COP 1838HD+ VerF Maintenance Instructions [PDF]

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Atlas Copco Hydraulic Rock Drill COP 1838 HD+ Version F Maintenance instructions

PM no. 9852 2943 01b 2015-04

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

1250 0071 04

© Copyright 2015, Atlas Copco Rock Drills AB, Sweden All product names in this publication are trademarks of Atlas Copco. Any unauthorised use or copying of the contents or any part thereof is prohibited. Illustrations and photos may show equipment with optional extras. No warranty is given regarding specifications or otherwise. Specifications and equipment are subject to change without notice. Consult your Atlas Copco Customer Centre for specific information.

Translation of original instructions

Atlas Copco Rock Drills AB SE-70191 Örebro, Sweden

Table of Contents

Table of Contents 1.

GENERAL .......................................................................................................... 3 1.1 Description of Manufacturing Number.......................................................................... 3 1.2 In the Event of Leakage Problems ............................................................................... 3 1.3 During Dismantling ....................................................................................................... 3 1.4 During Assembly .......................................................................................................... 3 1.5 Environment ................................................................................................................. 3 1.6 Safety Regulations ....................................................................................................... 4 1.6.1 Warning Boxes ....................................................................................................4 1.6.2 The Following General Safety Rules Must Be Observed ....................................4

2.

TOOL LIST.......................................................................................................... 7

3.

SERVICE INTERVAL ......................................................................................... 9 3.1 Overhaul Kits................................................................................................................ 9 3.2 Before Starting Up a New or Newly Overhauled Rock Drill.......................................... 9 3.3 After the First Shift With a New or Newly Overhauled Rock Drill ................................. 9 3.4 Before Each Shift ......................................................................................................... 9 3.5 After Every 40th Percussion-hour ................................................................................ 9 3.6 After Every 600th Percussion-hour .............................................................................. 9

4.

HOSE CONNECTIONS .................................................................................... 11 4.1 General....................................................................................................................... 11 4.2 Connecting the Hoses ................................................................................................ 11

5.

TIGHTENING TORQUES ................................................................................. 13 5.1 Bolted Joints............................................................................................................... 13 5.2 Nipples ....................................................................................................................... 14 5.3 Adjusting the Side Bolts ............................................................................................. 15 5.3.1 Tightening the Side Bolts ..................................................................................15 5.3.2 Retightening the Side Bolts ...............................................................................15

6.

ACCUMULATORS ........................................................................................... 17 6.1 Safety Label Locations ............................................................................................... 17 6.2 Safety Label Meanings............................................................................................... 17 6.3 Charging the Accumulators ........................................................................................ 18 6.4 Pressure Checking the Accumulators ........................................................................ 20 6.4.1 Damper Accumulator and Intake Accumulator ..................................................20 6.4.2 Return Accumulator ..........................................................................................20 6.5 Replacing Intake and Damper Accumulator............................................................... 21 6.5.1 Dismantling .......................................................................................................21 6.5.2 Assembly ...........................................................................................................22 6.6 Replacing the Return Accumulator............................................................................. 23 6.6.1 General .............................................................................................................23 6.6.2 Dismantling .......................................................................................................23 6.6.3 Assembly ...........................................................................................................24

7.

REPLACING THE HYDRAULIC MOTOR ........................................................ 25 7.1 Dismantling................................................................................................................. 25 7.2 Assembly.................................................................................................................... 25 7.3 Function and Condition Test of the Hydraulic Motor .................................................. 25 7.3.1 Function Test ....................................................................................................26 7.3.2 Belle Test ..........................................................................................................26 7.3.3 Half Belle Test ...................................................................................................27

1

Table of Contents

8.

FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM ............. 29

9.

SETTINGS ........................................................................................................ 31 9.1 Setting of ECL Lubricating System ............................................................................ 31 9.2 Setting Damper Pressure........................................................................................... 31

10. FRONT HEAD................................................................................................... 33 10.1 Dismantling .............................................................................................................. 33 10.2 Check....................................................................................................................... 35 10.3 Assembly ................................................................................................................. 38

11. DISMANTLING FROM CRADLE...................................................................... 41 11.1 Slinging .................................................................................................................... 41 11.2 Rock Drill Weights.................................................................................................... 41 11.3 Long-term Storage ................................................................................................... 41

12. LUBRICATION.................................................................................................. 43 12.1 Gear Housing........................................................................................................... 43

13. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 45 13.1 Hydraulic Fluid ......................................................................................................... 45 13.1.1 If the Viscosity is Too Low: .............................................................................45 13.1.2 If the Viscosity is Too High: .............................................................................45 13.1.3 The Hydraulic Fluid Must be Changed at Regular Intervals. ..........................45 13.2 Pneumatic Tool Oil................................................................................................... 46 13.3 Grease ..................................................................................................................... 46

2

1. General

1. General This instruction is intended as a guide when performing maintenance on your rock drill.

1.1 Description of Manufacturing Number All rock drills are given a manufacturing number depending on place of manufacture, year, family and version. The manufacturing number is stamped-on and the location on the rock drill varies, depending on the model. 1. Factory code for manufacturing unit: AVO= Atlas Copco Rock Drills AB

2

4

2. Year the product was produced.

4. Serial number in the "Family Group". 5. Version letter for the product. To show which manual/spare parts list that is relevant.

