9852 1752 01 Drill Rig Maintenance Instructions

Atlas Copco
Boomer & Rocket Boomer L1/L2 D

Maintenance instructions
PM No. 9852 1752 01

2005-06
SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.
Special attention must be paid

to information alongside
this symbol.
Only use genuine Atlas Copco parts.
1250 0071 04
© Copyright 2005, Atlas Copco Rock Drills AB, Sweden

Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
Safety
Safety
Reference................................................................................................................. 5
3
Safety
4
Safety
Reference
Note
Always read the safety information before operating the rig or beginning mainte-
nance work.
1250 0099 89
5
Safety
6
1. General ................................................................................................................... 19
Environment .......................................................................................................... 19
Contact details ....................................................................................................... 20
Target group and objective .................................................................................... 23
Hydraulic systems ................................................................................................. 24
General.............................................................................................................. 24
Repairing hydraulic components ...................................................................... 24
Hydraulic workshops ........................................................................................ 25
Replacement of hydraulic hoses ....................................................................... 25
Welding.................................................................................................................. 25
Electrode recommendations.............................................................................. 26
Tightening torque in bolted joints. ........................................................................ 26
Markings and plates............................................................................................... 27
Dismantling and assembly..................................................................................... 28
Fault finding .......................................................................................................... 28
Starting with an auxiliary battery .......................................................................... 29
2. Lubricants, coolants and propellants...................................................................... 30

Introduction ........................................................................................................... 30
Hydraulic oil.......................................................................................................... 30
Hydraulic systems............................................................................................. 30
Lubrication oil ....................................................................................................... 31
Rock drill (ECL lubrication system)................................................................. 31
Diesel engine .................................................................................................... 31
Hydraulic gearbox ............................................................................................ 32
Wheel axle centre and hub reduction gears ...................................................... 32
Compressor ....................................................................................................... 32
Reeling units ..................................................................................................... 33
Gears ............................................................................................................ 33
Lubrication grease ................................................................................................. 33
Rock drill .......................................................................................................... 33
Feeder ............................................................................................................... 33
Boom................................................................................................................. 33
Drill-steel support ............................................................................................. 34
Electrical system ............................................................................................... 34
Service platform................................................................................................ 34
Rod handling equipment................................................................................... 34
Propellants ............................................................................................................. 35
Diesel engine .................................................................................................... 35
Coolants................................................................................................................. 35
Diesel engine cooling system ........................................................................... 35
Air conditioning................................................................................................ 36
3. Feeder ..................................................................................................................... 37
Safety..................................................................................................................... 37
7
6000-series............................................................................................................. 37
Technical data ........................................................................................................ 38
6000-series ........................................................................................................ 38
Fitting the rock drill/rotation unit .......................................................................... 39
Preparation ........................................................................................................ 39
Assembly .......................................................................................................... 39
Check after four hours ........................................................................................... 39
Rock drill hoses ..................................................................................................... 40
Location of hoses .............................................................................................. 40
Adjusting the hoses ........................................................................................... 42
Haul and return ropes ............................................................................................ 42
Locations........................................................................................................... 42
Replacing the haul rope .................................................................................... 42
Adjusting haul and return ropes........................................................................ 43
Tension of return rope....................................................................................... 43
Adjusting the cradle on the feed beam .................................................................. 44
Adjusting the feed beam on the telescope feeder .................................................. 45
Replacing the slide pieces in the holder ................................................................ 46
Replacing slide rails............................................................................................... 46
Adjusting different drill steel lengths for the telescope feeder.............................. 47
Feed cylinder ......................................................................................................... 48
Dismantling the feed cylinder........................................................................... 48
Tension bushing for spacer ............................................................................... 49
Description ................................................................................................... 49
Dismantling .................................................................................................. 50
Assembly...................................................................................................... 50
Long-term storage.................................................................................................. 50
4. Boom ...................................................................................................................... 51
BUT 35 G .............................................................................................................. 51
Technical data ........................................................................................................ 52
BUT 35 G.......................................................................................................... 52
Bolted joints........................................................................................................... 53
Tightening torques ............................................................................................ 53
Bulkhead lead-through .......................................................................................... 56
Hose location .................................................................................................... 56
Starting to use a new boom.................................................................................... 56
Slinging and hoisting ............................................................................................. 57
Safety ................................................................................................................ 57
Hoisting............................................................................................................. 57
Slinging ............................................................................................................. 58
Dismantling the boom ........................................................................................... 58
Safety ................................................................................................................ 58
Dismantling the feeder...................................................................................... 59
Dismantling the boom....................................................................................... 59
Expander shafts...................................................................................................... 60
Dismantling....................................................................................................... 60
Assembly .......................................................................................................... 60
8
Boom telescope ..................................................................................................... 61

Dismantling the boom telescope....................................................................... 61
Safety ........................................................................................................... 61
Dismantling the boom.................................................................................. 61
Dismantling of telescope and bearing housing ............................................ 62
Checking the bushings in the bearing housing ................................................. 63
Checking the keys............................................................................................. 64
Checking the slide rails..................................................................................... 64
Rotation unit .......................................................................................................... 65
Safety ................................................................................................................ 65
General.............................................................................................................. 65
Function of the rotary actuator ......................................................................... 66
Reconditioning rotary actuators........................................................................ 68
Dismantling of rotary actuator from boom .................................................. 68
Constituent parts of the rotary actuator........................................................ 70
Removing the rotary actuator....................................................................... 71
Assembly of rotary actuator......................................................................... 75
Action after rotary actuator assembly .......................................................... 77
Mounting of rotary actuator on boom .......................................................... 78
Adjusting the feed lookout cylinder ...................................................................... 82
Directional control - angle sensor.......................................................................... 84
5. Engine .................................................................................................................... 85
Engine unit Deutz 1013 C ..................................................................................... 85
Technical data ........................................................................................................ 86
Tightening torques................................................................................................. 87
Safety..................................................................................................................... 88
Fuel system............................................................................................................ 88
Changing fuel filter........................................................................................... 88
Bleeding the fuel system................................................................................... 89
Draining the fuel tank ....................................................................................... 90
Air system.............................................................................................................. 91
General.............................................................................................................. 91
Changing filter insert ........................................................................................ 91
Cleaning the filter insert ................................................................................... 92
Cleaning the dust valve..................................................................................... 92
Cooling system ...................................................................................................... 93
Coolant level ..................................................................................................... 93
Cleaning the cooling system ............................................................................. 94
Draining the cooling system ............................................................................. 94
Topping up/bleeding the cooling system .......................................................... 95
Oil system.............................................................................................................. 96
Topping up with engine oil ............................................................................... 96
Changing oil...................................................................................................... 96
Checking oil level ............................................................................................. 97
Changing oil filter............................................................................................. 97
Belts....................................................................................................................... 98
Tension gauge ................................................................................................... 98
9
Tensioning belts ................................................................................................ 99

Fan belt......................................................................................................... 99
Generator.................................................................................................... 100
Coolant and fuel pump ............................................................................... 101
Changing belt on coolant / fuel pump............................................................. 101
Changing generator belt.................................................................................. 102
Valve clearance .................................................................................................... 102
Alternating current generator............................................................................... 103
Important......................................................................................................... 103
Lifting device....................................................................................................... 104
Fault finding ........................................................................................................ 105
........................................................................................................................ 105
Deutz instruction manual..................................................................................... 106
6. Transmission......................................................................................................... 107
Locations ............................................................................................................. 107
Technical data ...................................................................................................... 107
Wheels ............................................................................................................ 107
Steering ........................................................................................................... 107
Drive shafts ..................................................................................................... 108
Hydraulic gearbox........................................................................................... 108
Fitting tyres and rims........................................................................................... 108
Drive shafts.......................................................................................................... 108
Checking oil level in central gear ................................................................... 108
Changing oil in the final drive ........................................................................ 109
Checking oil level in hub gear ........................................................................ 110
Changing oil in hub gear................................................................................. 111
Hydraulic gearbox ............................................................................................... 112
Safety .............................................................................................................. 112
Checking oil level ........................................................................................... 112
Changing filter and oil .................................................................................... 113
Lubricating the chassis ........................................................................................ 114
Propeller shafts ............................................................................................... 114
Central lubrication of chassis.......................................................................... 114
Towing ................................................................................................................. 115
Safety .............................................................................................................. 115
Before towing ................................................................................................. 115
Release the brakes........................................................................................... 116
Removing propeller shafts .............................................................................. 116
Disconnecting the steering cylinder................................................................ 117
After towing.................................................................................................... 117
Steps to take ............................................................................................... 117
7. Brake system ........................................................................................................ 119

Safety ................................................................................................................... 119
General................................................................................................................. 119
Technical data ...................................................................................................... 120
Brake system................................................................................................... 120
10
Checking brake pressure...................................................................................... 120

Service brake pressure .................................................................................... 120
Parking brake pressure.................................................................................... 121
Bleeding the brakes ............................................................................................. 122
Checking brake discs........................................................................................... 122
Adjusting the brakes ............................................................................................ 123
Function check, parking brake ............................................................................ 124
Function check, service brakes............................................................................ 124
Checking accumulator charge pressure ............................................................... 125
Checking brake pressure control valve................................................................ 126
Checking the accumulators.................................................................................. 126
Scrapping an accumulator ................................................................................... 128
8. Drill system .......................................................................................................... 129

DCS 1200 and DCS 1800.................................................................................... 129
9. Hydraulic systems ................................................................................................ 130

Safety................................................................................................................... 130
Technical data ...................................................................................................... 130
Hydraulic system M2/L2 ................................................................................ 130
Filter .................................................................................................................... 131
Return oil filter ............................................................................................... 131
General ....................................................................................................... 131
Changing the return oil filter...................................................................... 132
Breather filter.................................................................................................. 133
General ....................................................................................................... 133
Changing the breather filter ....................................................................... 134
Oil sampling ........................................................................................................ 134
Changing oil ........................................................................................................ 134
General............................................................................................................ 134
Draining .......................................................................................................... 135
Filling up......................................................................................................... 135
General ....................................................................................................... 135
Filling manually ......................................................................................... 136
Electric filling, option ................................................................................ 136
Draining condensation from the hydraulic oil tank............................................. 137
Pumps .................................................................................................................. 139
Power unit pumps ........................................................................................... 139
Checking pump rotation direction .................................................................. 139
Starting a new or reconditioned pump............................................................ 140
Bleeding the pumps ........................................................................................ 140
Circulating the pump ...................................................................................... 141
Hydraulic motors ................................................................................................. 142
Starting a new or reconditioned hydraulic motor ........................................... 142
Settings ................................................................................................................ 143
Safety .............................................................................................................. 143
Illustrations showing locations ....................................................................... 143
Pressure settings and rotation speeds.............................................................. 143
11
Percussion pump ............................................................................................. 145

Safety valve................................................................................................ 145
Sequence valve........................................................................................... 146
Stand-by pressure ....................................................................................... 147
Collaring..................................................................................................... 148
Full drilling................................................................................................. 149
Positioning pump ............................................................................................ 150
Stand-by pressure ....................................................................................... 150
Positioning pressure ................................................................................... 152
Pressure reducing function for positioning pump ...................................... 152
Rotation pump................................................................................................. 154
Small hole bit ............................................................................................. 154
Reaming hole bit, option ............................................................................ 154
Rock drill damper pressure ............................................................................. 155
Setting the pilot pressure and boom positioning pilot pressure ...................... 156
Positioning pressure with diesel power .......................................................... 157
Maximum pressure and speed of reeling units ............................................... 158
Setting water pump speed ............................................................................... 159
Speed control for air flow ............................................................................... 159
Standard rig ................................................................................................ 159
General ....................................................................................................... 160
Compressor speed ...................................................................................... 161
Loading and unloading the compressor ..................................................... 162
Adjusting the ECL lubricating system............................................................ 163
Metering lubricating oil.............................................................................. 163
Lubricating air pressure, option ................................................................. 164
Lubricant level monitor, option.................................................................. 165
Feed pressure .................................................................................................. 165
General ....................................................................................................... 165
Max. feed pressure ..................................................................................... 166
Feed pressure for collaring......................................................................... 168
Feed pressure for full drilling in a small hole ............................................ 169
Feed pressure for full drilling of reaming holes, option............................. 170
Telescope feeder.............................................................................................. 171
General ....................................................................................................... 171
Feed pressure for rock drill cradle ............................................................. 171
Pressure difference between upper and lower cylinder.............................. 172
Feed pressure, reverse ................................................................................ 172
Locking the telescope feeder...................................................................... 172
Anti-jamming protection................................................................................. 173
Description ................................................................................................. 173
RPCF feed control...................................................................................... 173
Feed (rock drill) return movement ............................................................. 173
General ....................................................................................................... 173
Setting the feed return movement .............................................................. 174
Setting RPCF during drilling ..................................................................... 175
Setting ........................................................................................................ 176
Setting ........................................................................................................ 178
12
Function check ........................................................................................... 179
10. Compressor ........................................................................................................ 181

Safety................................................................................................................... 181
Compressor instructions ...................................................................................... 181
Compressor GAR 5......................................................................................... 181
Checking oil level ........................................................................................... 182
Oil and oil filter .............................................................................................. 183
Safety ......................................................................................................... 183
Changing oil and oil filter .......................................................................... 183
Air reservoir.................................................................................................... 184
Safety ......................................................................................................... 184
Changing the separator element................................................................. 184
Changing air filter........................................................................................... 185
Adjusting drive belts....................................................................................... 186
Safety valve .................................................................................................... 186
Fault finding ........................................................................................................ 187
Fault finding, compressor ............................................................................... 187
Compressor will not start................................................................................ 188
Compressor starts but does not load ............................................................... 188
Compressor will not unload, safety valve blowing ........................................ 188
Compressor air delivery or pressure lower than normal................................. 189
Abnormal oil consumption or oil in outlet line .............................................. 189
Oil in the air filter ........................................................................................... 189
Safety valve blowing after loading ................................................................. 189
Air outlet temperature higher than normal ..................................................... 189
11. Air and water systems ........................................................................................ 191

Technical data ...................................................................................................... 191
Hose dimensions ............................................................................................. 191
Safety................................................................................................................... 192
Water pump.......................................................................................................... 192
General............................................................................................................ 192
Checking the rotation direction ...................................................................... 192
Setting flow switches. ..................................................................................... 193
Cleaning the water strainer.................................................................................. 194
Freeze prevention measures ................................................................................ 194
Draining the water system .............................................................................. 194
12. Electrical system, IEC and Australia ................................................................. 196

Safety................................................................................................................... 196
General ................................................................................................................ 196
Safety standard................................................................................................ 196
Low-voltage circuit......................................................................................... 196
Extra low-voltage circuit ................................................................................ 197
Before starting ................................................................................................ 197
Cable marking................................................................................................. 197
Replacement of components........................................................................... 197
13
Electric cabinet, high-current .............................................................................. 197

Indicator lamps ............................................................................................... 197
IEC standard ................................................................................................... 198
Inside .......................................................................................................... 198
Australian standard ......................................................................................... 199
Inside .......................................................................................................... 199
Voltmeter, ammeter and hour counter............................................................. 199
Electrical system protection................................................................................. 200
Main switch..................................................................................................... 200
General ....................................................................................................... 200
Main circuit breaker dip switches .............................................................. 201
Overload protection.................................................................................... 201
Short circuit protection............................................................................... 202
Phase sequence switch .................................................................................... 202
Earth fault equipment...................................................................................... 202
IEC standard............................................................................................... 202
Australian standard..................................................................................... 203
Motor protection ............................................................................................. 204
Electronic motor protection relay............................................................... 204
If the motor protection has been triggered ................................................. 204
Setting rated current ................................................................................... 205
Setting triggering time................................................................................ 207
Power supply cubicle........................................................................................... 207
General............................................................................................................ 207
Setting charge voltage..................................................................................... 208
Cable recommendations ...................................................................................... 209
Fault finding ........................................................................................................ 210
13. Electrical system, Canada .................................................................................. 211

