbing chain cover 1 is wo...

Page 144: ...earing unit 2 and chain guide 1 7 4 1 Replacing the bearing unit chain feed After 5000 engine hours the bearing unit 2 should be replaced with a new unit Check the chain guide 1 for wear every 500 eng...

Page 145: ...rn sprocket Check whether there is any unevenness or if it jams when the chain engages and disen gages from the gears Inspect the teeth for reduced area and bent tips If the teeth are too worn then th...

Page 146: ...it 7 8 Replacing the slide pieces in the holder Each holder has replaceable slide pieces The slide piece C is kept in place by three keys D The slide pieces must be replaced at regular intervals so t...

Page 147: ...ivided up to facilitate replacement Before replacing the front slide rails run the rock drill rotation unit to its rear end position Before replacing the rear slide rails run the rock drill rotation u...

Page 148: ...g the feeder The feeder requires lubrication at certain intervals A number of red grease nipples A are located in different positions on the feeder B In order to reduce the wear of hoses over the drum...

Page 149: ...ipple should not be filled with grease during normal inspection Track tension is checked between the front wheel 3 and limberoller 1 when the drill rig is parked on a level surface with the tracks und...

Page 150: ...s Tightening torques for track frames Size Torque in Nm Quantity track frames Comments A M16 295 20 B1 M12 86 4 T45 C50 D50 D55 T50SF C65SF B2 M16 210 1 T50LF D60 D65 C65LF C M16 210 32 D M12 90 3 E M...

Page 151: ...in order to establish the extent of the wear and when replacement is necessary n The components must be thoroughly cleaned for measuring n Measuring must take place at several points The degree of wea...

Page 152: ...SF C65SF Limberoller T50LF D60 D65 C65LF Wear New limber oller 25 50 75 100 A mm 100 0 98 5 96 7 94 6 92 0 B mm 7 5 8 2 9 1 10 2 11 5 8 3 4 Check for wear on the front wheel Check the wear by measurin...

Page 153: ...g the distance A between the top and bot tom of the track shoe Track shoe Wear New track shoe 25 50 75 100 mm 25 0 20 4 15 7 10 9 6 0 Table 14 Triple grouser 8 3 6 Check for wear on the link and bushi...

Page 154: ...54 8 3 7 Check for wear on the chain Check the wear on the chain by measuring the distance between the centre point in the first pin to the centre point in the fifth pin Track shoe Wear New chain 25 5...

Page 155: ...a and apply a differential pressure 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...

Page 156: ...is adjusted with set screw CT3 and the fan wheel s brake time is adjusted with CT4 You should aim for a distribution of 70 pre separator 30 DCT Brake time should be 8 10 seconds Factory setting 140 b...

Page 157: ...SmartROC D65 Tier 4 Final 9 Dust collector DCT 157 Dust collector...

Page 158: ...SmartROC D65 Tier 4 Final 9 Dust collector DCT 158...

Page 159: ...gulations in force for both handling and waste dis posal 10 2 Coolant WARNING Serious injury Danger of scalding and pressure u Can cause serious personal injury u Release the pressure in the radiator...

Page 160: ...SmartROC D65 Tier 4 Final 10 Radiator 160 Radiator and expansion tank...

Page 161: ...nmentally hazardous u Changing oils replacing hydraulic hoses and different types of filter can be environ mentally hazardous u Always collect oil residue oil spillage waste with oil content and lubri...

Page 162: ...Both cleaning stages take place in the filter housing A filter s performance will improve right up until it becomes clogged For this reason the fil ter cartridge should not be replaced at regular int...

Page 163: ...lines apply Hours 0 500 1000 1500 2000 Replacing the filter cartridge and cleaning the filter housing New X X X X Replacing the safety cartridge New Changing Indicator test X X Table 15 Intervals for...

Page 164: ...rly This is done by gradually blocking the air intake with a piece of wood or similar The indicator should then signal and the warning symbol should be visible or the warning light should illuminate I...

Page 165: ...the filter a further three quarters of a turn by hand Do not tighten the filter too hard n Screw the clean filter bowl D back in place Replacing the secondary filter n Close the fuel cock for the prim...

Page 166: ...ith local regulations in force 11 4 5 Fuel tank brackets WARNING Serious injury Never remove the protective plate from the underneath of the drill rig without first checking that ALL fuel tank retaini...

Page 167: ...fill the fuel tank with clean diesel oil and fuel of the correct grade for the temperat ure 1 Undo the front protective plate on the underside of the drill rig 2 Undo the bottom plug by holding the nu...

Page 168: ...rrect engine al ternative 3 Secure the tensioner wheel in the position where the belt is slack using a pin A 4 Undo and pull out the four bolts 4 in the shaft coupling until there is play Undo the bol...

Page 169: ...11 Diesel engine 169 7 The belt is tensioned automatically when the lock out assembly is removed from the tensioning wheel 8 Refit the belt cover 11 4 8 For further instructions see separate instructi...