AVO 15 D 333B 1250 0404 84

3. Family letter identifying number series: D = Hydraulic rock drill P = Pneumatic rock drill T = Rotation units

1

3

5

1.2 In the Event of Leakage Problems Check the source of the leakage before removing the rock drill from the rig.

1.3 During Dismantling Always wash the rock drill externally using grease solvent before starting removal. An assembly fixture must be used when dismantling the rock drill.

1.4 During Assembly Pneumatic tool oil must be applied to the internal parts during all fitting unless otherwise stated.

1.5 Environment Environmental regulations Care for the environment! Leaking hydraulic couplings and grease are hazardous to the environment. Changing oils, hydraulic hoses and various types of filter can be hazardous to the environment. Always collect oil residue, oil spill, oily waste and grease residue and spill. Treat according to applicable local regulations. Use biodegradable hydraulic fluid and lubrication oil wherever possible.

3

1. General

1.6 Safety Regulations The Safety chapter contains important information for the prevention of accidents. 1.6.1 Warning Boxes The manual contains warnings. Warnings are preceded by a heading (Danger, Warning and Caution).

Warning Boxes Danger Indicates an imminent risk of serious or fatal injury if the warning is not heeded. Warning Indicates hazards or hazardous procedures which could result in serious or fatal injury if the warning is not heeded. Caution Indicates hazards or hazardous procedures which could result in personal injury or damage to property if the warning is not heeded. 1.6.2 The Following General Safety Rules Must Be Observed r

Important! Read through the maintenance instructions thoroughly before starting maintenance work. Follow the instructions given and local regulations. Do not use or intervene with the rock drill unless you have been trained to do so. Never attempt to carry out maintenance while the rock drill is in operation. Ensure that the hydraulic, water and air systems are depressurised, and that the electrical system is de-energised, prior to removing the rock drill or starting work on the system. Use approved lifting devices when handling the rock drill. Avoid lifting heavy weights yourself. To prevent injury during service and maintenance, all components that could possibly move or drop must be supported safely on blocks or trestles, or secured by means of adequately dimensioned slings. Check that the hoses used are of the right quality, and that all hose connections are in good condition and properly tightened. Hoses that loosen could cause serious injury. Use only Atlas Copco original parts. Any damage or malfunction caused by the use of non-original Atlas Copco parts is not covered by warranty or product liability.

Important! Make sure that the rock drill has been maintained in accordance with the applicable instructions. Before tramming the rig and rock drill or starting to drill, make sure that no personnel is in the immediate vicinity of the drill rig. Checks and adjustments that are necessary when the rock drill is in operation must be carried out by at least two persons. One person must be present at the operating station and have a good view of the work. Always wear a helmet and earmuffs when drilling. Follow local regulations Make sure that the place of work is well ventilated. Make sure that the safety labels are fitted, clean and fully legible. Particular attention must be paid to all warnings in the manual. Exercise caution when jointing drill rods and with drill bit handling. Watch your fingers! Make sure that clothes do not come too close to rotating machine parts. Negligence could cause serious injury.

4

1. General

Important! A mining machine has many components and functions that are controlled by a hydraulic system, directly or indirectly. Before working on or inspecting any part of the machine, it is important to know how the machine moves and how its functions are controlled by the hydraulic system. Prior to starting work or inspecting any part it must be physically locked/stopped from being able to move and causing bodily injury. The mechanic must be careful to not place any body part where a movement of the machine could cause injury if the hydraulic system fails or is disconnected. There may be occasions where components and or vehicles start moving when trapped energy is released. Where applicable, there must be confirmation that all measures to safeguard against involuntary movement have been taken by releasing the energy and/or physically locking/stopping the machine. It is also incumbent on the individuals involved to ensure that all local, national and federal safety regulations are followed, before and during the work or inspection.

5

1. General

6

2. Tool List

2. Tool List A1

A10

A4

A11

P

R A12 S

A13

A6

A14

V

A7

D

PP

Letter

Tools

A1 A4 A5 A6 A7 A10

Plastic mallet U-ring spanners 10-32 mm, 46 mm Hexagon wrench 4-10 mm, 3/16" Crowbar Mandrel 2-10 mm, copper mandrel 20x250 mm Torque wrench 10-100 Nm Torque wrench 75-400 Nm Socket wrench set with sockets 10-32 mm for external hexagon Socket wrench set with sockets 4-10 mm for internal hexagon Socket wrench set with socket 3/16" for internal hexagon Punch T-handle with 3/4" connection bracket, Power socket 32 mm Vernier calliper Mandrel Charging equipment for accumulators Pressure gauge inc. adapter Ring spanner Socket wrench Removal tool for flushing head

A11

A12 A13 A14 D P R S V PP

1250 0378 70

A5

Part No.

7

9106 1015 40 9106 1015 41

3115 1019 00 3115 3425 80 3115 3799 80 3115 2263 00 3115 1899 00 3115 5255 00

2. Tool List

8

3. Service Interval

3. Service Interval 3.1 Overhaul Kits Overhaul kits are available for all types of Atlas Copco rock drills and rotation units, the kits are designed to optimise the performance and service life of the rock drill/rotation unit. Information on the overhaul kits is available in the spare parts catalogue for each rock drill/rotation unit. There you can find information on what the kits contain and part numbers.