Safety ................................................................................................................... 211
General................................................................................................................. 211
Safety standard................................................................................................ 211
Low-voltage circuit......................................................................................... 211
Extra low-voltage circuit ................................................................................ 212
Before starting................................................................................................. 212
Cable marking................................................................................................. 212
Replacement of components ........................................................................... 212
Electric cabinet, high-current .............................................................................. 213
Front................................................................................................................ 213
Inside............................................................................................................... 214
Electrical system protection................................................................................. 214
Main switch..................................................................................................... 214
General ....................................................................................................... 214
Main circuit breaker short-circuit protection ............................................. 214
Main circuit breaker short-circuit protection ................................................. 0
Phase sequence switch .................................................................................... 215
Earth fault breaker .......................................................................................... 215
Motor protection ............................................................................................. 215
14
Electronic overload protection ................................................................... 215

Circuit breaker............................................................................................ 216
Power supply cubicle........................................................................................... 217
General............................................................................................................ 217
Setting charge voltage..................................................................................... 218
Fault finding ........................................................................................................ 218
14. Component locations.......................................................................................... 219

Component locations ........................................................................................... 219
Electric and hydraulic components................................................................. 219
Electrical cabinets and electric boxes ........................................................ 219
Guards ........................................................................................................ 220
Electrically controlled valves..................................................................... 221
Hydraulically controlled valves ................................................................. 222
Pressure gauges and test outlets ................................................................. 223
15. Reeling units....................................................................................................... 224

Cable reeling unit ................................................................................................ 224
Hose reeling unit.................................................................................................. 225
General ................................................................................................................ 225
Reeling unit gear.................................................................................................. 225
Adjusting reeling unit drive chain ....................................................................... 226
Adjusting the reeling unit slip clutch................................................................... 226
Collector, cable reeling unit................................................................................. 228
Collector F460/1 and K4122/1 ....................................................................... 228
Checking the collector .................................................................................... 228
Settings ................................................................................................................ 229
Limit switch, option............................................................................................. 229
Description...................................................................................................... 229
Adjusting......................................................................................................... 229
16. Exhaust filtering ................................................................................................. 232

Safety................................................................................................................... 232
Scrubber............................................................................................................... 232
General............................................................................................................ 232
Filling up with water....................................................................................... 233
Freeze prevention measures............................................................................ 234
Draining ..................................................................................................... 234
Catalytic converter............................................................................................... 235
General............................................................................................................ 235
Changing the catalytic converter .................................................................... 235
17. Fire fighting equipment...................................................................................... 236

Fire fighting systems ........................................................................................... 236
Description...................................................................................................... 236
Ansul............................................................................................................... 236
Forrex.............................................................................................................. 236
Locations ............................................................................................................. 237
15
Manual triggering ................................................................................................ 237

Maintenance of fire fighting system.................................................................... 238
Safety measures .............................................................................................. 238
Modification of the machine........................................................................... 238
Service ............................................................................................................ 238
Steps to take after a fire or activation of the fire-fighting system .................. 239
18. Service platform ................................................................................................. 240

HL 210-300 MB, HL 210-300 MBC, HL SP2 MBC .......................................... 240
Technical data ...................................................................................................... 240
HL 210 MB/MBC........................................................................................... 240
HL 230 MB/MBC........................................................................................... 241
HL 300 MB/MBC........................................................................................... 241
HL SP2 MBC.................................................................................................. 242
Safety ................................................................................................................... 243
Slinging................................................................................................................ 243
Distance to centre of gravity when slinging ................................................... 243
Supporting the service platform .......................................................................... 244
Tools .................................................................................................................... 244
Adjusting play in telescope tube guide................................................................ 245
Bleeding the hydraulic system............................................................................. 245
Rear boom link .................................................................................................... 245
Checking clearances ....................................................................................... 245
Lubricating before start ....................................................................................... 246
Function check..................................................................................................... 246
Menus in the RCS system.................................................................................... 247
General............................................................................................................ 247
Menu Lever..................................................................................................... 247
Calibration ...................................................................................................... 247
Actuations menu ............................................................................................. 248
Parameters menu............................................................................................. 248
Long-term storage................................................................................................ 249
Transport.............................................................................................................. 249
19. Directional control equipment............................................................................ 251

FAM..................................................................................................................... 251
Technical data ...................................................................................................... 251
Directional control FAM................................................................................. 251
Menus .................................................................................................................. 252
Password.............................................................................................................. 252
Connections ......................................................................................................... 254
Single-boom and dual-boom systems ............................................................. 254
Three-boom system......................................................................................... 256
Sensor connections ......................................................................................... 258
Power supply circuit, 24 V DC ....................................................................... 258
Sensor calibration ................................................................................................ 259
Conditions ....................................................................................................... 259
Adjusting the lookout cylinder ....................................................................... 259
16
Feeder inclination sensor ................................................................................ 261

Calibration menu........................................................................................ 261
Adjusting inclination sensor....................................................................... 261
Resetting inclination sensor ....................................................................... 264
Setting coefficient for inclination sensor ................................................... 265
Rear and front side angles............................................................................... 265
Calibration menu........................................................................................ 265
Setting coefficient for rear and front side angles ....................................... 265
Resetting rear side angle ............................................................................ 266
Resetting front side angle........................................................................... 266
Rock drill position (option - hole depth measurement) .................................. 266
Replacement of components................................................................................ 267
Replacement of angle sensors......................................................................... 267
Replacement of inclination sensors ................................................................ 269
Replacement of length sensor ......................................................................... 271
Rock drill mode.......................................................................................... 271
Replacement of resolver module .................................................................... 271
Fault finding ........................................................................................................ 272
Fault indication ............................................................................................... 272
System........................................................................................................ 272
CAN communication ................................................................................. 272
Function check................................................................................................ 273
Fault-finding menus........................................................................................ 273
Angle sensors.................................................................................................. 274
Inclination sensor............................................................................................ 275
Length sensor, rock drill ................................................................................. 276
20. Safe Bolting System ........................................................................................... 277

Introduction ......................................................................................................... 277
Description .......................................................................................................... 277
Function .......................................................................................................... 278
Component parts.................................................................................................. 278
Locations ............................................................................................................. 279
21. Rod handling equipment, option ........................................................................ 280

Rod adding system .............................................................................................. 280
RAS ..................................................................................................................... 280
Settings ................................................................................................................ 281
Valve block ..................................................................................................... 281
Inductive sensors ................................................................................................. 282
Position indication for RAS ........................................................................... 282
22. Air conditioning ................................................................................................. 284

Safety................................................................................................................... 284
Technical data ...................................................................................................... 284
Adjusting compressor speed................................................................................ 284
Adjusting compressor V-belts ............................................................................. 285
Fresh air filter and recirculation filter ................................................................. 285
17
Electric heater ...................................................................................................... 287

Fault finding ........................................................................................................ 287
No heating....................................................................................................... 287
No cooling....................................................................................................... 287
Poor cooling.................................................................................................... 287
Uneven cooling ............................................................................................... 288
Abnormal noise............................................................................................... 288
18
1. General
1. General
Environment
ENVIRONMENTAL DIRECTIONS
• Think of 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 rest oil, oil spill, oily waste
and grease rests and spill. Treat
according to local regulations.
• Use biodegradable hydraulic fluids and
lubrication oils for Atlas Copco products
wherever possible. Contact your local
Atlas Copco office for further information.

• Engine exhaust gases are toxic and
hazardous to the environment.
• Good ventilation is required when the
diesel engine is running.
• Well maintained air filters help to keep
emissions low.
19
1. General

• Fuel spillage is environmentally
hazardous and a fire risk.
• Always collect fuel rests and fuel spill.
Treat according to local regulations.

• Batteries contain acid and heavy metals.
Used batteries can therefore be
hazardous to the environment and
personal health.
• Old batteries must be sent for disposal
according to local regulations.

• Chemicals such as washer fluid additives
and other additives and coolants can be
hazardous to the environment.
• Treat according to local regulations when
handling and disposing.
Contact details
Table: Addresses, telephone numbers and fax numbers to Atlas Copco companies
Country Address Phone and fax number
Argentina Juncal 2869 Phone: +54 - (0)11 - 47 17 22 00
B1640 GRD Martinez, Buenos Fax: +54 - (0)11 - 47 17 02 27
Aires
20
1. General

Australia P O Box 6134 Phone: +61 - (0)2 - 96 21 97 00
Delivery Centre Fax: +61 - (0)2 - 96 21 98 13
Blacktown NSW 2148
Austria Postfach 108 Phone: + 43- (0)1 -76 01 20
A-1111 Vienna Fax: + 43 - (0)1 - 769 56 72
Bolivia P O Box 290 Phone: + 591 (0)3-343 68 68
Santa Cruz Fax: + 591 (0)3-343 69 69
Brazil P O Box 12737 Phone: + 55 - (0)11 - 247 88 00
Sao Paulo, SP Fax: + 55 - (0)11 - 541 76 71
04744-970
Canada 200 Mumford Road Phone: + 1 - 705 673 67 11
Walden Industrial Park Fax: + 1 - 705 692 31 01
Lively, Ontario P3Y 1L2
Chile Panamericana Norte 5001 - Phone: + 56 - (0)2-442 3600
Conchali Fax: +56 -(0)2 - 623 44 60
Santiago, 6553935 Conchali
China / Hong P O Box 1516 Shatin Central P Phone: + 86 -(0)25 - 852 27 97 68 00
Kong O Fax: + 86 - (0)25 - 852 23 41 43 13
New Territories, Hong Kong
CMT S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00
International Fax: + 46 - (0)8 - 702 21 29
Colombia A.A. 95310 Phone: +57 - (0)1 - 291 54 90
Santafé de Bogotá, D.C. Fax: +57 - (0)1 - 430 65 14
Czech Republic Prumyslová 10 Phone: + 420 - 225 434 000
102 00 Praha 10. Fax: + 420 - 225 434 222
Finland Tuupakankuja 1 Phone: + 358 - (0)9 - 296 64 41
SF-01740 Vantaa Fax: + 358 - (0)9 - 29 64 21 8
France B.P. 27055 Saint Quen Phone: + 33 - (0)1 33 09 30 00
l’Aumône Fax: + 33 - (0)1 - 39 09 30 49
FR-95052 Cergy Pontoise
Cedex
Germany Postfach 10 02 25 Phone: + 49 - (0)201 - 217 70
D-45002 Essen Fax: + 49 - (0)201 - 217 74 54
Ghana P O B 10071 Phone: + 233 - 21 77 45 12
Accra North Fax: + 233 - 21 77 61 47
Great Britain P O Box 79 Phone: +44 - (0)1442 - 22 21 00
Hemel Hempstead Fax: + 44 - (0)1442 - 23 44 67
Herts HP2 7HA
Greece 78, Kifissou Avenue Phone: +30 - (0)1 - 349 96 00
GR-182 33 Ag. I. Rentis Fax: +30 - (0)1 - 345 4783
Hong Kong P O Box 1516 Shantin Central P Phone: + 852 - 27 97 68 00
O Fax: + 852 - 23 41 43 13
New Territories, Hong Kong
21
1. General

India Sveanagar Phone: + 91- (0)20 -271 464 16 17, 271 444 17
Bombay Pune Road Fax: + 91 - (0)20 - 271 459 48
Dapodi
Pune 411 012
Indonesia P O Box 7021/JKS CCE Phone: +62 - (0)21 - 780 10 08
Jakarta 12075 Fax: +62 - (0)21 - 780 18 37
Iran PO Box 13145-1311 Phone: +98 - (0)21 - 693 77 11
Tehran 13454 Fax: +98 - (0)21 - 692 73 14
Ireland Kylemore Road Phone: +353 - (0)1 - 450 5978
Bluebell Fax: +353 - (0)1 - 456 7686
Dublin 12
Italy Casella Postale 77 Phone: + 39 - (0)2 - 61 79 91
I-20092 Cinisello Balsamo MI Fax: + 39 - (0)2 - 61 79 95 20
Japan Shiba Bldg. 11F Phone: + 81 - (0)3 - 57 65 78 90
13-4 Shiba 2-chome Fax: + 81 - (0)3 - 57 65 31 99
Minato-ku Tokyo 105-0014
Kenya PO Box 400 90 Phone: + 254 - (0)2 - 82 52 65/6
Nairobi Fax: + 254 - (0)2 - 82 52 15
Korea C-P.O. Box 8354 Phone: + 82 - (0)2 - 29 89 40 00
Seoul Fax: + 82 - (0)2 - 522 82 39
Malaysia 26 Jalan Anggerik Mokara 31/47 Phone: + 60 - (0)3 - 51 23 88 88
Kota Kemuning, Seksyen 31 Fax: + 60 - (0)3 - 51 23 89 49
40460 Shah Alam
Selangor Darul Ehsan
Mexico Apartado Postal Box 104 Phone: + 52 - 5 - 553 21 06 00
Tlalnepantla Fax: + 52 - 5 - 553 90 15 20
Edo. De Mexico
Morocco P O Box 13 844 Phone: + 212 - 2 - 600 040
20 300 Casablanca Fax: + 212 - 2 - 60 05 22
Norway P O Box 334 Phone: + 47 - 64 - 86 03 00
N-1401 Ski Fax: + 47 - 64 - 86 03 30
Peru Apartado 662 Phone: + 51 - 1 - 411 61 00 (Service)
Lima 100 Fax: + 51 - 1 - 224 77 12 (Service)
Philippines P.O. Box 1373 Phone: + 63 - (0)2 - 823 8178-80
1200 Makati City Fax: + 63 - (0)2 - 823 84 59
Poland (Sales) ul. Katowicka 32 Sales
P-40-173 Katowice Phone: + 48 -(0)32 - 209 57 74
(Sevice) ul. Krzywa 3, Fax: + 48 -(0)32 - 209 57 76
59-100 Polkowice Service
Phone: + 48 -(0)76 847 49 36
Portugal Apartado 14 Phone: + 351 - (0)21- 416 85 00
P-2796-953 Linda-a-Velha Fax: + 351 - (0)21 - 416 01 66
Saudi Arabia P O Box 7330 Phone: + 966 - (0)2 - 693 33 57
Jeddah 21462 Fax: + 966 - (0)2 - 693 28 92
22
1. General

Singapore Jurong Point Phone: + 65 - 68 62 28 11
P O Box 438 Fax: + 65 - 68 63 60 98 (Service)
Singapore 639456
South Africa P O Box 14110 Phone: + 27 - (0)11 - 821 90 00
Witfield 1467 Fax: + 27 - (0)11 - 821 91 83
Spain Apartado 24 Phone: + 34 - (9)1 - 627 91 00
E-28820 Coslada Fax: + 34 - (9)1 - 627 9239
Madrid
Sweden S-10523 Stockholm Phone: + 46 - (0)8 - 743 80 00
Fax: + 46 - (0)8 - 743 92 47
Switzerland Büetigenstrasse 80 Phone: + 41 - (0)32 - 374 14 14
CH-2557 Studen/Biel Fax: + 41 -(0)32 - 374 13 00
Taiwan P O Box 14-45, Chungli Phone: + 886 - (0)3 - 479 68 38
Tao yuen Hsien Fax: + 886 - (0)3 - 479 68 20
Taiwan,
R.O.C.
Thailand 1696 New Petchburi Road Phone: + 66 - (0)2 - 652 90 06
Bangkapi Fax: + 66 - (0)2 - 652 81 94
Huay Kwang
Bangkok 10320
Turkey Istasyon Arkasi Phone: + 90 - (0)216 - 395 24 60
34940 Tuzla Fax: + 90 - (0)216 - 395 23 01
Istanbul
Venezuela Apartado 76111 Phone: + 58 - (0)2 - 256 23 11
Caracas 1070-A Fax: + 58 -(0)2 - 257 18 10
Vietnam No. 42, Street 37, Thao Dien Phone: + 84 - 8 - 898 96 38
Ward Fax: + 84 - 8 - 898 96 37
District 2
Ho Chi Minh City
Zambia P O Box 11291 Phone: + 260 - (0)2 - 31 12 81, 31 30 15
Chingola Fax: + + 260 - (0)2 - 31 38 77
Zimbabwe P.O. Box CY 935 Phone: + 263 - (0)4 - 62 17 61 5
Fax: + 263 - (0)4 - 62 17 94
Target group and objective