Page 170: ...SmartROC D65 Tier 4 Final 11 Diesel engine 170...

Page 171: ...reach temperatures of 130 C during operation When replacing air hoses use only Atlas Copco original hoses or consult Atlas Copco In the event of a suspected leakage you must absolutely not use your ha...

Page 172: ...h percussion pressure 4 Control valve low percussion pressure 5 Intake valve 6 Air filter 7 Filter indicator 8 Drain valve 9 Compressor low pressure stage 10 Compressor high pressure stage 11 Oil stop...

Page 173: ...alve 25 Minimum pressure valve 26 Air receiver 27 Restriction Compressor parts 3 Control valve high percussion pressure 4 Control valve low percussion pressure 5 Intake valve 9 Compressor low pressure...

Page 174: ...ing points 1 Engine radiator 2 Hydraulic oil cooler 3 Compressor cooler 4 Compressor element 5 Engine oil 6 Compressor tank 12 3 1 Draining the condensate in the pressure tank The pressure tank must b...

Page 175: ...on a daily basis preferably before the work shift Drain by opening the cock under the water separator filter 12 3 3 Replacing the filter element in the water separator filter The filter element A must...

Page 176: ...in the maintenance instructions Oil should be changed more frequently when working in high ambient temperatures or very dusty or damp conditions 1 Run the compressor to operating temperature Switch o...

Page 177: ...ystem must be flushed clean before new oil is filled See Changing to new type of oil for the method NOTE Never fill with too much oil Overfilling results in high oil consumption Take care to use the c...

Page 178: ...ssure washed so that the remaining oil will be blown out See step 1 and 2 under the heading Change of oil and oil filter for detailed description 2 Remove the oil filters a 3 Open the cover plate on t...

Page 179: ...he compressor oil cooler clean using compressed air in order to maintain efficient cooling 12 3 8 Test pressurising the safety valve 1 Disconnect the cables for the flushing air valves Y115 and Y116 2...

Page 180: ...2 Try to start the engine again immediately while the pressure exceeds 1 5 bar The en gine cannot be started 12 3 11 Checking the minimum charge pressure If tank pressure is less than 4 bar then the...

Page 181: ...eing directed over the high pressure regulator 3 Now the high flushing air valve will also open Y115 which results in full pressure and full air flow to the hammer 12 4 2 Setting the percussion pressu...

Page 182: ...SmartROC D65 Tier 4 Final 12 Compressor and air system 182...

Page 183: ...he engine before topping up the fuel Do not handle fuel in the vicinity of hot surfaces sparks or naked flames Cleanliness is important when filling with fuel Ensure that the tank and tank cover are c...

Page 184: ...ine is switched off 13 3 1 Filling DEF Diesel Exhaust Fluid DEF Diesel Exhaust Fluid tank 1 The DEF tank 1 is topped up at each refuelling 2 DEF filler location Do not overfill the tank In cold climat...

Page 185: ...ge waste with oil content and lubrication grease residue and spillage Treat in accordance with local regulations in force u Always use biodegradable hydraulic fluids and lubrication oils for Atlas Cop...

Page 186: ...a good indication of how well the hydraulic system has been main tained 13 7 Hydraulic oil CAUTION Risk of injury Protect your eyes from hydraulic oil NOTE Do not fill up with too much hydraulic oil a...

Page 187: ...ubricating oil tank 1 is fitted on the hydraulic oil tank 2 The lubricating oil level can be read in the sight glass 4 In the event of a low level there is also a warning on the display for engine and...

Page 188: ...icating system is fully drained of oil then the system must be bled See the maintenance instructions for the drill system 13 9 For engine oil and fuel see chapter Diesel engine 13 10 Draining the flui...

Page 189: ...0 Table 16 Ambient temperature C 13 11 2 Hydraulic oil Use mineral based or synthetic polyalphaolefin or diester hydraulic oil with good rust wear oxidising and foam inhibitive properties and good air...

Page 190: ...Use an oil with good lubricating properties intended for compressed air tools n Depending on ambient temperature the oil should have the following viscosity grades if the viscosity index VI is about...

Page 191: ...Oil recommendations for two stage compressor Atlas Copco recommends only using Atlas Copco PAROIL for the two stage compressors Use of another oil is at customer s own risk The type of PAROIL should...

Page 192: ...SmartROC D65 Tier 4 Final 13 Oil and fuel 192...

Page 193: ...ted at a distance of 0 5 metres apart There must not be any permanent fixture between the anten nas and the horizon apart from the drill rig s feeder 14 1 2 General data Voltage 24V DC Current usage 0...

Page 194: ...een lamp that indicates that the drill rig s direction data has been sent onward to the CAN BUS 4 Primary antenna 5 Secondary antenna GPS cables Wire Conductor 1 Conductor 2 Conductor 3 Conductor 4 Co...