3.2 Before Starting Up a New or Newly Overhauled Rock Drill • • • • • •

Chapter Connect up the hoses ..........................................................................................................................4 Charge the accumulators .....................................................................................................................6 Select a suitable hydraulic oil and lubricant........................................................................................13 Fill the lubricating system with oil .........................................................................................................8 Adjust and set the lubricating system ...................................................................................................9 Set the damper pressure ......................................................................................................................9

3.3 After the First Shift With a New or Newly Overhauled Rock Drill • Tighten all threaded unions ..................................................................................................................5

3.4 Before Each Shift • Check that air and lubricating oil escapes between the shank adapter and front guide, and also  out of the hole in the front head. .......................................................................................................10 • Check that the drill rig’s damper pressure gauge is showing normal values while it is running at  drilling speed. In the event of deviation, adjust the damper pressure ..................................................9 • Check that the shank adapter’s threads are not damaged.................................................................10 • Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators .....................6 • Check that the machine does not leak. If the flushing medium leaks from the flushing head,  replace the seals and O-rings.............................................................................................................10 • When replacing the shank adapter or removing the front head, check the internal components  including piston, driver and the visible parts of the rotation chuck bushing ........................................10 • In the event of oil leakage from the front head: close percussion and only activate the damper  in order to determine if the leakage is coming from the percussion or damper. .................................10

3.5 After Every 40th Percussion-hour • • • •

Grease the gear .................................................................................................................................12 Tighten all threaded unions ..................................................................................................................5 Check the safety labels on the accumulators. Replace them if they are damaged or illegible.............6 Check the accumulators .......................................................................................................................6

3.6 After Every 600th Percussion-hour • Remove the rock drill from the drill rig.  Transport the rock drill to a suitable workshop for inspection .............................................................11

Important! Servicing should be carried out at appropriate time intervals based on local conditions. The condition of the rock has a major affect on the amount wear and with that the need of servicing.

Important! Always function-test the rock drill after service.

9

3. Service Interval

10

4. Hose Connections

4. Hose Connections 4.1 General Caution! Never attempt any maintenance or work on the rock drill, connections or hoses while the hydraulic, lubrication or flushing pressure systems are pressurised. Air or oil can spray out at high pressure and high temperature. There is a risk of serious injury to the eyes and skin. Pressure hoses with an internal diameter of 19 mm (3/4") or greater are of the quality SAE 100 R9R (high-pressure hose with four layers of steel reinforcement). See the rock drill’s spare parts list. For reasons of safety, under no circumstance may these hoses be replaced with hoses of a lower quality. There is a risk of injury if these instructions are not observed!

8 7 1

1250 0380 49

6

1. 2. 3. 4. 5. 6. 7. 8.

5 2

3

4

Percussion drainage (HD) Rotation, intake (RRL) Rotation, return (RRR) Percussion return (HT) Percussion intake (HP) Flushing (F) Lubricating air (ECL) Damper, intake (HDP)

4.2 Connecting the Hoses • Clean the rock drill’s hose connections before undoing the protective caps. • Never remove a protective cap until the hose is ready to be connected. • Always store the rock drill with all hose connections plugged. Use suitable protective caps, and make sure that they are clean.

11

4. Hose Connections

12

5. Tightening Torques

5. Tightening Torques 5.1 Bolted Joints

1

4

13

14 12 8

9

10

17

15

6 16

9

5

1

1250 0380 50

7 3

11 2

9

16

9

6 15

Lubricate the nuts’ threads and the washers’ contact surfaces with Never-Seez Regular Grade. Ref. No.

Qty.

Check point

Torque Nm

1

2

Side bolts

300

2 3

1 4

Front bolt Side bolt

300 300

4

3

Back head

220

5 6

1 4

Regulating plug Accumulator

80 220

7 8

4 2

65 30

9

4

Hydraulic motor Clamping bracket, return accumulator Rock drill mounting

250

10 11

1 4

Plug Valve covers

45 145

13

Instructions

Tighten the rear nuts alternately to full torque Tighten the front bolt Tighten the front nuts alternately to full torque Tighten the bolts alternately to full torque, top bolt last Tighten the screws alternately to full torque Tighten the nuts alternately

Tighten the screws alternately to full torque Tighten the screws alternately to full torque

5. Tightening Torques

Ref. No.

Qty.

Check point

Torque Nm

12

2

Connecting plate

120

13 14

1 2

Flushing connector Intake, flushing medium

300 220

15 16 17

2 2 1

Plug, accumulator Filler nipple, accumulator Pressure screw

45 30 170

Instructions

Tighten the screws alternately to full torque Tighten the screws alternately to full torque

5.2 Nipples

8 7 1

1250 0380 49

6 5 2

3

4

Ref. No.

Def.

Check point

Torque Nm

1 2 3 4 5 6 7 8

HD RRL RRR HT HP F ECL HDP

Percussion, drain Rotation, intake Rotation, return Percussion, return Percussion, mechanism Flushing Lubricating air Damper, intake

70 85 85 170 170 300 70 70

14

Instructions

5. Tightening Torques

5.3 Adjusting the Side Bolts 5.3.1 Tightening the Side Bolts 1. Check whether the side bolts, dome nuts or washers have cracks, scratches or rust. Replace damaged side bolts, dome nuts and washers.

1

3. Tighten the rear dome nuts (1) alternately to tightening torque. 4. Tighten the side bolt (2) to the tightening torque.