The maintenance instructions are intended for mechanics and personnel in mainte-
nance and service. The user should have undergone Atlas Copco's training courses
for the equipment concerned.
The objective of these maintenance instructions is to detect and rectify faults at an

early stage so that breakdowns, costly secondary damage and accidents can be pre-
vented. Regular maintenance is a precondition for planning necessary interruptions in
23
1. General
operation such as reconditioning and repairs. This allows maintenance to be carried

out when most suitable with regard to production instead of causing complete break-
down.
Hydraulic systems
General
Hydraulic systems are sensitive to impurities and pollutants. The environment in
which rock drilling equipment usually works is generally unsuitable as a place for
repairing hydraulic components. Work on the hydraulic system at the worksite should
therefore be limited to what is absolutely essential, i.e. only the replacement of com-
ponents. When changing valves, the unit concerned should be securely strapped in
place and firmly supported. The components should then be repaired in a suitable
environment, see Hydraulic workshops .
Observe the following points to avoid breakdowns and interruptions in operation due
to fouled hydraulic oil:
• Keep the rig clean. Hose it down at regular intervals, preferably with a grease sol-
vent as an additive
• Before opening any connection, clean the area round it.
• Use clean tools and work with clean hands.
• Always plug hydraulic connections immediately after they have been detached.
• Use clean protective plugs.
• Hydraulic components like hoses, valves, motors, etc. must always be stored with
suitable protective plugs fitted in place.
• Spare parts for hydraulic components must always be kept in sealed plastic bags.
• Change filter cartridges as soon as the filters indicate clogging.
Repairing hydraulic components

Repairing and/or reconditioning hydraulic components should be carried out by
expert personnel and in a suitable place. The following alternatives are possible:
• Suitable premises for hydraulic repairs to be arranged at the workplace. Repairs to

be carried out by your own specially trained personnel, the manufacturer's techni-
cians or Atlas Copco personnel.
• Components to be sent to the manufacturer's local agent for repair.
• Component repairs are carried out by Atlas Copco. Repair instructions are availa-
ble for the most important and most complicated hydraulic components.
24
1. General
Hydraulic workshops
Workshops used for the repair of hydraulic components must:
• be separate from activities which generate dust and particles, such as welding,
grinding, the transportation of vehicles, etc.;
• have their own suitable washing equipment which is required for repairing the
components;
• have the necessary tools, both standard and special, and that are only used in the
hydraulic workshop.
• have a ventilation system that does not admit dust into the premises.
• have well-trained mechanics.
Replacement of hydraulic hoses

A high percussion pressure, vibrations and other mechanical interference puts high
demands on the hydraulic hoses.
When replacing hydraulic hoses, make sure they are replaced with hydraulic hoses:
• with correct crimped couplings

• of the correct quality
• with the right dimension
All pressurised hydraulic hoses have crimped couplings and should therefore be pur-
chased ready made from Atlas Copco. Qualities and hose dimensions are specified in
the spare parts catalogue for each rig. Make also sure that hose couplings are clean, in
good condition and properly tightened.
Welding
Note
It is important to consult Atlas Copco for approval of welding and choice of elec-
trodes.
The following must be observed when welding:
• Turn off the supply of current to the unit.

• Disconnect the cables from the generator and battery.
• Grind off rust and paint from the area that is to be welded and carefully prepare the
joint.
• Weld in a dry area.
• Connect the welding earth cable to a clean surface as close as possible to the weld-
ing area. Avoid welding close to bearings and bushes. If these cannot be removed,
connect earth cables on both sides of the weld.
25
1. General
• Alterations and reinforcements must not be made without previous consultation

with Atlas Copco.
• Do NOT do any welding on the hydraulic oil reservoir, valve block, compressed
air receiver or compressed air lines.
• Always keep a fire extinguisher for oil fires near at hand during all types of weld-
ing, cutting and grinding. Screen off the work area from flammable materials.
• Always protect hoses, cables and electric components.
• Grind off spatter after welding. If possible, also grind the surface of the weld
smooth and treat it with anti-corrosion paint.
Electrode recommendations
Use only intact and clean electrodes that have been stored in a dry place. The gener-
ally recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the
equivalent in accordance with the standard below:
Table: Electrode recommendations

ISO: 2560 E51 5B 120 20 H
SS: 14 3211 H10
DIN 1913: E51 55 B10
AWS: A/SFA 5.1 E 7018
The use of MIG welding equipment is perfectly acceptable. The generally recom-
mended type of electrode is ESAB-OK Autorod 12.51 or the equivalent in accord-
ance with the standard below:
Table: MIG electrodes

SS: 14 3403 3423
DIN 8559: SG 2
AWS: A/SFA 5.18: ER 70 S-6
If in any doubt, contact Atlas Copco for advice.
Tightening torque in bolted joints.

All joints are tightened to torque as specified in Atlas Copco Standard 4369:01 K
unless specified otherwise. If so, this will be specified in the maintenance instructions
for the component in question.
Note
All bolted joints in the table below must be greased with Molycote 1000 or equivalent
thread lubricant with coefficient of friction 0.11 µ.
26
1. General
Table: Atlas Copco Standard 4369:01 K.

Size Strength Torque in Tolerance
class Nm. ±
M6 8.8 9 1
M8 8.8 23 2
M10 8.8 44 5
M12 8.8 76 8
M14 8.8 120 12
M16 8.8 187 19
M20 8.8 365 37
M24 8.8 627 63
M12 x 1.25 10.9 114 6
M16 x 1.25 10.9 276 15
M18 x 1.25 10.9 460 20
M6 12.9 15 2
M8 12.9 38 4
M10 12.9 75 8
M12 12.9 128 13
M14 12.9 203 20
M16 12.9 315 32
M20 12.9 615 62
M24 12.9 1058 106
Markings and plates

Signs are placed on the larger carrier components. Always quote the type designation
and serial number when ordering spares or enquiring about the carrier. The type des-
ignation and serial number are specified on a separate document, DRI (Drill Rig
Identification). Spares can always be ordered from Atlas Copco.
27
1. General
Dismantling and assembly
CAUTION
• Take great care when strapping and lifting
heavy objects.
• Can cause personal injury.
• Lift at the centre of gravity.
• Use only straps that are intact and
intended for the load they are to carry.
• Secure the slings in the lifting eyes,
where available
Before transport in shafts or the like it may be necessary to remove the drilling rig in
larger or smaller parts. Observe the following when dismantling, lifting and refitting:
• Before dismantling, hose the entire rig clean with water and/or detergent contain-
ing a grease solvent.
• Observe the strictest cleanliness when dismantling hydraulic, compressed air and
water flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes,
or seal and protect them from dirt in some other suitable way.
• Mark hoses, pipes and other connections, where this has not already been done, to
make reassembly easier and prevent mix-ups.
• Use properly secured lifting tackle of generous dimensions.
Note
When a rig is scrapped, all materials that are harmful to the environment must be
disposed of in a manner prescribed by the authorities.
Fault finding
Fault finding is a logical sequence of activities to locate a fault, thereby making it
possible to rectify the fault as soon as possible.
Always try to investigate the location of the fault in order to limit fault finding to a
certain system or function.
28
1. General
Starting with an auxiliary battery

Note
Owing to the surge of current, the batteries could explode if a fully-charged battery is
connected to a completely flat one.
The connections to the carrier's batteries must on no account be removed while in
operation as this could give rise to faults occurring in the generator.
For this reason, proceed as follows:
1. Check that the auxiliary starting batteries (1) have the same voltage as the batter-
ies on the chassis.
1250 0064 41
Figure: Starting assistance

1 Auxiliary batteries
2 Rig batteries
2. First connect the positive terminal of the auxiliary battery to the positive terminal
of the chassis battery (2).
3. Then connect the negative terminal of the auxiliary battery (1) to earth on the
chassis (not to the chassis battery's negative terminal).
4. Once the engine has started, first remove the starter cable between the chassis and
the negative terminal on the auxiliary battery (1).
5. Then remove the cable between the positive terminals of the batteries.
29
2. Lubricants, coolants and propellants
Introduction
This chapter contains recommendation on hydraulic fluids, lubricants, diesel oils and
coolants. The following applies in addition to these recommendations:
• Never mix oils of varying type and grade.

• Dispose of excess oil in an environmentally-friendly manner prescribed by the
authorities.
If in doubt concerning hydraulic fluids, lubricants, etc., get in touch with your Atlas
Copco representatives.
Hydraulic oil
Hydraulic systems
Use mineral based or synthetic (polyalpha olefine or diester) hydraulic oil with good
rust, wear, oxidising and foam inhibitive properties and good air and water separation
ability. Select an oil with viscosity grade (VG) and viscosity index (VI) specified in
the table below. Oil with high viscosity index is less temperature dependent.
Table: Recommended viscosity grades and viscosity index

Normal Minimum starting Maximum Viscosity grade (VG) Viscosity index
operating temperature in temperature in (ISO 3448) VI
temperature in hydraulic oil hydraulic oil
hydraulic oil reservoir, °C reservoir, °C
reservoir, °C (viscosity min.
(viscosity 25-50 1000cSt)
cSt)
+ 50 to + 70 +5 + 80 ISO VG 100 Min. 100
+ 45 to + 60 -5 + 75 ISO VG 68 Min. 100
+ 35 to + 50 - 10 + 65 ISO VG 46 Min. 100
+ 25 to + 40 - 15 + 55 ISO VG 32 Min. 100
+ 10 to + 25 - 25 + 35 ISO VG 15 Min. 100
30
Lubrication oil
Rock drill (ECL lubrication system)

Use a mineral-based pneumatic tool oil with additives against wear, ice formation
and oil mist. The viscosity grade should be suitable for the ambient temperature as
follows
Table: Recommended viscosity grades

Ambient temperature °C Viscosity grade (ISO 3448)
- 30 to 0 ISO VG 32 - 68
- 10 to + 20 ISO VG 68 - 100
+ 10 to + 50 ISO VG 100 - 150
Diesel engine
Engine oils have different properties and are classified in different grades. The API
(American Petroleum Institute) or ACEA (Association des Constructeurs Européens
d’Automobiles) classification systems are normally used.
The following grades are allowed for API oils.
CC, CD, CE, CF, CF-4 and CG-4
The following grades are allowed for ACEA oils.
E2-96, E3-96 and E4-98
Since engine oils change their viscosity, the ambient temperature is decisive to the
choice of viscosity grade (SAE classification). A temporary drop below the tempera-
ture limit will impede cold starting but not lead to engine damage. Any transgression
for a long period of time should be avoided to prevent wear.

Upper temperature Viscosity SAE Lower temperature
+30 5W/30 (Synthetic) -30
+35 5W/40 -30
+30 10W/30 -20
+35 10W/40 -20
+35 15W/40 -15
+35 20W/50 -5
31
Hydraulic gearbox
Different types of oil can be used in the hydraulic gearbox.
• Dexron IID oil or Dexron IID equivalents
Dexron IID and Dexron IID equivalents must not be mixed with the other oils.
The following oils can be mixed with each other.
• Transmission oils to CAT TO-4 or Allison C-4 specifications

• Universal oils to API CD or Allison C-4 specifications
• Multigrade engine oils to API CD or Allison C-4 specifications

Lowest temperature Highest temperature Viscosity SAE
°C °C
-30 +20 SAE 0W20
-20 +10 SAE 10W
-15 +20 SAE 20
0 +35 SAE 30
+5 +45 SAE 40
Wheel axle centre and hub reduction gears

Use transmission oil with grade classification API GL-5 LSA and viscosity grade
SAE 85W-90.
Compressor
Use compressor oil or hydraulic oil. It must be a mineral oil of high quality with addi-
tives to inhibit oxidation, foaming and wear. The viscosity grade must suit the ambi-
ent temperature and fulfil ISO 3448 as follows.
Table: Recommended viscosity grades and viscosity index

Ambient temperature °C Viscosity grade (ISO 3448) Viscosity index
More than + 25 ISO VG 68 Min. 95
± 0 to +25 ISO VG 46 Min. 95
32
Reeling units
Gears
For lubrication of the gear on cable and hose reels use engine oil. The oil must be of
good quality with viscosity SAE 20W-40.
Lubrication grease
Rock drill
Table: Recommended lubrication grease, rock drill

Application Type of grease Properties
Rock drill gear housing NOTE: Having regard to the NLGI number: 2
temperature inside the gear Drop point: 250 °C
housing: high-temperature Base oil viscosity: 110cSt at 40 °C
grease with ashless thickener
Operating temperature: - 20 to +150 °C
and oxidation and rust
inhibiting additives as well as
good water resistance.
Feeder
Table: Recommended lubrication grease, feeder

Feeder sliding Molybdenum disulphide
surfaces
Cradle hinge Universal grease with EP NLGI number: 2
additives Drop point: 180 °C
Base oil viscosity: 150cST/40 °C
Operating temperature: -30 to +110 °C
Boom
Table: Recommended grease, boom

Grease nipples Universal grease with EP NLGI number: 2
Threaded joints Molycote 1000 Thread friction coefficient: 0.11 µm
33
Drill-steel support
Table: Recommended lubrication grease

Electrical system
Table: Recommended contact grease

Contacts Contact grease with additives to NLGI number: 1-2
prevent corrosion and oxidation. Drop point: 200 °C
Service platform
Table: Recommended lubrication grease, service platform

Rod handling equipment
Table: Recommended lubrication grease, rod handling equipment

34
Propellants
Diesel engine
The diesel engine must be driven on commercial diesel fuel with a sulphur content
less than 0.5 %. A higher sulphur content will involve tighter oil change intervals.
Use diesel fuel complying with one of the following specifications.
• DIN EN 590
• BS 2869: A1 and A2
• ASTM D 975-88: 1-D and 2-D
• NATO Code F-54 and F-75
At low temperatures, paraffin deposits in the diesel can cause blockages resulting in
disturbances in the fuel system. A special winter diesel should therefore be used with
ambient temperatures below 0 °C.
Coolants
Diesel engine cooling system

It is important that the water used in the diesel engine cooling system is the right
quality. The values in the following table must not be exceeded.
Table: Recommended water quality

Water quality Min. Max.
pH value at 20 °C 6.5 8.5
Chloride ion content (mg/dm3) - 100
Sulphate ion content (mg/dm3) - 100
Total hardness (°dGH) 3 20
An anti-freeze additive will protect against corrosion, cavitation and freezing. Use
anti-freeze that is free from amines, nitrites and phosphates. Anti-freeze concentra-
tion in the coolant must be kept between the following minimum and maximum lim-
its.
• Min = 35% by volume

• Max = 45% by volume
The following tables show the freezing point for different mixtures of anti-freeze and
types of engine.
35
Table: Deutz BF4M 1013 C engine

Freezing Anti-freeze, volume Anti-freeze, concentration
point (°C) (litres) (% by volume)
-22 4.8 35
-28 5.4 40
-35 6.1 45
Table: Deutz BF6M 1013 C engine

-22 5.7 35
-28 6.5 40
-35 7.3 45
Table: Deutz BF6M 1013 CP engine

-22 5.9 35
-28 6.8 40
-35 7.6 45
Air conditioning
R134a refrigerant it used in the cooling system for the air conditioning. The amount
of refrigerant is 1.6 kg.
36
3. Feeder
3. Feeder
Safety
WARNING
• Dismantling and assembling
components.
• Risk of personal injury.
• During service and maintenance work, all
components that can be brought in
motion or fall down must be securely
supported or strapped up.
6000-series
1250 0046 95
Figure: BMH 6000 and BMHT 6000
37
3. Feeder
The hydraulic feeders on the BMH/BMHT-6000 series are principally intended for
drift and tunnel drilling. They are fitted on hydraulic booms of type BUT 32 and
BUT 35. The feeders are available in different versions depending on the rock drill
being fitted on them. The different numbers have the following meaning.
Example: BMH 6618 and BMHT 6616/10
The first number states the type of feed: 6 = 6000 series
The second number states the type of rock drill for which the feeder is intended:
• 3 = COP 1238
• 6 = COP 1432/1532
• 8 = COP 1838
The third and fourth numbers state the length of drill steel in feet: 16 = 16 feet
The fifth and sixth numbers state the length of the short drill steel in feet and only
applies to the telescopic feeders (BMHT).
Technical data
6000-series
Lengths
Note
The total length of the feed depends on the type of rock drill and the length of drill
steel for which it is intended. By adding the following length to the length of the drill
steel (XX) (XX/XX), it is possible to obtain the overall length of the feed.
BMH 63XX 1580mm

BMH 66XX 1211mm
BMH 68XX 1580mm
BMHT 63XX/XX 1588mm
BMHT 66XX/XX 1254mm
BMHT 68XX/XX 1588mm
Weights
Note
Only the weight of the shortest and longest standard feed is specified for each type of
feed.
BMH 6312 - BMH 6320 425 - 540kg
38
3. Feeder
BMH 6612 - BMH 6620 424 - 550kg

BMH 6812 - BMH 6820 430 - 545kg
BMHT 6314/08 - BMHT 6318/10 635 - 680kg
BMHT 6614/08 - BMHT 6618/10 600 - 640kg
BMHT 6814/08 - BMHT 6818/10 640 - 685kg
Fitting the rock drill/rotation unit
Preparation
Preparatory measures
1. Clean the feeder free from rust inhibitor.
Assembly
1. Remove burrs, paint or other coatings from the cradle and the contact surfaces on
the rock drill.
2. Remove the mounting bolts from the cradle.
3. Position the rock drill with any shims on the cradle and refit the bolts. Make sure
the rock drill fits firmly in place.
4. Screw on the rock drill. Tighten the bolts (four pcs.) alternately until a torque of
200 Nm (20 kgf m) has been attained.
5. Connect and fit the hoses to the rock drill.