Page 195: ...2 Service equipment 14 2 1 Service tool bag RCS Service bag A CAN tester B Resolver tester C Multimeter D Encoder tester E CAN Open cable F I O tester G Signal cable H Test cables I Test box J Connect...

Page 196: ...an be measured and checked using the CAN tester NOTE Always use the torque tools to tighten cable connections n MAIN POWER lights if power is being supplied to the module n CAN POWER comes on if there...

Page 197: ...power supply CAN POWER 20 24V shines green n CAN communication CAN HI about 2 5V flashes green n CAN communication CAN LO about 2 3 V flashes green Fault indication n CAN HI glows red constantly for s...

Page 198: ...or X4 3 Select CABLE TEST on the CAN tester The multimeter should read about 60 65 Ohms if the cable is intact Fault indication n If the multimeter reads 120 Ohm the end plug is missing or there is a...

Page 199: ...Measure the voltage according to the table Checking the digital outputs There are two digital outputs designated A and B in each contact Pin Function 1 24V DC 2 Signal B 3 GND 4 Signal A 5 GND Table...

Page 200: ...and the A or B output that is of interest 4 Activate the function Normally the multimeter will read 24V Fault indication n If the valve is not activated there is an open circuit in the cable running t...

Page 201: ...there is an open circuit in the coil in the valve Checking the analogue inputs Pin Function 1 24V DC 2 0 5V 3 GND 4 4 20mA 5 5V DC Table 23 Pin configuration Measuring voltage power 1 Connect the 5 po...

Page 202: ...the output of interest on the I O module and the valve as illustrated Connecting the I O tester 2 Connect the multimeter in series with the A or B output that is of interest 3 Actuate the function and...

Page 203: ...eck that the angle shown on the sensor menu changes Resolver tester If the angle changes the sensor on the boom is faulty If the angle does NOT change the cable on the boom must be checked 2 Connect t...

Page 204: ...y to the resolver module input Turn the test sensor slowly and check that the length measurement shown on the sensor menu changes If the measured value changes the cable on the boom is faulty If the m...

Page 205: ...solver module is replaced the program must be read into the system again 3 Insert the USB memory stick with the program into the USB port and start the RCS system 4 When the program has been fully loa...

Page 206: ...m For maintenance of the rotation unit see the separate documentation For maintenance of the down the hole rock drill see the supplier s documentation 14 3 2 Lubrication The lubrication points are on...

Page 207: ...aximum of a couple of presses with grease in each nipple is sufficient Too much lubrication can pressurise the seals and lead to heat development which damages seals and bearings In addition lubricati...

Page 208: ...the down the hole rock drill s inner tube can vary greatly with a probable average life of around 800 m but in some abrasive rock types the service life can be as low as 300 m Drill pipe The drill pip...

Page 209: ...nd bearing may be many times this service life However seal replacement is unavoidable During dismantling the lock nut 6 retaining washer 7 and holder washer 3 are re moved so that the shell 1 can be...

Page 210: ...65 Tier 4 Final 14 Options 210 Outlet swivel with Metzke Blowdown Valve 1 Metzke Blowdown Valve 2 Seal 3 Seal 4 O ring 5 Seal 6 Hex head screw 7 Washer 8 Short adapter housing 9 Washer 10 Socket head...

Page 211: ...al 5 on the outlet swivel requires regular lubrication There is a grease nipple for this on the adapter housing 8 Grease must be applied daily to this seal 5 via the grease nipple Replace the seals wh...

Page 212: ...h is easy to replace by removing the bridge 1 and the cover plate 2 As the service life varies greatly depending on rock conditions this block should be checked every month or every 250 engine hours u...

Page 213: ...eds replacing Be careful not to tighten too hard as this could cause the knife blade to lock The rope seals must be replaced as necessary About inner tubes All components from the rotation head shaft...

Page 214: ...sed against using blow up adapters 14 3 5 Metzke Blowdown Valve The Metzke Blowdown Valve directs the compressed air down through the inner tube and so clears away any blockages and forces return air...

Page 215: ...ing from the centre of the cover plate then this indicates that O rings are either missing or are in poor condition or that there is a hole in one of the inner tubes above the cover plate If the leaki...

Page 216: ...at a qualified engineer has inspec ted and approved the fire fighting system annually We recommend checking with your in surance company to find out if they have any requirements concerning this syste...

Page 217: ...illing orifice cover plate The winch gear holds 0 5 L oil Drain out the old oil by removing the oil drain plug 1 Pour in new oil into the winch transmission via the oil filling orifice cover plate 2 1...

Page 218: ...ntrollably Increase braking force 1 Undo the lock nut on the adjusting screw 3 2 Rotate the brake nipple clockwise one quarter turn 3 3 Tighten the locking nut Decrease braking force 1 Undo the lock n...

Page 219: ...14 Options 219...

Page 220: ...www atlascopco com 2015 12 17 No 713991051 3...

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Atlas Copco SMARTROC D65 TIER 4 FINAL, Maintenance Manual

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