1250 0378 85

2. Lubricate the threads and contact surfaces of the side bolt, dome nuts and washers with Never-Seez Regular Grade.

3

2

5. Tighten the front dome nuts (3) alternately to tightening torque. 5.3.2 Retightening the Side Bolts 1. Undo the front dome nuts (3) so that the tension releases.

1

2. If the threads are seized, remove the dome nuts, clean them and lubricate with NeverSeez Regular Grade. 4. Tighten the rear dome nuts (1) alternately to tightening torque. 5. Tighten the side bolt (2) to the tightening torque.

1250 0378 85

3. Tighten the front dome nuts (3) hand-tight.

6. Tighten the front dome nuts (3) alternately to tightening torque.

15

3

2

5. Tightening Torques

16

6. Accumulators

6. Accumulators Check the safety labels on the accumulators. Replace them if they are damaged or illegible.

6.1 Safety Label Locations 31. Damper accumulator 30. Intake accumulator 35. Return accumulator

1250 0380 51

31

35

30

6.2 Safety Label Meanings 1. Read the operator’s instructions carefully before service or replacement of the accumulator

1250 0187 04

2. Must only be charged with nitrogen gas

17

N2

1

2

6. Accumulators

6.3 Charging the Accumulators Caution! Charge the accumulators when they are assembled on the rock drill. There is a risk of injury if these instructions are not observed!

Warning! A gas other than N2 could cause an explosion.

1250 0345 16

1. Remove the charge valve’s protective cap (A).

2 A

18

6. Accumulators

2. Fit the gas hose with the connection adapter (3) on the new charging valve (2). Tighten the connection adapter (3) using manual force.

31

3. Close the bleed valve (8) by turning the control knob clockwise. 4. Close the pressure regulator (7) by turning the control knob anticlockwise (-).

Notice! Charge at the bottom if possible rather than too high. 6. Turn the pressure regulator control knob (7) slowly clockwise (+) and set the desired filling pressure on the low pressure gauge (6) or high pressure manometer (5). Damper accumulator (31): 20-25 bar Return accumulator (35): must not be charged with N2 Intake accumulator (30): 80-100 bar*

30

35 1250 0380 52

5. Open the bottle valve (9) slowly and check that the high pressure gauge (4) gives readings to full bottle pressure.

9 5

3

2

6 8 4

7

*Intake accumulator 30-40 bar below collaring pressure. Normal 80-100 bar. Max. 100 bar.

7. In the event of the pressure being too high, adjust the pressure regulator control knob (7) anticlockwise (-). Evacuate the overpressure carefully by turning the control knob for the bleed valve (8) anticlockwise and then close the bleed valve. Adjust the pressure regulator (7) slowly to the correct accumulator pressure. 8. Close the pressure regulator (7) by turning the control knob anticlockwise (-). 9. Close the bottle valve (9).

1250 0345 16

10.Loosen the connection adapter (3) from the charging valve (2). Notice! The gas in the hose will hiss out. The accumulator is switched off and will not release gas when the adapter is removed. 11. Mount the protective cover (A) on the charge valve, tighten using manual force.

2 A

19

1 N2

6. Accumulators

6.4 Pressure Checking the Accumulators Warning! The hydraulic system must be depressurised before checking the accumulators.

6.4.1 Damper Accumulator and Intake Accumulator 1. Remove the charge valve’s protective cap (2). 2. Fit the pressure gauge (10) onto the charging valve (1). Tighten using manual force. 3. Read the pressure gauge (10) and check that the correct accumulator pressure is obtained. Damper accumulator (31): 20-25 bar Intake accumulator (30): 80-100 bar* *Intake

1

accumulator 30-40 bar below collaring pressure. Normal 80-100 bar. Max. 100 bar.

4. Remove the pressure gauge (10) with connection adapter (3). 5. If required, charge the accumulators with nitrogen gas (N2). See chapter: Charging the accumulators.

30 1250 0358 58

6. Refit the charge valve’s protective cap (2), tighten using manual force.

3

2

10 6.4.2 Return Accumulator 1. Position the rock drill in horizontal position. 2. Remove the plug (11) with O-ring (12). If oil escapes then the diaphragm is damaged or the accumulator has been overcharged. 3. Replace the accumulator, diaphragm and/or filler valve if they are not functioning properly. 4. If the diaphragm is resting against the outer pipe, press the diaphragm with a cylindrical (blunt) mandrel (7-9 mm).See Figure A. Correct position for diaphragm, see Figure B.

35

11

12

5. Refit the plug (11) and O-ring (12). 6. Charge by means of admitting air at atmospheric pressure into the accumulator.

1250 0378 71

A

20

B

11

6. Accumulators

6.5 Replacing Intake and Damper Accumulator Warning! All gas must be released before removal, by means of removing the protective cap and fitting the connection adapter (3). There is a risk of injury if these instructions are not observed!

Caution! Defective bolts may lead to dangerous oil leakage or the accumulator working loose. Oil spray can injure the eyes and skin. Parts that come loose can cause serious injury.

Important! Use 65 mm long screws when using the HD accumulator. 6.5.1 Dismantling 1. Remove the charging valve’s (2) protective cap (A). 1250 0345 15

2. Fit the connection adapter (3), and the nitrogen gas (N2) in the accumulator is released. Notice! Align the connection adapter so that there is no risk of personal injury. 3. Remove the connection adapter (3) and refit the protective cap (A) of the charge valve (2), tighten hand-tight.