6. Adjust slide rails and hoses according to the directions in this instruction manual.
Check after four hours

1. Check and tighten all bolted joints.
2. Check and adjust the tension of the ropes.
3. Check all hoses for leaks.
4. Tighten and adjust the tension of the hoses if necessary.
5. Check and adjust the slide rail alignment on the feed beam.
39
3. Feeder
Rock drill hoses
Location of hoses
Depending on the rock drill fitted on the feeder, the hoses should be positioned in the
water-hose drum and the feed hose retainer as described below.
Table: Hose designations

New, existing hose Older, existing hose
designations designations Explanation
AL1 L1 Air lubrication
D1 D1 Draining
HDP1 PD1 Reflex damper
HP1 S1 Percussion in
HT1 TS1 Percussion return
RRL1 R1 Rotation left
RRR1 R2 Rotation right
WF2 V1 Flushing
Table: Hose location

Water-hose drum Feed hose retainer
HDP1/PD1 WF2/V1
HDP1/PD1
AL1/L1 D1
WF2/V1 AL1/L1
D1 HP1/S1
RRL1/R1
RRL1/R1
HP1/S1
HT1/TS1 RRR1/R2 HT1/TS1
RRR1/R2
1250 0043 31
1250 0043 32
Figure: COP 1838/1638 Figure: COP 1838/1638
40
3. Feeder
Water-hose drum Feed hose retainer
Figure: COP 1838/1638 (feeder with bulkhead Figure: COP 1838/1638 (feeder with bulkhead
lead-through) lead-through)
WF2/V1
WF2/V1
AL1/L1
HP1/S1 AL1/L1
RRR1/R2 HDP1/PD1
HP1/S1
RRR1/R2
RRL1/R1
HDP1/PD1
RRL1/R1 HT1/TS1
HT1/TS1
1250 0043 29 1250 0043 30
Figure: COP 1432/1532 Figure: COP 1432/1532
AL1/L1 WF2/V1
WF2/V1
HP1/S1 D1
AL1/L1
RRR1/R2 HP1/S1
D1
RRR1/R2
RRL1/R1
RRL1/R1
HT1/TS1 HT1/TS1
1250 0047 11 1250 0047 10
Figure: COP 1238 Figure: COP 1238
41
3. Feeder
Adjusting the hoses

1. Loosen the bolts on the hose retainer slightly when adjusting and tensioning the
hoses.
2. Tension the hoses and make sure they are not crossed.
Haul and return ropes
Locations
B
C
A D
1250 0046 97
Figure: Locations
A Adjustment for haul rope
B Adjustment for return rope
C Scraper plate
D Haul rope tensioner
E Holder for intermediate drill-steel support
Replacing the haul rope

1. Operate the rock drill to about half its length of travel.
2. Slacken the tension on the ropes, bolt A and nut B.
3. Remove the haul rope from its front attachment on the rock drill cradle.
4. Remove the scraper plate C from the intermediate drill-steel support.
42
3. Feeder
5. Loosen the intermediate drill-steel support holder E so that the intermediate drill-
steel support can be lifted.
6. Remove the rope from the rope tensioner D in the rear part of the beam.
Note
Make sure the new rope is fitted in the same hole as the old one.
7. Fit the new rope and bolt the scraper plate back on.
8. Adjust the ropes as described below.
Adjusting haul and return ropes

1. The haul rope is adjusted with bolt A and the return rope with nut B.
2. The cradle position on the feed beam should be adjusted when it is in its rear posi-
tion and when the drill steel with bit is fitted on the rock drill.
3. Adjust the ropes so that the bit is behind the dowel. The measurement M1 is spec-
ified in the list of spare parts.
1250 0064 89
Figure: Adjustment measurement M1
Tension of return rope

1. Position a plank between the rock drill cradle and the intermediate drill-steel sup-
port.
2. Run the cradle forward until it stops against the plank. Keep the feed force
applied.
3. Tension the return rope so there is no risk of it jumping out of the cable drum. Do
not tension the cable too tightly. There should be a couple of centimetres of slack
remaining when the cable is correctly tensioned.
43
3. Feeder
Adjusting the cradle on the feed beam

The cradle plates for the rock drill, the intermediate drill-steel support and the water-
hose drum are guided along the feed beam by means of holder A. Each pair of hold-
ers is locked in position with bolts B. The bolt holes in the holders are in the form of
angled grooves. The cradle can be adjusted on the feed beam by shifting the holders
lengthways. Make sure the holders are turned the same way as in the illustration so
that the outer part of the angled grooves is facing to the rear of the beam. Make sure
the feed is in the horizontal position and the drill steel is fitted in the rock drill.
D
A
C
B
1250 0064 90
Figure: Adjusting the cradle holders
1. Remove the bolts B securing the holders.
2. Start by adjusting the upper holders so the cradle is lying straight on the beam and
is 5 - 7 mm above the beam. In this way, the rock drill adapter will be at the correct
height.
5mm
m
1m
1250 0064 91
Figure: Adjustment measurement
3. Then shift the lower holders lengthways until a clearance of 1 mm has been
attained between the lower holder and feed beam.
44
3. Feeder
4. Tighten the bolts B.
5. Check by running the cradle along the entire beam. The pressure required to run
the cradle forwards should be max 30 bar with the hydraulic oil at operating tem-
perature. If the pressure exceeds 30 bar, this means that the holders are too tight
and must be readjusted.
6. Replace damaged hoses and tighten leaking connections. The hoses are correctly
adjusted when they do not hang down when the feeder is in the horizontal posi-
tion.
Adjusting the feed beam on the telescope feeder

The upper beam is guided on the lower by means of similar holders to the ones used
for the cradle. Check that the holders are turned so that the outer part of the angled
groove is facing to the rear. Put the feeder in horizontal position and run the upper
beam along the lower beam to about half its length of travel.
1. Remove the bolts B securing the holders A.
2. Start by adjusting the upper holders so that the upper beam is positioned straight
on the lower and the measurement is 5 - 7 mm.
3. Then shift the lower holders lengthways until a clearance of 1 mm has been
attained between the lower holder and feed beam.
4. Tighten the bolts B.
5. Check by running the beam along its entire length of travel. The pressure required
to run the beam forwards should be max 30 bar with the hydraulic oil at operating
temperature. If the pressure exceeds 30 bar, this means that the holders are too
tight and must be readjusted.
5mm
A
m
1m
B
1250 0046 96
Figure: Adjusting the holder for the telescope feeder
45
3. Feeder
Replacing the slide pieces in the holder

Each holder has a replaceable slide piece. The slide piece C is kept in place by three
keys D. The slide pieces must be replaced at regular intervals so that the steel in the
holder does not wear against the beam. Replace if there is less than 1 mm of wear
allowance on the slide piece. It is a good idea to change all the slide pieces at the
same time, even if some of them are slightly thicker.
D
A
C
B
1250 0064 90
Figure: Replacing slide pieces
1. Prise off the slide pieces C from the holder using a screwdriver and remove the
keys D.
2. Slide a new slide piece into the holder track and fit the new keys.
3. Make sure the holders are refitted correctly in the cradle and are adjusted accord-
ing to the directions.
Replacing slide rails

Slide rails should be replaced if they are worn or severely scratched.
A
1250 0020 11
Figure: Replacing slide rails
46
3. Feeder
1. Remove the cradle for the rock drill, the intermediate drill-steel support and the
water hose drum from the beam.
2. Remove the old slide rails A by prising the lower edges of the bars outwards using
a screwdriver.
3. Clean the beam surfaces thoroughly.
4. Fit the new slide rails. The larger edge on the slide rail must be facing upwards.
The rails should be pressed in place by hand.
5. Refit the rock drill cradles, intermediate drill-steel support and water-hose drum.
Adjust the holders on the cradles as described in the instructions.
Adjusting different drill steel lengths for the tele-

scope feeder
The use of different drill steel lengths is made possible by moving a mechanical stop
mechanism on the lower feed cylinder.
1. Run the lower feed cylinder backwards towards the mechanical stop mechanism.
2. Undo the six hexagonal socket screws A and move one of the screws to the top of
the mechanical stop mechanism.
3. Operate forward or reverse to the required drill-steel length. Remember that the
drill bit B must be behind the rubber dowel.
4. Replace the hexagonal socket screw A to its ordinary position and tighten the
mechanical stop mechanism.
A
1250 0020 12
Figure: Adjusting the length stop
47
3. Feeder
Feed cylinder
Dismantling the feed cylinder
CAUTION
• Hazardous hydraulic oil pressure.
• Working on the hydraulic system can
involve a high risk of danger. Ensure the
system is depressurised before starting
work.
CAUTION
• Hazardous hydraulic oil and water
pressure.
• Never replace high pressure hoses with
hoses of lower quality than the originals
or with hoses fitted with removable
couplings.
1. Operate the rock drill cradle to about half the feed length.
2. Relieve the tension on the haul and return ropes, bolt A and nut B.
3. Remove the hose drum by undoing the 4 bolts in the centre of it and lifting off the
entire drum.
4. Detach the hoses at the hose retainer.
48
3. Feeder
5. Undo bolts C and D on cradle plates E and F.
C
E
SP
D
G H
N
F
A
K
M
L I
1250 0020 87
Figure: Dismantling the feed cylinder.
6. Remove bolt A completely. Remove also end piece G and the end plate H.
7. The cylinder and fork can now be pulled backwards out of the beam.
8. If necessary, dismantle the fork I by knocking away the pin K.
Note
Avoid dismantling the spacer L. If it must be dismantled, measure SP first so that
the spacer can be refitted in the same position.
Measurement SP is specified in the list of spare parts.
Tension bushing for spacer
Description
The spacer at the front of the cylinder is held in place with a tension bushing. In order
for the feeder to function correctly, the spacer measurement SP must be correct. This
measurement varies depending on the feed length and type of feeder, see relevant
spare parts catalogue.
49
3. Feeder
1250 0065 30 SP
Figure: Spacer and tension bushing
Dismantling
1. Remove the plastic plugs M from their holes.
2. Unscrew the bolts N from the bushing.
3. Fit the bolts into the threaded holes and pull them alternately until the bushing
parts.
Assembly
1. Assemble the bushing as illustrated but do not tighten the bolts.
2. Fit the spacer and bushing into the sleeve and make measurement SP is the same
as before.
3. Tighten the bolts N alternately until a torque of 38 Nm (3.8 kgf m) is attained.
Long-term storage
1. Clean the feeder thoroughly.
2. Lubricate as directed, see maintenance schedule Feeder.
3. Protect unpainted surfaces with rust inhibitor.
4. Store the feeder in a dry and clean environment.
50
4. Boom
4. Boom
BUT 35 G
8 7
6
5
9 4
1
3
1250 0105 70
2
Figure: Boom
1 Attachment plate
2 Rear boom cylinders
3 Telescopic unit
4 Front boom cylinders
5 Boom head
6 Rotary actuator
7 Feed lookout cylinder
8 Feed extension cylinder
9 Bulkhead lead-through
The hydraulic boom is of telescopic type with 360° feed rotation. It features three-
point suspension at front and rear. Each three-point suspension unit includes two
hydraulic cylinders which, through series connection in pairs, provide parallel feed
both vertically and horizontally.
A tilt cylinder enables the feeder to be positioned for roof and cross-cut drilling.
The rotary motion is obtained by a hydraulic rotary actuator and transferred via a stub
shaft to the feeder.
Boom BUT 35 G is available in two different basic versions, model M (medium) and
model L (large). Both models are available for left-mounted and right-mounted
feeder and with or without bulkhead lead-through.
51
4. Boom
3
1 2
1250 0105 74
Figure: BUT 35 G model M, left-mounted feeder

1 Rear boom section
2 Intermediate boom section
3 Front boom section
3
1 2
1250 0105 73
Figure: BUT 35 G model L, left-mounted feeder

1 Rear boom section
2 Intermediate boom section
3 Front boom section
Technical data
BUT 35 G
Model M (medium)
Weight
Note
All weights are in respect of boom, excluding feeder and rock drill.
Complete boom, including hydraulic hoses 3060 kg

Rear boom section (1) 1700 kg
Intermediate boom section (2) 410 kg
Front boom section (3) 640 kg
Length
Telescope contracted 7252 mm
Telescope extended 8852 mm
52
4. Boom
Model L (large)
Weight
Note
All weights are in respect of boom, excluding feeder and rock drill.
Complete boom, including hydraulic hoses 3200 kg

Rear boom section (1) 1840 kg
Intermediate boom section (2) 410 kg
Front boom section (3) 640 kg
Length
Telescope contracted 7952 mm
Telescope extended 9552 mm
Bolted joints
Tightening torques
The following table specifies the bolted joints requiring a special tightening torque.
Other bolted joints can be tightened to the torque specified in Atlas Copco standard
K4369, see maintenance instructions General.
Note
All bolted joints in the following table should be lubricated with Molycote 1000
thread grease or other thread grease having a friction coefficient of 0.11 µ.
53
4. Boom
14 5
19 1 10
13
16 13
6 7, 18 8 15
11
3
2 12
1250 0107 03
2 9
11
Figure: Bolted joints, BUT 35 G model M
14 5
19 1 10
13
16 13
17 6 7, 18 8 15
11
2 3
12
1250 0107 04
2 9
11
Figure: Bolted joints, BUT 35 G model L
Table: Tightening torques

Tolerance +/- Quantit
No. Bolted joints Thread Torque Nm Nm y
1 Bolt, rear boom link M20 365 36 2
2 Expander shaft, rear cylinder link M20 290 50 2
3 Expander shaft, rear cylinder M20 290 50 4
4 Expander shaft, telescope cylinder M16 195 20 1
5 Expander shaft, feed extension cylinder M16 195 20 1
54
4. Boom
Tolerance +/- Quantit

No. Bolted joints Thread Torque Nm Nm y
6 Bolt, bearing housing-rear boom body M16 315 31 16
(model M)
Bolt, bearing housing-extension (model
L)
7 Bolt, telescope-front boom attachment M16 315 31 12
8 Bolt, front boom link M20 365 36 1
9 Bolt, front boom link M16 187 18 1
10 Expander shaft, front cylinder M16 195 20 4
11 Expander shaft, front cylinder link M16 195 20 2
12 Bolt, front boom attachment-rotary M16 315 31 15
actuator
13 Expander shaft, feed lookout cylinder M16 195 20 2
14 Bolt, feed holder-attachment shaft M12 128 13 4
15 Lock nut, feed extension cylinder M24 290 50 1
16 Bolt, rotary actuator-cover M12 128 13 4
17 Bolt, extension-rear boom body M16 315 31 16
18 Bolt, telescope-intermediate boom M12 128 13 12
section
19 Bolt, attachment plate-boom console M24 630 60 18
Note
The bolts in bolted joint number 19, attachment plate-boom console, must be of
strength class 12.9. The strength class for other joints is given in the spare parts list
for the boom.
55
4. Boom
Bulkhead lead-through
Hose location
HD FL
AL
HP FL
AF BFL BAN BRR F
BFR BRL FR
F
HT WF BE BE FR
RRL FE
RG WAM
F FE
RGF RRR
WC
DS
RGR F HDP
SR
DS
RA M LS
SR
RA LS
1250 0064 65
Figure: Hose location in bulkhead lead-through

AF Air flushing
AL Air lubrication
BAN Anti-parallel holding
BE Boom telescope
BFL Left boom cylinder front
BFR Right boom cylinder front
BRL Left boom cylinder rear
BRR Right boom cylinder rear
DS Hydraulic drill-steel support, option
F Feed
FE Feed extension
FL Feed lookout cylinder
FR Feed rotation
HD Percussion drain
HDP Reflex damper, rock drill
HP Percussion in
HT Percussion tank
LS Automatic rock drill return
M Electric cable, option RAS
RA Rod handling arm, option RAS
RG Gripper claw, option RAS
RGF Front gripper claw, rod handling, option RAS
RGR Rear gripper claw, rod handling, option RAS
RRL Rotation left, rock drill
RRR Rotation right, rock drill
SR Stinger, option
WAM Water mist, option
WC Water lubrication feeder, option
WF Water flushing
Starting to use a new boom

When starting to use a new or reconditioned boom, or one that has been out of service
for a long period, the following steps should be taken:
56
4. Boom
1. Lubricate the boom as described in the maintenance schedule. It is important for

lubrication to be effective right from the start.
2. Thoroughly clean all piston rods and sliding surfaces that have been treated with
corrosion inhibitor.
3. Check and retighten all bolted joints and expander shafts at least once every shift
during the first week the boom is in use.
4. Make sure the pressure in the hydraulic circuits is correctly adjusted. The pressure
should be 195-220 bar in the high-pressure circuit and 40 bar in the pilot circuit.
5. Check all operating movements to ensure that all hydraulic cylinders travel to
their end positions.
6. Also check that no hoses can be caught up or pinched and that no oil leakage
occurs.
Slinging and hoisting
Safety
CAUTION
• Take great care when strapping and lifting
heavy objects.
• Lift at the centre of gravity.
• Use only straps that are intact and
intended for the load they are to carry.
• Fasten the straps to lifting eyes where
appropriate.
Hoisting
1. Check that the lifting equipment is designed for the load it is to carry. For weight
details, see section Technical data.
2. Apply the slings so that lifting is performed over the centre of gravity, see section
Slinging.
57
4. Boom
3. Hoist carefully. Make sure the boom does not start to swing and that the slings do
not start to slide off.
Slinging
Tp
3000
1250 0107 09
Figure: Slinging BUT 35 G, model L
Dismantling the boom
Safety
WARNING
• Dismantling and assembling
components.
• During service and maintenance work, all
components that can be brought in
motion or fall down must be securely
supported or strapped up.
Note
No modification or reinforcement work on the boom should be performed without
first consulting Atlas Copco Rock Drills AB.
58
4. Boom
Dismantling the feeder
A A
1250 0105 76
Figure: Dismantling the feeder
1. Fit slings round the feeder before dismantling it so that it cannot fall down.
2. Detach all hoses from the feed hose retainer.
3. Unscrew the feed extension cylinder from the feeder.
4. Remove the feeder from the boom by unscrewing the holders (A) from the feed
holder.

The boom can be shortened by separating it between the rear boom section (telescope
tube flange) and intermediate boom section (front cylinder attachment).
1250 0105 75
Figure: Dismantling the boom body

1. Fit a sling round the front boom beam or support it on stands before starting dis-
mantling work.
2. Detach the hydraulic hoses from the cylinders and plug the hoses and nipples.
59
4. Boom
3. Disconnect any sensor cables.
4. Then undo and remove the twelve bolts (A) and washers.
Expander shafts
Most of the cylinder brackets and links are fitted with expander shafts. Play can be
eliminated by tightening a nut. The slotted bushings will then be forced up on the
tapered shaft so that the joints will be free from play.
Dismantling
1. Fit a sling round that part of the boom that is held by the expander shaft or rest it
on supports before starting to dismantle the shaft.
2. Undo nut (A) and withdraw bolt (B).
3. Screw in a bolt that fits the threads in the bushings (C) and tighten it until one of
the bushings loosens.
4. Remove the other bushing and shaft (D).
B
C
C
1250 0020 16
Figure: Expander shaft
Assembly
1. Fit the shaft (D) in the cylinder lug or link. Lubricate the shaft before assembly.
2. Fit the two bushings (C). Make sure that they are located symmetrically at the
attachment point.
3. Fit the bolt (B) and nut (A) in the expander shaft and tighten. The nut should only
be tightened until there is no play. If it is tightened too much, the attaching lug
may crack. Only use the recommended tightening torques specified in the torque
table, see section Bolted joints.
60
4. Boom
Boom telescope
Dismantling the boom telescope
Safety
CAUTION
• Observe great care when dismantling the
boom telescope.
• Support rotary actuators and front boom
member securely before dismantling the
boom telescope.

The boom must be separated before the telescope device can be dismantled for main-
tenance or replacement.
Figure: Dismantling the boom
1. Extend the telescope to its front end position.
2. Rotate the feed beam up and down.
3. Lower the boom until the feed beam rests on the ground.
4. Position supports firmly under the rotary actuator and front boom beam before
dismantling the telescope.
5. Remove the bolts (A) from the front boom beam.
61
4. Boom
Dismantling of telescope and bearing housing

The figure below shows the BUT 35 G model M. The method of dismantling the tel-
escope and bearing housing is the same as for model L. The only difference is that the
bearing housing (B) on model L is screwed into the extension segment instead of in
the rear boom body.
A 1
2
1250 0105 77
Figure: Dismantling of telescope and bearing housing
1. Retract the telescope to the rear end position.

2. Fit slings round the bearing housing. Use an overhead travelling crane or hoist,
etc.
3. Detach the hydraulic hoses (C).
4. Unscrew the bearing housing bolts (B).
5. Remove the expander shaft (D).
6. Carefully withdraw the telescope tube, cylinder and bearing housing.
62
4. Boom
Checking the bushings in the bearing housing
C
D
G H B A
1250 0042 97
Figure: Checking the bushings in the bearing housing

A Telescope tube
B Cover
C Bushings
D Bearing housing
G Washer
H Seal
Thoroughly inspect the telescope device for signs of damage and wear.
1. Extend the telescope tube (A).
2. Remove the washer (G) and seal (H) and then undo the cover (B).
3. Measure the play between the telescope tube (A) and the two upper bushings (C).
If the play (I) is greater than 1 mm, dismantle the bearing housing (D) and change
the worn bushings.
D
A
1250 0043 28
Figure: Play between the telescope tube and bushings
63
4. Boom
Checking the keys

1. Check the keys (E) carefully. If they are deformed, the damaged area should be
ground smooth so that future damage to the slide rails (F), bearing house (D) and
bushings (C) can be avoided.
E E
1250 0042 96
C D C
Figure: Telescope device

C Bushing
D Bearing housing
E Keys
F Slide rails
Checking the slide rails

1. Remove the washer (G) and seal (H) and then undo the cover (B).
2. Place the feeder on a support and rotate the boom so that the load is taken up on
only one side of the keys.
64
4. Boom
3. The slide rails (F), see above figure, can then be removed from the bearing hous-
ing and inspected. Change them if they are worn or scratched.
C
D
G H B A
1250 0042 97
Figure: Bearing housing

A Telescope tube
B Cover
C Bushing
D Bearing housing
G Washer
H Seal
Rotation unit
Safety
CAUTION
• Observe great care when dismantling the
rotation unit.
• Support the feeder securely so it is
stable.
General
The rotation unit consists of a rotary actuator and a bearing housing attached to the
feed holder attachment shaft
65
4. Boom
E
1250 0109 89
Figure: Rotation unit

A Feed holder
B Attachment shaft
C Rotary actuator
D Bearing housing
E Feed lookout cylinder
Function of the rotary actuator

The rotary actuator converts the linear motion of the piston (B) into rotary motion.
The rotary actuator consists of a housing (A) with a ring gear (C) and two moving
parts: a piston (B) and a shaft (D). The shaft has splines that engage with the internal
splines of the piston. The external splines of the piston engage with the ring gear
splines.
The piston moves back and forth in the housing and the splines rotate the shaft.
66
4. Boom
1250 0058 32
Figure: Function of the rotary actuator
67
4. Boom
Reconditioning rotary actuators
Dismantling of rotary actuator from boom

1. Rotate the feeder 90° until it and the rock drill are under the boom. Position sup-
ports firmly under the feeder to hold it steadily in place.
1
2
3
5 6
8
9
10
11
1250 0107 34
Figure: Dismantling the feeder
2. Dismantle the expander shaft (11) of the feed lookout cylinder.
68
4. Boom
3. Remove the bolts (1) and protection (2).
4. Remove the bolts (3) and sensor (4).
Note
This point applies only to rigs with the RCS electronic control system and one of
the ABC Regular or ABC Total options.
5. Remove the bolts (5) and the outer cover (6).
6. Remove the bolts (7), the inner cover (8) and the shim (9).
7. Detach the hydraulic hoses to the feeder. Plug all hoses and connections.
8. Carefully lift the boom straight up so that the sliding bearings (10) in the bearing
housing are not damaged.
9. Rotate so that the bearing housing (E) reaches its original position.
10. Apply slings round the bearing housing (E).
11. Remove the bolts (A), hose retainer (B) and cover (C).
1250 0107 35
A
D B
Figure: Removing the cover and hose retainer
12. Remove the bearing housing by unscrewing the bolts (D).
13. Remove the hydraulic hoses from the overcentre valve and plug the hoses and
connections.
69
4. Boom
14. Apply slings round the rotary actuator and remove it from the boom head by undo-
ing the bolts (F).
1250 0109 90
Figure: Removing the rotary actuator
Constituent parts of the rotary actuator

102
105
05
113
04
207
204
206 100
304
205
302
202
203
300
200
201
111 03.1
211
210
211
111 301
302
03.2
302
205
112 304
01 206
112 02
1250 0107 07
Figure: Constituent parts of the rotary actuator
70
4. Boom
Table: Constituent parts of the rotary actuator

Pos. no. Description Pos. no. Description
01 Housing 200 Inner piston seal
02 Shaft 201 Inner piston seal (without O-ring)
03.1 Piston skirt 202 Outer piston seal
03.2 Piston 203 Outer piston seal (without O-ring)
04 Cover 204 O-ring
05 Retaining ring 205 Shaft seal
206 Seal
100 Locking pin 207 Thrust ring
102 Screw 210 O-ring
105 Plug 211 Thrust ring
111 Lubricating nipple
112 Grease relief valve 300 Wear ring
113 Locking pin 301 Wear ring
302 Wear ring
304 Washer
Removing the rotary actuator

Note
When assembling the component parts of the rotary actuator, the splined parts (shaft
and piston) must be refitted in their original positions.
There are two permanent position marks:
• One mark for piston-ring gear

• One mark for shaft-piston
1250 0109 87
Figure: Permanent marking piston-ring gear
71
4. Boom
1250 0109 88
Figure: Permanent marking shaft-piston
Assembly of the rotary actuator will be facilitated if additional positioning marks are
made during dismantling.
1. Place the rotary actuator on a clean workbench.
2. Detach all hydraulic connections.
3. Remove the overcentre valve and associated components.
4. Mark the relative positions of the retaining ring (05), cover (04) and shaft (02)
using a scriber or pen.
5. Unscrew the bolts (102) and plugs (105). Screw two of the bolts (102) in the
threaded holes of the retaining ring (05). By means of the bolts, remove the retain-
ing ring from the shaft splines (ring gear).
1250 0109 82
B A 05
102
105
102
05
Figure: Removing the retaining ring
72
4. Boom
6. Screw two bolts with washers or sleeves in the cover (04) and use a tommy bar or
the like to unscrew the cover from the shaft.
04
1250 0109 83
Figure: Removing the cover
Note
In certain cases the cover may be screwed in extremely hard. An iron bar can then
be welded to the cover to provide greater leverage.
7. Screw two bolts in the shaft (02) flange. These bolts enable the shaft to be turned
with the aid of a tommy bar or the like. Turn the shaft clockwise. It will start to
rotate out of the housing.
Note
Do not turn the shaft so much that it no longer engages with the piston. Before the
shaft is unscrewed all the way out its position relative to the piston must be
marked, see next point.
02
A
1250 0109 84
Figure: Removing the shaft
73
4. Boom
8. Using a pen, mark the position of the shaft relative to the piston, i.e. mark one of
the shaft splines and the corresponding groove in the piston. See example in the
following figure.
A
1250 0109 85
Figure: Marking shaft-piston
9. Unscrew the shaft all the way out of the housing.
10. Use a plastic drift and hammer to drive the piston (03.2) (including piston skirt
(03.1)) out of the housing (01).
Note
Auxiliary marks must be made to ensure that the piston will be refitted in its cor-
rect position. For this to be possible, however, the piston must first be released
fully from the ring gear. Hold the piston in this position and use a pen to mark the
housing (01), piston skirt (03.1) and piston (03.2).
01
03.1
03.2
1250 0109 86
Figure: Marking housing-piston skirt-piston
After marking, the piston can be removed from the housing. Exercise care to avoid
damaging the piston and housing.
74
4. Boom
11. The piston and piston skirt need not be dismantled further unless it is suspected
that the O-ring (210) may be damaged. If the O-ring (210) is to be changed mark
the relative positions of the piston and piston skirt and then remove the wear rings
(300 and 301). Press out the locking pins (100) and unscrew the piston from the
piston skirt.
Change the O-ring (210) and reassemble piston and piston skirt.
12. Unscrew the grease nipples (111) and valves (112).
13. Remove all seals and bearings.
14. Clean all parts thoroughly and check them for wear.
Note
The maximum thickness of the wear rings (300, 301 and 302) should be 3.098 mm.
The washers (304) should have a maximum thickness of 3.048 mm.
Assembly of rotary actuator