A 4. Remove the accumulators (30 and 31) with seal rings (350) by loosening the bolts (10).

2

3

30

5. Send the accumulators to a workshop for overhauling!

10

1250 0378 72

350

21

31 10 350

6. Accumulators 6.5.2 Assembly 1. Position the seal rings (350) in the grooves on the intermediate segment. Notice! The seal rings (350) must be turned in accordance with the figure. 2. Make sure that the seal rings (350) do not get damaged during the assembly.

30

10 350

4. Intake accumulator (30) on the right side of the rock drill (hose side). 5. Mount with undamaged original bolts. The intake accumulator (30) must have two bolts with a length of 65 mm. The damper accumulator (31) must have two bolts with a length of 65 mm. Replace the bolts in pairs even if only one bolt is corroded or damaged in some other way.

1250 0378 72

3. Mount the damper accumulator (31) on the left side of the rock drill.

6. Tighten the screws alternately to the tightening torque in accordance with the chapter Tightening torques. 7. Charge the accumulators with nitrogen gas (N2), see chapter Charging the accumulators.

22

31 10 350

6. Accumulators

6.6 Replacing the Return Accumulator 6.6.1 General

Caution! Ensure that the hydraulic, water and air systems are depressurised before starting work on the system. For reasons of safety, under no circumstance may the pressure hoses be replaced with hoses of a lower quality. The hoses must be high-pressure hoses with four layers of steel reinforcement, quality SAE 100R9R. There is a risk of injury if these instructions are not observed! 6.6.2 Dismantling 1. Remove the hydraulic hose from the return accumulator (35). 2. Remove the return accumulator (35) by removing the nuts (24), the bolts (23), the bolt (1) and the holder (22).

1

3. Pull away the clip (21).

23

4. Unscrew the pressure screw (5) with O-ring (6). 5. Detach the return accumulator (35) with Oring (7) from the cylinder.

11

6. Send the return accumulator (35) to a workshop for reconditioning.

21

7

35 24

23

6 5

1250 0378 73

22

6. Accumulators 6.6.3 Assembly 1. Mount the pressure screw (5) with the O-ring (6) on the return accumulator (35). 2. Fit the O-ring (7) in the groove on the pressure screw (5).

4. Thread on the clamp (21) and fit the holder (22) with screws (1, 23) and nuts (24). Tighten the screws and nuts to the tightening torque according to chapter Tightening torques.

1 23 22 11 21

7

35 24

5. Tighten the pressure screw (5) to the tightening torque in accordance with the chapter Tightening torques. 6. Connect the hydraulic hose to the return accumulator (35).

24

6 5

1250 0378 73

3. Mount the return accumulator (35) on the cylinder with the pressure screw (5) and Oring (7). Screw the pressure screw (5) loosely. Notice! Carefully check that the O-ring (7) is not damaged and that the plug (11) remains accessible for checking the accumulator membrane.

7. Replacing the Hydraulic Motor

7. Replacing the Hydraulic Motor Caution! Ensure that the hydraulic, water and air systems are depressurised before starting any work on the systems. Pressure hoses with an internal diameter of 19 mm (3/4") or greater are of the quality SAE 100 R9R (high-pressure hose with four layers of steel reinforcement). See the rock drill’s spare parts list. For reasons of safety, under no circumstance may these hoses be replaced with hoses of a lower quality. There is a risk of injury if these instructions are not observed!

7.1 Dismantling Depending on the size of the hydraulic motor, the rock drill needs to be detached from the cradle. 1. Remove the hydraulic hoses. 2. Loosen the nuts (25) with a ring spanner (S) and remove the hydraulic motor (20) and gasket (24).

S

1250 0378 74

3. Pull out the coupling (21).

401

22 21

24 25

20

7.2 Assembly 1. Make sure that the groove ring (22) is fitted in the coupling (21).

S

2. Lubricate the coupling’s splines with grease and fit the coupling (21) on the hydraulic motor (20).

4. Tighten the nuts (25) alternately to the correct tightening torque according to chapter Tightening torques with a ring spanner (S). 5. Connect the hydraulic hoses. Check that the correct direction of rotation is obtained.

1250 0378 74

3. Fit the gasket (24) and hydraulic motor (20) onto the cylinder (401). Replace the gasket (24) if it is damaged.

401

22 21

24

7.3 Function and Condition Test of the Hydraulic Motor The following tests give an approximation of the present state of the motor. The following items are required to conduct the tests: • • • • • •

Apparatus for hydraulic flow and pressure. A pressure gauge. A flow meter in the 0-15 l/min range, preferably with an accuracy of at least 0.5 l/min Couplings and hoses to assemble the components. A fixture to lock the rotation of the rear axle. Oil grade HLP46 at 50 degrees and viscosity approx. 35 CST

25

25

20

7. Replacing the Hydraulic Motor 7.3.1 Function Test 1. Connect the hydraulic hoses P (Pressure) and R (return) to the hydraulic motor. 2. Allow the motor to rotate for about 30 seconds with a maximum flow of 10 l/min. 3. Make sure rotation is smooth and without noise.

P

1250 0403 55

R

7.3.2 Belle Test For motors with external drainage line only. The test indicates the general state of the motor, including axial wear, condition of seals, valves, etc. Replace the motor if the size of the leak exceeds table value. Test procedure:

B

1. Plug port "B" with a suitable plug.

AA

2. Connect a flow meter to the motor’s drainage line.

T (drain)

3. Make sure the motor shaft can rotate freely. 4. Pressurise port "A" in accordance with the following table. Make sure to use the correct pressure for the current motor type!