1. Thoroughly clean all parts and blow them dry with compressed air. Make sure that
all position marks are still clearly visible.
2. Carefully inspect the threads on the shaft (02) and cover (04) and rub down any
burrs with abrasive cloth.
3. Screw the cover on the shaft.
4. Lubricate all seals and contact surfaces with hydraulic oil.
Note
Always change the seals and bearings when assembling rotary actuators.
Never use sharp tools when fitting seals.
5. Fit the wear rings (300 and 301) on the piston.
Note
Fitting the piston is the most difficult part of reassembling the rotary actuator. It
may therefore be a good idea to practice this without any seals on the piston.
75
4. Boom
6. Stand the housing (01) upright with the flange upwards. Fit the piston in the hous-
ing. Use the markings to make sure it is in the right position. Lay the housing
down in a horizontal position when the piston has engaged with the ring gear and
check at the other end of the housing that the position of the piston coincides with
the permanent markings.
1250 0109 87
Figure: Permanent markings piston-ring gear
Screw the piston in fully so that the piston skirt bottoms against the ring gear.
7. Grease the washers (304).
8. Fit a set consisting of washer (304) and seals (205) and (206) on the shaft (02) and
another set on the cover (04).
04
206
304
205
205
1250 0107 08
304
206
02
Figure: Fitting washers and seals
76
4. Boom
9. Stick masking tape on the ring gear of the shaft so that the piston seals will not be
damaged when the shaft (02) is fitted.
1250 0107 37
Figure: Shaft ring gear and threads
10. Fit the shaft in place so that its marking is opposite the piston skirt marking. Then
remove the masking tape.
11. Apply thread paste to the threaded part of the cover (04) and screw it on the shaft.
Tighten to a torque of 800-950 Nm.
12. Apply grease generously to the shaft ring gear. Also grease the bright metal sur-
faces of the cover.
13. Fit the retaining ring (05) on the shaft and try to find a position where its through
hole comes opposite the threaded hole of the cover (04). It may be necessary to
loosen or tighten the cover slightly to achieve this.
14. Apply Loctite 242 (or the equivalent) to the bolts (102) and tighten them to a
torque of 116 Nm. Apply sealing compound to the plugs (105) and screw them
flush into the retaining ring.
15. Pump grease into the grease nipples (111) to remove any impurities and to check
that they are in working order. Wipe off surplus grease.
16. Screw the grease nipples (111) and valves (112) in place.
17. Fit the hydraulic connections and overcentre valve.
Action after rotary actuator assembly

After mounting of the rotary actuator a check for oil leakage should be performed. If
possible, connect up the rotary actuator in a hydraulic test bench and give it a trial run
before fitting it on the boom.
77
4. Boom
1. Pressurise port P2 at 210 bar. No oil should leak out of port P1 or round the cover.
2. Pressurise port P1 with 210 bar. No oil should leak out at port P2 or round the
shaft flange.
3. Pump grease into the grease nipples (111) until it comes out through the vales
(112). Repeat this after having run the rotary actuator through a number of cycles.
4. Run at least 15 cycles and check that no oil leakage occurs.
Mounting of rotary actuator on boom

1. Apply slings round the rotary actuator and mount it on the boom head using the
bolts (F).
1250 0109 90
Figure: Mounting of rotary actuator on boom

2. Connect the hydraulic hoses to the overcentre valve.
78
4. Boom
3. When mounting the bearing housing it is important to ensure that the stop position
for feed rotation is correct.
A A
1250 0109 93
B B
45 ° 45 °
Figure: Stop position for feed rotation

A Bearing housing in horizontal position
B Bearing housing rotated in under boom to stop position
a. Rotate the rotary actuator to the stop position.
b. Then rotate it in the opposite direction so that the pattern of holes on the rotary
actuator's shaft flange is displaced two holes.
79
4. Boom
c. With the rotary actuator rotated to this position the bearing housing (E) can be
mounted hanging vertically. Tighten the bolts (D) to a torque of 315 Nm.
D
E
1250 0109 94
Figure: Mounting the bearing housing
4. Mount the cover (C) and hose retainer (B) using the bolts (A). Tighten the bolts
(A) to a torque of 128 Nm.
1250 0109 92
B
Figure: Mounting of cover and hose retainer
80
4. Boom
5. Mount the feeder by rotating the bearing housing through 90°. Lower the boom
straight down against the feed holder's attachment shaft (12). Take care to avoid
damaging the sliding bearings (10) in the bearing housing.
1
2
3
5 6
8
9
10
11
12
1250 0109 91
Figure: Mounting the feeder
6. Mount shims (9) and inner cover (8). Tighten the bolts (7) to a torque of 128 Nm.
7. Mount the inner cover (6) using the bolts (5). Tighten the bolts (5) to a torque of
75 Nm.
81
4. Boom
8. Mount the sensor (4) using the bolts (3).
Note
This point applies only to rigs with the RCS electronic control system and one of
the ABC Regular or ABC Total options.
9. Mount the protection (2).
10. Mount the feed lookout cylinder with the aid of the expander shaft (11). Tighten
the expander shaft (11) to a torque of 195 Nm.
11. Lift the boom and rotate the feeder through 90°. Refit the hydraulic hoses.
Adjusting the feed lookout cylinder

Note
When mounting the feed lookout cylinder, start from the basic setting of 782 mm
between the expander shaft centres. Then continue with fine adjustment of the feed
lookout cylinder as described below:
82
4. Boom
782
A
B
1250 0145 73
Figure: Adjusting the feed lookout cylinder

1. Position the boom horizontally.
2. Position the rotary actuator bearing housing horizontally using a spirit level
(placed vertically on the rotary actuator flange).
3. Operate the rotary actuator to bring the feed holder into a horizontal position.
4. When the boom is in this position, the feed holder can be tilted with the feed look-
out cylinder. When the feed lookout cylinder piston rod is all the way inside the
cylinder, the feed holder should be horizontal.
5. To adjust, slacken the locking screws (A) and screw the piston rod in or out using
an open-ended spanner on the piston rod flats (B) until the feed holder is horizon-
tal.
83
4. Boom
Directional control - angle sensor

Directional control is covered in another section of the maintenance instructions, see
maintenance instructions Directional control.
84
5. Engine
5. Engine
Engine unit Deutz 1013 C
1250 0064 39
Figure: Engine
Engine type (A), engine number (B) and engine data are shown on the type plate (C)
affixed to the crankcase. The engine number is also stamped on the crankcase at the
arrow.
Lift up the cover to see these numbers.
Figure: Engine type plate

Note
Engine type and engine number must be specified on spare part orders.
85
5. Engine
Technical data
Deutz BF4M 1013C
Max. power at 2300 rpm 109KW
Max. torque at 1400 rpm 572Nm
Swept volume 4.76dm 3
Valve clearance
Inlet 0.3 +0.1 mm
Outlet 0.5 +0.1 mm
Idling speed 800rpm
Cooling Water-cooled
Fuel injection Bosch
Generator (Bosch) 35A
28V
Starter motor 4KW
24V
Weight 490Kg
Deutz BF6M 1013C

Max. power at 2300 rpm 170KW
Max. torque at 1400 rpm 847Nm
Swept volume 7.14dm 3
Valve clearance
Inlet 0.3 +0.1 mm
Outlet 0.5 +0.1 mm
Idling speed 800rpm
Cooling Water-cooled
Fuel injection Bosch
Generator (Bosch) 55A
28V
Starter motor 4KW
24V
Weight 670Kg
86
5. Engine
Tightening torques
Table: Tightening torques, Deutz 1013 diesel engine
Bolted joints Tightening torque (Nm) Comments
Valve cover 8.5
Set screw, rocker arm 21
Engine mounting, flywheel side 187 M16 x 40, 8.8 A4C
Engine mounting, fan side 187 M16 x 40, 8.8 A4C
Intake manifold 8.5
Exhaust manifold 21
Oil drain plug 50
Injector mounting 16 Torx
Injector line 30 M14 x 1.5
Oil sump (cast) 29
Oil sump (sheet metal) 21
87
5. Engine
Safety
WARNING
• Hot engine parts.
• Make sure the engine is turned off during
all maintenance work and before
refuelling.
• Take care when draining hot oil and
fluids.
• Never handle flammable fluids in the
vicinity of hot surfaces, sparks or naked
flames.
Fuel system
Changing fuel filter
Figure: Fuel filter
The diesel engine has two fuel filters. The engine diesel filter (1) and a pre-filter (2)
located between the diesel tank and engine. The pre-filter has a loose insert that must
be cleaned every month. A damaged pre-filter insert must be changed.
The diesel engine filter (1) must be changed and cleaned:
88
5. Engine
1. Close the fuel cock.
2. Loosen the fuel filter (1) using a suitable tool and unscrew it.
3. Collect any residual fuel.
Figure: Changing fuel filter
4. Clean the filter holder sealing surface.
5. Lightly oil the new fuel filter rubber seal.
6. Screw in the filter by hand until the gasket is home.
Figure: Changing fuel filter
7. Tighten the filter an additional half turn.
8. Open the fuel cock.
9. Check that the fuel filter does not leak.
Bleeding the fuel system

The fuel system must be bled when the engine is started for the first time or when the
tank has been run dry.
1. Switch on the ignition.
2. Place a receptacle to collect any fuel under the filter.
89
5. Engine
3. Open the bleed screw (1).

1250 0102 21
1
Figure: Fuel filter bleed screw (1)
4. Use hand pump (2). Pump until the fuel flowing out is free of air.
2
1250 0102 22
Figure: Location of hand pump (2)
5. Torque tighten the bleed screw (1) to 15 Nm.
6. Continue to pump until the resistance increases.
7. Start the engine.
8. Check that the fuel filter bleed screw (1) is not leaking.
Draining the fuel tank

Always fill the fuel tank with clean diesel oil and fuel of the correct grade for the
temperature.
1. Loosen the bottom plug about one turn and allow the water to run out.
2. Tighten the plug so the diesel oil cannot leak out.
90
5. Engine
1250 0020 28
Figure: Draining the fuel tank
Air system
General
It is important to keep the air filter and air cleaner in good condition so that the
exhaust gases are as clean as possible. Repeated dismantling and assembly can dam-
age the gasket between the insert and the filter housing. Smoke and poor engine per-
formance can be an indication of clogged filters.
1. A clogged air filter is indicated on the operator panel. See operator's instructions
Repositioning: Control panel functions.
Changing filter insert
N.B.
The safety cartridge must not be cleaned and reused.
1. Loosen the filter cover (2) by undoing the retaining clips (1).
2. Remove the fouled filter insert (3).
3. Check the adhesive gasket for cracks or other damage.
4. Clean the insert (3) or replace it with a new one.
5. Change also the safety cartridge (4) if necessary. Undo the nut (5) and pull out the
cartridge (4).
6. Refit the filter insert (3), refit the filter cover (2) and secure with the retaining clips
(1).
91
5. Engine
1250 0138 00
Figure: Changing filter insert
Cleaning the filter insert
N.B.
The filter insert and safety cartridge must be changed after cleaning five times.
Safety cartridges must be changed after a year's operation. Do not blow the filter
housing clean with compressed air.
1. Carefully tap the front of the filter insert (A) against the palm of your hand or
some other soft object a few times, or blow the filter insert clean with dry com-
pressed air.
2. Make sure the filter insert is not damaged.

3. Illuminate the filter insert with a torch to see if it is damaged.
4. Refit the filter insert.
Cleaning the dust valve

1. Empty the dust valve (1) by squeezing the slit together in the direction of the
arrow.
2. Clean the slit at regular intervals.
3. Remove any accumulation of dirt by squeezing the upper part of the valve.
92
5. Engine
Figure: Cleaning the dust valve
Cooling system
Coolant level
1. Coolant level (1) must be above the Kalt-Cold mark when the engine is cold.
2. Top up with coolant if the level is below the min. mark or if the coolant level
warning indicator is activated, see topping up the cooling system.
Figure: Checking the coolant level
93
5. Engine
Cleaning the cooling system

1. Place a receptacle under the heat exchanger (2) to collect the dirt.
Figure: Cleaning the cooling system

2. Remove the upper inspection cover on the heat exchanger.
3. Cleaning with compressed air.
a. Blow through the heat exchanger with compressed air from below (3) and then
from above (1).
b. Flush out any dirt that has come loose with a water jet.
Note
Do not damage the cooling ribs.
4. Cleaning with cold detergent.
a. Squirt normal cold detergent into the heat exchanger and allow to act for about
10 minutes.
b. Flush clean through (3) first and then through (1) with a sharp water jet.
Note
Do not spray on sensitive engine components such as the generator, cables or electri-
cal parts.
5. Fit the inspection cover.
6. Warm up the engine to evaporate residual water.
Draining the cooling system
N.B.
Take care when draining hot coolant. Risk of burns.
94
5. Engine
1. Place a suitable receptacle under the drain plug (3).
Figure: Draining the cooling system
2. Unscrew the cap (1).
3. Unscrew the drain plug (3) completely.
4. Drain off the coolant.
Topping up/bleeding the cooling system

1. Unscrew the cap (1).
Figure: Topping up the cooling system

2. Unscrew the drain plug (3) to the last groove (arrow).
3. Undo the air screws (2) and (4).
4. Top up with coolant to the top of the filler pipe (the temperature valve must be
open if fitted).
5. Tighten the air screws (2) and (4).
6. Tighten the drain plug (3).
95
5. Engine
7. Fit the cap (1).
8. Check the water level when the engine has cooled down after running the first
time.
Oil system
Topping up with engine oil
1. Fill up with oil through filler hole (C). See maintenance instructions Lubricants,
coolants and propellants.
A
B C
1250 0037 66
Figure: Topping up with oil
2. Check the oil level on the dipstick (A).
Changing oil
1. Place the rig horizontally.
2. Warm up the engine. Oil temperature approx. 80 °C.
3. Stop the engine.
4. Place a receptacle at the drain cock.
5. Screw out the oil drain plug.
6. Drain the oil.
7. Screw in the oil drain plug with a new gasket and tighten it.
8. Fill up with oil. See maintenance instructions Lubricants, coolants and propel-
lants.
9. Start the engine and allow it to idle for abut two minutes.
96
5. Engine
Figure: Changing oil
Checking oil level

1. Stop the engine.
2. Check the oil level against the marked line on the stick.
3. Top up with oil to the top line if necessary.
Figure: Oil level check
Changing oil filter

1. Loosen the oil filter using a suitable tool and unscrew it.
2. Collect the oil.
Figure: Changing oil filter
97
5. Engine
3. Clean the filter holder sealing surface.
4. Lightly oil the rubber gasket on the new oil filter.
5. Screw in the filter by hand until the gasket is home.
6. Screw in the filter half a turn.
7. Check the oil level.
8. Check the oil pressure.
9. Make sure the oil filter does not leak.
Belts
Tension gauge
Check the belt tension with a tension gauge.
98
5. Engine
1. Press down the arm (1) in the gauge.
Figure: Belt gauge
2. Place the guide (3) on the belt (2) between the two belt pulleys, making sure the
stop fits laterally.
3. Press the button (4) at right angles to the belt (2) so that the spring can be felt or
heard releasing.
4. Carefully lift up the gauge without changing the position of arm (1).
5. Read off the value at the intersection (arrow) of the scale (5) and the arm (1).
6. Readjust the tension if necessary.
Tensioning belts
Fan belt
1. Undo the intercooler guard to expose the belts.
99
5. Engine
2. Undo the bolts (1) and (2).
Figure: Fan belt
3. Tension the belt by inserting a square spanner into the square and turning in the
direction of the arrow until the correct belt tension is attained.
4. Tighten the bolts (1) and (2).
Generator
Figure: Generator belt
2. Move the generator (3) in the direction of the arrow by turning the bolt (2) until
the belt tension is correct. The maximum tightening torque of 28 Nm at the gear
must not be exceeded when rack tensioning.
100
5. Engine
Coolant and fuel pump

Figure: Fuel pump
2. Press the fuel pump (3) in the direction of the arrow until the correct belt tension
has been attained.
Table: Belt tensioning

Generator / fan 400 N / Re-tensioning 250 N
Fuel pump, coolant pump 400 N / Re-tensioning 250 N
Changing belt on coolant / fuel pump

Change belts on a stationary engine only.
Figure: Coolant pump
2. Press the fuel pump (3) in the direction of the arrow.
101
5. Engine
3. Pull off the belt and fit a new one.
4. Press the fuel pump (3) in the opposite direction to the arrow until the correct belt
tension has been attained.
Changing generator belt

Figure: Tensioning generator belt
2. Move the generator (3) in the opposite direction to the arrow by turning the bolt
(2) until the generator goes free.
3. Pull off the belt, fit a new one and tension it.
Valve clearance
1. Detach the ventilation valve and turn it to one side.
2. Remove the valve cover.
3. Adjust the crankshaft according to the adjustment schedule.
4. Allow the engine to cool down for at least 30 minutes before adjusting the valves.
Oil temperature below 80 °C.
102
5. Engine
5. Check the valve clearance (1) between the rocker arm (2) and the valve (3) with a
feeler gauge (6). It should be possible to insert the feeler gauge with only slight
resistance.
Figure: Valve adjustment and crankshaft adjustment
6. Adjusting valve clearance
a. Undo the lock nut (4).
b. Adjust the set screw (5) with a screwdriver (7) so that the valve clearance is
correct once the lock nut has been tightened.
7. Check the adjustment on all cylinders
8. Fit the valve cover. Change the gasket if necessary.
9. Turn back the ventilation valve into position and fasten it.
Alternating current generator
Important
Note
• Do not break connections between battery, generator and regulator when the
engine is running!
103
5. Engine
• If the generator must be started and run without the battery, the cable between
the regulator and generator must be detached before starting the engine!
• Do not mix up the battery connections!
• The charge lamp must be changed immediately if it has blown!
• Do not spray water directly on the generator when cleaning the engine. Run the
engine warm afterward to evaporate excess water!
• The method of checking whether the generator is energised by undoing one of
the contacts and grounding it must in no circumstances be used! Sparks can
cause engine fires!
• When carrying out electric welding, connect the ground directly to the part
being welded!
Lifting device
1. Make sure all connections to the engine have been detached.
2. Use only suitable lifting devices when moving the engine.
1250 0021 12
Figure: Lifting
104
5. Engine
Fault finding
1. Problems usually arise due to defective operation and maintenance.
2. Check that all maintenance instructions have been adhered to if a problem arises.
3. If you cannot determine the cause of a problem, get in touch with your closest
DEUTZ service centre.
Table: Fault finding table

Symptom
1 Engine difficult to start or does not start at all
2 Engine starts but does not run smoothly and
stops
3 Engine overheats, temperature switch triggers
4 Poor engine performance
5 Engine misfires
6 No (or low) engine oil pressure
7 Excess engine oil consumption
8 Engine produces blue smoke
9 Engine produces white smoke
10 Engine produces black smoke
Check that... 1 2 3 4 5 6 7 8 9 10
the engine is decoupled (if possible) X
the start temperature limit is reached X X
the solenoid is not faulty X X
the oil level is not too low, top up if necessary X X
the oil level is not too high, reduce if necessary X X X X
the pitch of the engine is too great, adjust if necessary X X X
the drive lever is not in the intermediate position, adjust if X
necessary
the air filter is dirty, change if necessary X X X
the air filter indicator is not faulty X X X
the smoke limiter is not faulty X X
the boost air outlet does not leak, change if necessary X X X
the coolant water pump is not faulty, clean if necessary X
the intercooler is not dirty, clean if necessary X X
the coolant water heat exchanger is not dirty, clean if X
necessary
105
5. Engine
Check that... 1 2 3 4 5 6 7 8 9 10
the cooling fan is not faulty (damaged or without belt), change if X X X X X
necessary
the cooling air is not heated X X
the battery is not faulty (or flat) X
the cable terminal is not loose or oxidised X
the starter motor is not faulty (gear does not engage), adjust if X
necessary
the valve clearance is correct X X X X X
the injector line does not leak, clean or change if necessary X X X X
the air line is not blocked X
the glow plug is not faulty, change if necessary X X
the injector is not faulty, change if necessary X X X X X X X
there is no air in the fuel system X X X
the fuel filter is not dirty X X X X
the oil filter is not faulty, change if necessary X
the correct engine oil grade is used, change if necessary X X X
the correct fuel grade is used, change if necessary X X X X
there are no coolant water problems, top up if necessary X
Deutz instruction manual

Note
Consult the Deutz instruction manual if further information on the engine is required.
The instruction manual can be ordered via Atlas Copco.
106
6. Transmission
6. Transmission
Locations
1
3
2
1250 0146 50
Figure: Transmission
1 Boom shaft
2 Engine shaft
3 Hydraulic gearbox
Technical data
Wheels
Tyres (boom and engine section) 14.00 x 20 XKA Michelin or
12.00 x 20 XKA Michelin
Rims (boom and engine section) 8.00 x 20
Tyre pressure 10 bar
Tightening torque, wheel nuts 570 Nm
Steering
Control valve Danfoss OSBP 800 LS
Gear pump:
Displacement 40.6cm 3 /rev
Max. working pressure 175bar
107
6. Transmission
Steering cylinder 125/63-400

Steering wheel turns, lock-to-lock 6.0 turns from full left lock to
full right lock
Drive shafts
Boom shaft
Shaft type Clark Hurth 176/273
Max. load 15000 kg
Weight 600 kg
Engine shaft
Shaft type Clark Hurth 176/274
Max. load 15000 kg
Weight 600 kg
Hydraulic gearbox
Transmission type Clark 24 000 long drop
Fitting tyres and rims

When fitting tyres and rims, check that:
• the tyre is pumped to the correct pressure.

• contact surfaces between the hub and rim are clean so that the correct tightening
torque can be obtained.
• the wheel nuts are tightened to the correct torque.
Drive shafts
Checking oil level in central gear

1. Make sure the rig is standing level.
108
6. Transmission
2. Unscrew plug (A) and check that the oil level reaches up to the hole.
A
1250 0020 43
Figure: Drive shaft centre
3. Top up with oil as necessary. See maintenance instructions Lubricants, coolants

and propellants.
Changing oil in the final drive

Note
Oil changing should be carried out after operating the machine while the oil is still
hot.
1. Unscrew the three plugs (B).
B
B
B
1250 0020 42
Figure: Changing oil

2. Drain the oil into a receptacle.
109
6. Transmission
3. The oil will drain faster if plug (A) is also unscrewed.
A
1250 0020 43
Figure: Drive shaft centre
4. Refit the plugs (B) and tighten them.
5. Fill with new oil through the hole for plug (A) until the oil reaches the hole.
6. Screw in and tighten plug (A).
Checking oil level in hub gear

1. Make sure the rig is standing level.
2. Rotate the wheel so that the two level markings (A) on the hub are horizontal.
3. Remove screw (B) and check that the oil reaches up to the hole.
Figure: Hub gear

4. Top up with oil as necessary. See maintenance instructions Lubricants, coolants
and propellants.
110
6. Transmission
Changing oil in hub gear

Note
Oil should be changed after operating the machine while the oil is still hot.
1. Rotate the hole so that plug (B) reaches its lowest point.
Figure: Hub gear
2. Unscrew plug (B).
3. Drain the oil into a receptacle.
4. Rotate the wheel so that the two level markings (A) on the hub are horizontal.
5. Fill with new oil through the hole for plug (B) until the oil reaches the hole.
6. Screw in and tighten plug (B).
111
6. Transmission
Hydraulic gearbox
Safety
WARNING
• Make sure the engine is turned off for all
maintenance work.
• Take care when draining hot oil and fluid
to avoid burns.
Checking oil level

Note
Allow the oil to reach normal operating temperature (80-95 °C) before checking the
level.
1. Check the oil with the dipstick (A) while the engine is idling, 800-850 rpm.
2. Top up as needed through the filler pipe (A) to the “full” mark on the dipstick. See
maintenance instructions Lubricants, coolants and propellants.
A
1250 0148 39
Figure: Checking oil
112
6. Transmission
Changing filter and oil

Note
The oil must reach normal operating temperature (80-95 °C) before filter replace-
ment and oil change can take place.
1. Drain the oil from the transmission housing when it has reached normal operating
temperature by opening the plugs (B). Screw the plugs back in place.
2. Remove filter (C) and fit a new one in its place.
3. Fill the transmission housing with oil through (A) up to the "low" mark on the dip-
stick (A). See maintenance instructions Lubricants, coolants and propellants.
4. Start the diesel engine and let it idle, 750-800 rpm, to fill up the torque converter
and lines.
5. Check the oil level again with the engine idling and top up to the "low" mark on
the dipstick (A).
6. Check the oil again once it has reached normal operating temperature, 80-95 °C.
7. Fill with oil to the "full" mark on the dipstick.
1250 0020 39 B
Figure: Changing oil in the transmission
113
6. Transmission
Lubricating the chassis
Propeller shafts
1. Pump grease into the grease nipples in the centre (A) of the universal joints. For
lubricant recommendations, see maintenance instructions, Lubricants, coolants
and propellants.
A B
1250 0148 43
Figure: Propeller shaft lubrication points
2. Make sure the grease appears.
Central lubrication of chassis

The chassis is equipped with a central lubrication system that lubricates the engine
shaft pendulum suspension, steering links and articulated joint (B) from one nipple
(A).
1. Pump grease into grease nipple (A). See maintenance instructions Lubricants,
coolants and propellants.
2. Make sure grease comes out at all locations (B).
114
6. Transmission
A
B
B
1250 0020 41
Figure: Central lubrication
Towing
Safety
WARNING
• The rig has no working brakes when it is
being towed.
• Couple the drawbar between the rig and
the tractor before releasing the brakes or
detaching the propeller shafts. Otherwise,
there is a risk that the rig will start
moving.
• Ensure the tractor vehicle and the
drawbar are suitable for the load being
pulled.
Before towing
• The carrier cannot be started by towing. Any attempt to do so could seriously
damage the hydraulic gearbox.
115
6. Transmission
• The carrier should only be towed if absolutely necessary.

• A drawbar must always be used for towing.
• The carrier must never be towed farther than 1 km or at a speed greater than 5 km/
h.
• The brakes must be released and the propeller shafts disconnected before towing.
Note
If the diesel engine is not working, the steering cylinder must also be disconnected
hydraulically, see disconnecting the steering cylinder below.
Release the brakes

1. Undo lock nut (A).
2. Screw in bolt (B) until the brake releases. Lock the bolt with the nut so that it can-
not work loose.
3. Release the brakes on all four wheels.
A
B
1250 0042 57
Figure: Releasing the parking brake
Removing propeller shafts

1. Mark the flanges on the propeller shafts so they can be refitted in the same way.
116
6. Transmission
2. Remove the bolted joints (B) and remove the propeller shafts.
A B
1250 0148 43
Figure: Remove the propeller shaft
Disconnecting the steering cylinder

1. Detach both hoses to the steering cylinder.
2. Plug the hoses and protect the cylinder well against dirt, e.g. with a plastic bag.
Note
Do not plug the unions on the cylinder as oil must be allowed to run out. Protect
them so that dirt cannot enter the cylinder and allow the oil to be collected for dis-
posal in an appropriate manner.
After towing
Steps to take
1. Refit the propeller shafts.
2. Connect the hoses to the steering cylinder.
117
6. Transmission
3. Apply the brakes. Undo lock nut (A) and unscrew the bolt until it protrudes 47
mm.
A
B
47mm
1250 0020 05
Figure: Setting the brake screw.
4. Remove the drawbar between the chassis and the towing vehicle.
5. Check the brakes after towing. See maintenance instructions Brake system:
Checking service brake pressure.
118
7. Brake system
7. Brake system
Safety
WARNING
• Ensure the system is depressurised
before starting any maintenance work. To
make sure the system is depressurised,
the brake pedal must be depressed 30-40
times after shutting down the system.
General
1
3
2
1250 0146 50
Figure: Transmission
1 Boom shaft
2 Engine shaft
3 Hydraulic transmission
119
7. Brake system
Technical data
Brake system
Service brakes
System Dual independent circuits.
Hydraulic disc brakes in oil
bath on all wheels.
Hydraulic pressure 80 +5/-0 bar
Parking/emergency brake
System SAHR (Spring Applied
Hydraulic Released)
Max. hydraulic pressure 35 bar
Checking brake pressure
Service brake pressure

1. Connect a pressure gauge to the brake system test outlet (A) on the axle.
A
1250 0020 21
Figure: Checking service brake pressure
2. Start the diesel engine.
3. Depress the brake pedal and read the pressure shown on the pressure gauge. The
pressure must be 80 +5/-0 bar.
The pressure is factory set and cannot be adjusted.
120
7. Brake system
4. Stop the diesel engine and disconnect the pressure gauge from the pressure test
outlet.
5. Check the service brake pressure on the boom and engine axles.
Parking brake pressure

1. Connect a pressure gauge to the brake system pressure test outlet (B).
B
1250 0020 22
Figure: Checking parking brake pressure
3. Release the parking brake while reading off the pressure on the pressure gauge.
The pressure should be 35 bar. The pressure can be adjusted on the pressure regu-
lator (13) under the control platform.
13
1250 0061 56
7
Figure: Regulating parking brake pressure
4. Stop the diesel engine and disconnect the pressure gauge from the pressure test
outlet.
121
7. Brake system
Bleeding the brakes

N.B.
The fluid in the brake system must not contain any air if the brakes are to attain
full effect. Make sure the rig is standing on a level surface with the wheels
chocked.
1. Attach plastic hoses to the nipples (C).
C
1250 0020 23
Figure: Bleeding the brakes
3. Open the nipples (C) about half a turn.

4. Fully depress the brake pedal (do not pump).
5. Tighten the nipples when there is no air in the fluid.
6. Turn off the diesel engine and remove the plastic hoses.
Checking brake discs

The brakes must be applied when checking brake disc wear. The discs can be
checked in connection with changing oil in the final gear.
1. Undo the level plugs on the central gear, one on each side of centre.
122
7. Brake system
2. Check the distance between the brake discs. Check the distance from both level
plugs. Use a drift or similar tool with diameter 4.5 mm.
1250 0021 36
min 4,5 mm
Figure: Checking brake disc wear
3. If the distance between the discs is less than 4.5 mm, they must be changed. A new
disc is 4.9 mm thick
Adjusting the brakes

N.B.
Make sure the rig is standing on a level surface and supported on its jacks.
1. Start the diesel engine and release the parking brake.
2. Undo bolt (A) and remove the lock plate (B) on both sides of the shaft and from
both the boom and engine shaft.
C B
+
-
1250 0020 24
Figure: Adjusting the brakes
123
7. Brake system
3. First screw the adjusting screw (C) anticlockwise to take up any play. Continue to
turn anticlockwise until a torque of 40 Nm is attained.
4. Then screw the adjusting screw (C) clockwise three turns.
5. Refit the lock plates (B) and the bolts (A).
Function check, parking brake

N.B.
This test must not be performed for longer than four (4) seconds as there is a risk
of overheating the hydraulic system.
1. Make sure the parking brakes are applied.
2. Start the diesel engine and engage 2nd gear.
3. Increase the diesel engine speed to max.
4. Check to see if the rig moves. If the rig moves, the brakes must be adjusted imme-
diately.
Note
The parking brake is applied if the oil pressure in the engine or hydraulic transmis-
sion drops too much. This will also be indicated by the warning lamps on the opera-
tor panel.
Function check, service brakes

N.B.
This test must not be performed for longer than four (4) seconds as there is a risk
of overheating the hydraulic system.
2. Depress the brake pedal and hold it down.
3. Release the parking brake.
4. Engage 2nd gear.
5. Gradually increase the speed of the diesel engine to max.
6. Check to see if the rig moves. If the rig moves, the brakes must be adjusted imme-
diately.
124
7. Brake system
Checking accumulator charge pressure
WARNING
• There will be accumulated brake pressure
of up to 150 bar in the brake circuit even
after stopping the engine. If the system is
opened without relieving this pressure,
oil will spurt out at high pressure.
1. Connect a pressure gauge to the pressure test outlet at (DS2).
DS2
1250 0061 55
Figure: Checking service brakes

2. Depressurise the system by depressing the brake pedal 30-40 times.
3. Disconnect fuse F112 in fuse box (A50) and crank the starter motor. The pressure
gauge will indicate a rapid increase in pressure to the lowest pressure with which
an accumulator is charged.
4. The pressure will subsequently rise very slowly. The accumulators are charged to
60-70 bar.
5. An accumulator with charge pressure lower than 35 bar is faulty and must be
changed.
6. For identifying which accumulator to change, see section Checking the accumula-
tors.
125
7. Brake system
Checking brake pressure control valve