P

Motor Type

Pressure Port A

Permitted Flow in Drainage Line

MS

210 bar

3,5 l/min

1250 0403 56

5. Measure the flow from the drainage line. Replace the motor if it exceeds the specified value.

26

R

7. Replacing the Hydraulic Motor 7.3.3 Half Belle Test

The following test indicates the condition of the gear wheel in the motor. It can be used for all motors. Test procedure:

B A

1. If the motor has a drainage line, couple it to port "B" with a T-coupling.

T (drain)

2. Couple the flow meter to port "B" on the motor. 3. Secure the rear axle with suitable equipment. It must not rotate. 4. This unit can be ordered for type MS motors.

S

5. Pressurise port "A" in accordance with the following table. Make sure to use the correct pressure for the current motor type!

1250 0403 57

P

6. Measure the flow from port "B" (if necessary in combination with the drainage line). Replace the motor if it exceeds the specified value.

Motor Type

Pressure Port A

Permitted Flow in Drainage Line

MS 80-160cc

140 bar

10 l/min

MS 200-315

110 bar

10 l/min

MS 400-475

70 bar

10 l/min

27

R

7. Replacing the Hydraulic Motor

28

8. Filling with Lubricating Oil and Bleeding the System

8. Filling with Lubricating Oil and Bleeding the System Caution! Never work on the lubrication system when it is pressurised. Lubricating oil could spray out. There is a risk of serious injury to the eyes and skin.

Important! Use the recommended lubrication air pressure and recommended lubrication oil. Some moving parts on the rock drill are lubricated with oil mixed with compressed air. Is important that these parts receive good lubrication.

Check the level in the lubricating oil tank for every shift. Exercise cleanliness and fill with the right grade oil. The lubricating oil tank holds 5 l. See chapter: Hydraulic oil and lubricant recommendations. If the lubricating system has been empty of oil, it must be bled after filling. See the respective Rig manuals for instructions.

29

8. Filling with Lubricating Oil and Bleeding the System

30

9. Settings

9. Settings 9.1 Setting of ECL Lubricating System ECL=Electric Controlled Lubrication

Rock drill lubrication must be set with regard to local conditions. 1. Start the lubricating system. 2. Check the lubricating air pressure at the rock drill using a pressure gauge. The pressure should be 2.53 bar. If the pressure is too low, clean the restriction or increase the diameter of the restriction. 3. Set the correct lubricating oil dose: Pump (3217 8667 50) - 35-40 pulses/min Pump (3217 8667 52) - 20-25 pulses/min 4. After setting, check that the correct pulse frequency has been obtained and that oil is emerging from the front head’s hole and between the shank adapter and front guide.

9.2 Setting Damper Pressure Notice! The setting should take place at normal operating temperature for the hydraulic oil.

1

1250 0378 75

1. Fully close the constant flow valve (B) on the drill rig. 2. Connect a pressure gauge (A), calibrated for 0-60 bar, between the hose and the damper union (1). 3. Pressurise the damper circuit. 4. Check that the shank adapter is unloaded and in the forward position. 5. Adjust the constant flow valve until the pressure gauge (A) shows 35 bar (operator panel shows 40 bar). 6. Disconnect the pressure gauge (A) and connect the hose to the union (1).

31

B

9. Settings

32

10. Front Head

10. Front Head Caution! Never attempt to carry out maintenance while the drill rig is in operation. Ensure that the hydraulic and air systems are depressurised before starting any work. There is a risk of injury if these instructions are not observed!

Caution! The percussion mechanism must not be enabled, when the shank adapter is dismantled. Piston and front piston guide can be damaged. Notice! Always clean the outside of the rock drill before dismantling.

10.1 Dismantling 1. Remove the flushing hose. 2. Remove the connecting plate (186) by undoing the bolts (188) with the washers (189). 3. Remove the seal (194).

194 186

1250 0378 78

189 188

4. Remove the front nuts (10) with their washers (11). 5. Remove the front head (172) by pulling the shank adapter (1) or by tapping with a plastic mallet.

191 1250 0378 79

172

33

1

11

10

10. Front Head

6. Remove the drill sleeve (5). 7. Pull the shank adapter (1) from the front head (172).

1 172

181

1250 0378 80

5

8. Mount the tool (PP) in the cup seals (175) through the flushing connection hole in the front head. 9. Use a mandrel and a plastic mallet to tap out the stop ring (185), washer (184) and flushing head (174).

A1 PP

172

175 PP 184 185

1250 0378 77

174

10.If necessary, press the guide (177) out of the front head (172). Use a mandrel (D) to remove the guide.

D

172

34

1250 0378 86

177

10. Front Head

10.2 Check Overview illustration of the front head

5

177 172 174 184 185 152 260 202 261 360 430

1250 0378 81

1

178 175 192 175 192 176 195 193 Many of the position numbers in the instructions below are included in the figure above.

1250 0380 55

1. Check that air and lubricating oil escape between the shank adapter (1) and front guide (177), and also out of the hole (B) 2. Blow clean the lubricating air ducts with compressed air and check that the restrictions are open 1

B

3. Replace the guide (177) if the inside diameter exceeds 39 mm. Notice! Max. dimension.

178

4. Check the lubricating channels on the guide. 5. Check that the wiper (178) is not worn or damaged. Notice! The wiper (178) must be turned in accordance with the figure.

1250 0378 82

177

35

39 mm

10. Front Head

6. Check the seal rings (192) and the cup seals (175-176) if air is escaping from the hole (C) in the front head. Replace the seal rings (192) and cup seals (175-176) if they are worn or damaged. Notice! The cup seals must be turned in accordance with the figure.

175

176

174 192

175 1250 0378 83

7. Replace the flushing head (174) if it is seriously corroded, or if it contains cracks.

192

8. Replace the stop ring (185) if:

i

• any point within the wear surface (S) is worn more than 1 mm, compare with a new stop ring • any cracks (signs of breakage) are found • the wear surface (S) is uneven M - Measuring point S - Wearing surface

1,0 193 185

S

195

9. Check and replace the O-rings (193, 195) if they are worn or damaged.

1250 0378 84

M

10.Look inside the gear housing and check the splines on the driver (260). If the splines are less than 2 mm in width, the driver (260) must be replaced.

185

1250 0318 84

260

36

10. Front Head

11. Send the rock drill to a workshop for inspection if:

1,0 261

• the rotation chuck bushing (261) is worn more than 1 mm on the wear surface (S) • after 600 percussion hours • if the impact piston’s (430) impact surface is damaged in any way 12.Also replace the rotation chuck bushing (261) if marks (wave type) from splines are visible on the wear surface (S).

M

13.Notice! Fit the rotation chuck bushing so that the lubricating grooves are directed towards the damper piston (360).

S 1250 0325 89

M - Measuring point S - Wearing surface

14.Replace the shank adapter (1) if:

1250 0318 87

• the thread is worn out • the impact surface is crushed or chipped • the front or rear end surfaces of the splines are worn

15.Check that the drill sleeve (5), to be used with upwards directed drilling, is not damaged and rotates with the shank adapter (1).

1

1

37

1250 0380 53

5

10. Front Head

10.3 Assembly Important! Before fitting the parts must be lubricated with clean hydraulic oil.

1. Check that the lubricating duct (A) is open by blowing with compressed air.

A

2. Press the guide (177) with wiper (178) into the front head (172). Use mandrel (D).

172 178 177

3. Fit the cup seals (175-176) in the flushing head (174). Notice! The cup seals (175-176) must be turned in accordance with the figure.

1250 0378 87

D

192

4. Fit the seal rings (192) on the flushing head.

175

176

174 175 1250 0378 83

192

38

10. Front Head

5. Press in the flushing head (174) using the mandrel (D) and the sleeve (V). Notice! The flushing head must be turned so that the lubricating grooves are upwards. See the figure.

D

6. Also make sure that the flushing hole in the flushing head is aligned with the hole (A) in the front head (172).

V 172 174 1250 0378 93

A

7. Fit the washer (184) in the front head (172).

193 185 195 184

8. Fit the stop ring (185) with O-rings (193, 195) in the front head. Tap with a plastic mallet.

1250 0378 94

172

9. Slide the shank adapter (1) into the front head (172).

1

10.Fit the drill sleeve (5) on the shank adapter.

172

11. Check and replace the seal ring (181) if it is worn or damaged.

181

1250 0378 80

5

39

10. Front Head

12.Make sure that the pin (191) is fitted in the cover plate. Place the front head (172) on the side bolts. 13.Lubricate the threads and contact surfaces for the washers (11) and nuts (10) with thread grease.

191

14.Fit the washers (11) and nuts (10).

16.Tighten the front nuts (10) alternately to the tightening torque given in chapter Tightening torques.

172 1250 0378 79

15.Check the tightening torques on the rear sidebolt nuts and the front side bolt. See chapter Tightening torques.

1

11

10

17.Fit the seal ring (194) into the flushing head. 18.Fit the connecting plate (186) on the front head using washers (189) and screws (188). Notice! Also make sure that the flushing hole in the flushing head aligns with the hole in the front head. 19.Tighten the screws (188) alternately to the tightening torque in accordance with the chapter Tightening torques.

194 186

20.Replace the seal washer if it is damaged.

1250 0378 78

21.Fit the nipple on the connecting plate. Tighten to the tightening torque in accordance with the chapter Tightening torques. 22.Connect the flushing hose and tighten the nut. After assembly Check that air and lubricating oil escape from the holes (B and C) in the front head and between the shank adapter and guide.

40

189 188

11. Dismantling From Cradle

11. Dismantling From Cradle 11.1 Slinging Caution! Lifting devices and straps must be approved for lifting at least 500 kg. Incorrect lifting devices could cause the rock drill to start moving or fall down. Incorrect operation could cause crushing damage.

1250 0380 54

Make sure that the rock drill is safely slung for lifting. Make sure that the rock drill is securely anchored for transportation.

11.2 Rock Drill Weights COP 1838 HD+

185 kg

11.3 Long-term Storage If the rock drill is not going to be used for a long time, the following precautions should be taken.

1. Check that all connections, including the one for the flushing medium, are properly capped with protective caps of the right size 2. Clean the rock drill carefully. Use degreasing agent and rinse with water. 3. Clean thoroughly and oil in the front head components in contact with flushing medium (especially in high humidity). 4. Fill grease in the nipples in the front. 5. Release gas from the accumulators. 6. Store the rock drill in a dry place.

41

11. Dismantling From Cradle

42

12. Lubrication

12. Lubrication 12.1 Gear Housing 1. Unscrew the bleed plug (214) with gasket (215).

215 214

2. Lubricate with heat-resistant grease through the grease nipple (212) until grease escapes through the hole (3) for the bleed plug.

3

1250 0319 01

3. Tighten the bleed plug (214) with gasket (215).

43

212

12. Lubrication

44

13. Hydraulic and Lubricant Recommendations

13. Hydraulic and Lubricant Recommendations 13.1 Hydraulic Fluid Atlas Copco offers a range of hydraulic oils based on operational requirements and varying temperature ranges. These oils provide superior protection against wear, rust and oxidation, as well as air and water separation and good anti-foaming. All Atlas Copco hydraulic oils conform to standard ISO 11158 HM, DIN 51524 HLP/HVLP and ISO 15380 (for biodegradable options). The diversity of Atlas Copco hydraulic oil helps fulfil all limit values for viscosity as required for different operating conditions and ambient temperatures. It is important to have the viscosity grade suited for your operating environment (please review the table below). There are different types of oils across these ranges, varying from mineral to synthetic-based. These oils ensure high efficiency operation with superior purity and excellent filtration. Hydraulic oil

Climate

20 Litres

209 Litres

1000 Litres

100 ISO VG 46 120 ISO VG 46

Normal Normal

9106 2303 20 9106 2303 22

9106 2303 26 9106 2303 33

200 ISO VG 32 300 ISO VG 68

Arctic Tropical

9106 2303 21 Degradable 9106 2303 23 9106 2303 27 9106 2303 30

9106 2303 28 9106 2303 31

9106 2303 29 9106 2303 32

13.1.1 If the Viscosity is Too Low:

• The hydraulic fluid may not form a lubricating layer between surfaces, thus increasing the risk of wear. • The hydraulic fluid can leak past seals more easily in the rock drill causing increasing fluid losses and increasing energy requirements. 13.1.2 If the Viscosity is Too High:

• Flow losses in the hydraulic lines will be high increasing energy consumption and pressure levels, putting increased strain on seals. • The risk of cavitation will increase, thus also the risk of damage to the rock drill and hydraulic pumps. The hydraulic fluid must be filtered to a purity of 20/18/15 in accordance to ISO 4406. The viscosity will change during the period that the hydraulic fluid is used. In general viscosity will drop with increased operating hours. To ensure that the viscosity of the fluid does not drop to a critical level before the recommended service interval, a hydraulic fluid of sufficient stability must be used. The viscosity in cSt of suitable hydraulic fluids shall drop a maximum of 25% when tested for shear stability in accordance with DIN 51350-6 at 100ºC. 13.1.3 The Hydraulic Fluid Must be Changed at Regular Intervals.

Factors influencing the interval between changes: • The viscous stability of the hydraulic fluid as specified above. The hydraulic fluid must be changed before the viscosity drops to a critical level. • Contamination with water. If the hydraulic fluid becomes cloudy and light grey, the water content has become such that the hydraulic fluid must be changed. • Deterioration of properties such as oxidation inhibition and anti-foaming.

Environment! Excess and/or waste hydraulic fluid must be disposed of in an environmentally-friendly manner and in accordance with regulatory requirements.

45

13. Hydraulic and Lubricant Recommendations

13.2 Pneumatic Tool Oil Atlas Copco recommends the use of Atlas Copco COP OIL which has been specially developed for our hydraulic rock drills. COP OIL is an environmentally friendly, degradable oil which can be used in ambient temperatures between -25 ºC and +50 ºC. COP OIL can be ordered with the following part numbers: Quantity

Part Number

1 can of 4 litres 1 can of 20 litres 24 cans of 20 litres 1 barrel of 208 litres

3115 3125 02 3115 3125 01 3115 3126 01 3115 3127 00

If COP OIL is not available then the oil should have the following properties: • • • •

Use an oil with good lubricating properties intended for compressed air tools. The oil must have good adhesion capacity. The oil must have additives that prevent foam formation. Depending on ambient temperature, the oil should have the following viscosity grades if the viscosity index (VI) is about 100: Ambient Temperature ºC

Viscosity grade (ISO 3448)

-30 to 0 -10 till +20 +10 till +50

VG 32-68 VG 68-100 VG 100-150

• The oil must have an EP additive which covers the following load-bearing properties: ASTM D 2783

Min. 250 kg

ASTM D 4172 (40 kg)

Max. 0.5 mm

13.3 Grease Notice! Because of the operating temperature in the rock drill gear housing, always use a high-temperature grease with lithium complex soap based on a synthetic base fluid (polyalphaolefin/synthetic ester) with additives that protect against oxidation, corrosion and wear at high loads and with EP additive.

NLGI number

Drop point

Base oil viscosity

Operating Temperature

2

260 ºC

220 cSt at 40 ºC

-15 to +150 ºC

Atlas Copco recommends the use of Atlas Copco COP Grease, gear housing grease, which has been specially developed for our hydraulic rock drills. COP Grease withstands temperatures between -40ºC to +150ºC, and temperatures of up to 220ºC during shorter periods. COP Grease can be ordered with the following part numbers: Quantity

Part Number

Tube 0.4 kg Can 18 kg

3115 3422 00 3115 3423 00

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