1. Connect a pressure gauge to the pressure test outlet at DS2.
DS2
1250 0061 55
Figure: Checking brake pressure control valve
2. Start the engine and let it run until max. brake pressure is attained.
3. Stop the diesel engine and brake repeatedly. The "low brake pressure" lamp should
come on when the pressure has dropped to 110 bar.
4. Start the diesel engine and brake repeatedly with the engine idling. When the pres-
sure has dropped to 125 bar, the brake system control valve should engage so the
pressure rises again to max. for the brake system, 150 bar.
5. Stop the engine when max pressure is attained.
6. Brake hard four times, i.e. depress the pedal fully and release completely each
time. If the brake pressure drops below 90 bar after braking hard four times, there
is a fault in the brake system. This can be caused by:
a. air in the brake lines.
b. there is no charge pressure in an accumulator or the pressure is too low, e.g. due
to a broken diaphragm, see section Checking accumulator charge pressure.
7. Continue to brake hard until the pressure drops below 80 bar and the parking
brake is applied.
8. For identifying uncharged accumulators, see section Checking the accumulators.
Checking the accumulators

After detecting that there is no charge pressure in one or more accumulators or the
pressure is too low, each accumulator can be checked individually in a depressurised
system as follows.
126
7. Brake system
N.B.
Note that the system may still be pressurised even when the brake pressure gauge
(where fitted) indicates zero pressure.
Thorough cleanliness must be observed during all work on the brake system. Clean
all relevant contact points before starting work. Protect hoses and unions with
plugs and caps as they are detached.
1. Stop the engine.
2. Depress the brake pedal repeatedly (30-40 times) until the fluid stops flowing
through the brake valve. This can be noticed when the hissing sound heard when
the brake pedal is depressed ceases.
3. Connect a pressure gauge to the pressure test outlet in the accumulator circuit
being checked. All the accumulators must be checked individually. Watch out for
any pressure remaining in the brake system.
1250 0061 54
Figure: Measuring points in accumulator circuit

4. Carefully remove the connecting hoses on the accumulator block and plug them in
all the accumulator circuits except the one being checked first.
5. Disconnect fuse F112 in fuse box (A50) and crank the starter motor. The pressure
gauge at pressure test outlet (11) will first show a rapid increase in pressure to the
pressure the accumulator is charged with. This pressure should be at least 35 bar.
If this charge pressure is not attained, the accumulator must be scrapped and
replaced with a sound one. See section Scrapping an accumulator. The system
must then be depressurised before any measures are taken, after which it must be
rechecked.
6. Disconnect the tested accumulator and connect the next accumulator to be

checked. Repeat steps 4-6 and so on.
7. Start the engine and let it run at high speed until full brake pressure is attained.
127
7. Brake system
8. Reduce engine speed to idling. Bleed the brake system, see section Bleeding the
brakes.
Scrapping an accumulator
WARNING
• Pressure vessel
• A discarded accumulator must be made
harmless.
• A discarded accumulator that has not
been punctured must be handled as a
pressure vessel.
• Take care when draining the accumulator.
1. An accumulator can be scrapped by unscrewing the protective cap at the top.
2. Then, carefully unscrew the plug (P) with a hex key wrench, one turn at a time, to
release any pressure.
P
1250 0020 26
Figure: Scrapping an accumulator
128
8. Drill system
8. Drill system
DCS 1200 and DCS 1800

DCS (Direct Control System) 1200 and 1800 are drilling systems with directly oper-
ated valves that are controlled manually.
The drilling system comprises a number of sub-systems:
• Hydraulic systems
• Electrical system
• Water system
• Air and lubrication system
The hydraulic system includes one pump unit per rock drill.
Each pump unit comprises three pumps. A pressure-compensated axial plunger pump
that only supplies percussion. A further pressure-compensated axial plunger pump
that provides oil for feed, positioning, compressor, water pump and for the DCS 1800
also for the rock drill damper.
The electrical system supplies the electric motors for the hydraulic pumps, the lubri-
cating pumps, the lighting and the battery charger, and controls the solenoid valves.
Water is used to flush the cuttings from the borehole and to cool the hydraulic sys-
tem. A hydraulically powered booster pump on the rig increases the pressure to
ensure sufficient amounts of water are supplied to the borehole.
To lubricate certain parts, each rock drill is supplied with lubricant by an electric pis-
ton pump. The oil is distributed in the rock drill using compressed air from a hydrau-
lic screw compressor on the rig. This air also prevents debris from entering the rock
drill.
The drilling systems can be fitted with various options (optional equipment), e.g. a
reaming hole bit, extension drill rod, water flow monitor and air flushing equipment.
129
9. Hydraulic systems
Safety
CAUTION
system is depressurised before starting
work.
CAUTION
• Hazardous hydraulic oil and water
pressure.
• Never replace high pressure hoses with
hoses of lower quality than the originals
or with hoses fitted with removable
couplings.
Technical data
Hydraulic system M2/L2
Pumps, electric
Percussion pump
Type Axial plunger pump
Model A10V
Displacement 71cm 3 /rev
130
Positioning pump
Type Axial plunger pump
Model A10V
Displacement (rock drill 1238) 45cm 3 /rev
Displacement (rock drill 1838) 71cm 3 /rev
Rotation pump
Type Gear pump
Model P330
Displacement 48cm 3 /rev
Pump, diesel
Pump for positioning/steering and brake

Type Dual gear pump
Model, positioning/steering and brake P315
Displacement, positioning 20.3cm 3 /rev
Displacement, steering and brake 40.6cm 3 /rev
Tank module
Tank including oil, electric motors, hydraulic
pumps, etc.
Weight 1800kg
Hydraulic oil reservoir

Capacity min 200 max 250litres
Filter
Return oil filter
General
The return oil filter cleans the oil before it is returned to the tank.
A return oil filter comprises a tube containing three filter inserts. The tubes are
mounted inside the hydraulic oil reservoir.
131
The filter cartridges (1) must be replaced as described in the maintenance schedule
but if the pressure gauge used for the return filter (Grf) on the operator panel indi-
cates “Clogged filter” (the red zone on the scale), all return oil filters must be
replaced immediately.
1250 0094 24
Figure: Filter insert location, return oil filter (2-boom)
Note
The filter cartridges cannot be cleaned but must be replaced when they are clogged.
Changing the return oil filter

The filter inserts can be dismantled by removing the cover and lifting them up.
1. Clean on and around the filter cap and unscrew the nuts (A).
C
1250 0020 53
Figure: Changing filter
132
2. Lift off the cap (B) and change the O-ring (C) if it is damaged.
3. Lift up the whole filter canister by the handle.
4. Detach the pressure relief valve (E) by pressing down and turning the handle anti-
clockwise.
5. Take out the filter cartridges (D) and replace with new ones.
6. Refit the overflow valve and filter canister and screw on the cap.
Breather filter
General
There is a breather filter (A) on the rig that is used to compensate pressure differences
in the tank that would otherwise arise when the level in the tank changes e.g. if the
jacks are operated out/down.
1250 0021 15
Figure: Breather filter (2-boom)
The breather filter must be replaced as set forth in the maintenance 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.
133
Changing the breather filter

1. Wash clean on and around the filter (A).
1250 0021 15
Figure: Breather filter (2-boom)
2. Unscrew the old filter.
3. Fit a new filter.
4. Tighten the filter by hand.
Oil sampling
An oil sample gives a good indication of how well the hydraulic system has been
maintained.
The system is equipped with nipples that are used together with special equipment to
take oil samples. The nipples are located on the delivery line from the percussion
pump and positioning pump.
The oil sampling nipple has part number 3177 3016 00. The nipple can also be used
as a pressure test outlet for a pressure gauge.
Changing oil
General
If filter changing has been carried out in accordance with the instructions and oil
cooling presents no problems the hydraulic oil need not be changed. On the other
hand, if samples indicate that the oil is oxidised or contains a lot of water, it must be
changed. See maintenance intervals Percussion hours.
134
Draining
1. Underneath the hydraulic oil tank is a ball valve. On the ball valve there is a plug.
Remove the plug.
1250 0020 54
Figure: Ball valve underneath hydraulic oil tank
2. Screw a hose to the ball valve and place the other end of the hose into an empty oil
drum.
3. Drain the oil from the tank by opening the ball valve.
4. Close the ball valve once the oil has stopped running out of the hose.
5. Unscrew the hose.
6. Screw back the plug to protect the ball valve.
Filling up
General
New oil must only be filled with the filler pump fitted on the machine. This is
because the oil must be filtered before reaching the tank. This is achieved automati-
cally if the filler pump is used.
Note
Take into account that the position of the cylinders will affect the level in the tank.
Make sure all the cylinders are retracted.
If the tank is overfilled, the breather filter will be destroyed. In this case, the filter
must be changed. See section Filter: Breather filter.
135
Filling manually
1. Check the return oil filter, see section Filter: Breather filter.
2. Make certain all connections and hoses that are used to fill oil are clean.
3. Pump manually using hand pump (A).
B
C
1250 0094 19
Figure: Hydraulic oil tank hand pump

A Hand pump
B Oil level glass
C Thermometer
4. Check the level in oil level glass (B).
5. Stop pumping when the correct level is attained.
The correct level is obtained when oil becomes visible in the upper part of the oil
level glass.
Electric filling, option

1. Check the return oil filter, see section Filter: Return oil filter.
2. Make certain all connections and hoses that are used to fill oil are clean.
136
3. Press button (S195) to start pump (A).
M102
A50
S195
1250 0094 18
Figure: Electric filling, hydraulic oil tank

A Electric pump
B Oil level glass / Oil level tube
C Thermometer
S195 Button, start electric pump
4. Check the oil level in the level glass / level tube (B).
5. Release button (S195) when the correct level is attained.
The correct level is obtained when oil becomes visible in the upper part of the oil
level glass.
Draining condensation from the hydraulic oil

tank
Water in the hydraulic oil can seriously damage components in the hydraulic system
and cause corrosion.
Before draining the hydraulic oil tank, the system must stand unused for approx. 12
hours so that any condensation has had time to sink to the bottom of the tank. The
water can then be drained off through the ball valve on the bottom of the tank.
137
1250 0020 54
Figure: Ball valve underneath hydraulic oil tank
1. Underneath the hydraulic oil tank is a ball valve. On the ball valve there is a plug.
Remove the plug.
2. Place a receptacle under the ball valve.
3. Open the ball valve and allow the water to run out.
4. Close the valve when the water has been replaced with oil.
5. Screw back the plug to protect the valve.
138
Pumps
Power unit pumps
P1
P2
P3
1250 0046 21
Figure: Power unit pumps

P1 Percussion pump
P2 Positioning pump
P3 Rotation pump
Checking pump rotation direction

An arrow on the pump coupling housing indicates the correct direction of rotation.
1250 0046 24
Figure: Pump rotation direction
1. Start the pump and stop it again at once so that it rotates only a few turns. Check
the direction in which the motor-pump coupling rotates.
139
2. If the pump rotates in the wrong direction, reverse two of the phase leads in the
electric motor connection cable.
Note
This work is to be carried out by authorised electricians.
Starting a new or reconditioned pump

If the rig has been idle for a long time, or if a major intervention has been made in the
system (replacing or reconditioning components in the hydraulic system for example)
the following steps are to be carried out:
1. Fill the pump casing with oil.
2. Bleed air from the pump casing, see section Pumps: Bleeding the pumps.
3. Circulation-pump the system, see section Pumps: Circulating the pump.
Bleeding the pumps

1. Make certain that all hoses are connected to the pump.
2. Check the level of the hydraulic oil in the oil level glass on the hydraulic oil tank.
If filling is needed, see section Changing oil.
3. Remove plug (B).
The pump housing is now filled with oil via drain hose (A) connected between
pump and tank.
A
B
1250 0139 90
Figure: Hydraulic pump

4. Screw plug (B) into place when oil starts to run out of the plug hole.
The pump casing is now half full.
5. Loosen drain hose (A) somewhat.
The upper part of the pump casing will be filled while air escapes.
140
6. Tighten hose (A) when clean oil with no air bubbles runs out of it.
The pump casing is not completely full.
Circulating the pump

Note
The rig must be connected to water to prevent the oil temperature from rising too
high.
Circulation pumping must be carried out to make certain that any contaminants are
collected in the filter. This is done by connecting the delivery and return lines in the
percussion, rotation and feed circuits, and allowing oil to be pumped through the sys-
tem at no pressure for at least five minutes.
1250 0020 51
Figure: Principles for circulating the pump
1. Connect together the delivery and return hoses for the percussion unit with suita-
ble unions.
2. Connect together the delivery and return hoses for the rotation motor with suitable
unions.
3. Connect together the delivery and return hoses for the feeder's hydraulic cylinder
with suitable unions.
4. Start the hydraulic pump.
5. Start drilling.
6. Allow oil to circulate in the hoses for at least five minutes.
7. Stop the hydraulic pump.
8. Reconnect the hoses to their previous positions.
141
Hydraulic motors
Starting a new or reconditioned hydraulic motor

If the rig has been idle, or if a major intervention has been made in the system such as
replacing or reconditioning components in the hydraulic system, the following points
are to be carried out:
1. Fill the hydraulic motor at (A) with oil.
1250 0071 02
Figure: Hydraulic motor
2. Run the hydraulic motor for a few minutes.
3. Bleed the hydraulic motor by carefully opening the plug (A) a few turns.
4. Close plug (A) when pure oil without air runs out from (A).
The hydraulic motor is now filled with oil.
142
Settings
Safety
CAUTION
• Pressure settings are always performed
on a pressurised system. Always
exercise the greatest caution. Pressure
settings must only be performed by
trained personnel.
Illustrations showing locations

Locations of valves, pressure gauge outlet fittings and other components on rig, see
maintenance instructions, Component locations.
Pressure settings and rotation speeds

Suitable rotation speeds for the rock drill as well as suitable pressure for percussion
and anti-jamming depend on:
• the state of the rock

• type of drill bit
• diameter of drill bit
Pressure and speed can therefore require adjustment if the drilling conditions change.
The feed pressure must also be adjusted with regard to:
• dimension of drill steel

• type of feeder
• percussion pressure
It must be set so that there is no play in the threaded joints of the drill steel equipment
so that they are not damaged or suffer abnormal wear. It should not be so high that the
drill rods are subjected to abnormal loads or the risk of jamming increases.
143
Table: Pressure settings and rotation speeds

Small/
Reamin Valve /
Setting g hole Option Valve plate Value Read from
Percussion pressure for V2 130-140 bar Pressure gauge
collaring for percussion
unit Gh
Percussion pressure for full Vhp 180-230 bar Pressure gauge
drilling for percussion
unit Gh
Positioning pressure Vpp 210-230 bar Pressure gauge
outlet fitting G1
Positioning pressure V4 160-170 bar Pressure gauge
reduction for full drilling outlet fitting G1
Rotation speed Small V3a Depends on type of Drill steel rev
hole drill bit and its counter
diameter
Rotation speed Reaming Yes V3b Depends on type of Drill steel rev
hole drill bit and its counter
diameter
Rock drill damper pressure Vdp 40 bar Pressure gauge
Drilling system DCS 1800 for damper
pressure Gdp
Max feed pressure for full Vfm 120 bar Pressure gauge
drilling for feed Gf
Feed pressure for collaring Vfl 40 bar Pressure gauge
for feed Gf
Feed pressure for full drilling Small Vfh 65-120 bar Pressure gauge
hole for feed Gf
Feed pressure for full drilling Reaming Yes V6 50-70 bar Pressure gauge
hole for feed Gf
Feed pressure reverse, Yes 33 120 bar Pressure gauge
telescope feeder outlet 34
Pressure difference upper Yes 31 30-35 bar Pressure gauge
and lower feed cylinder, outlet 30
telescope feeder
Anti-jamming protection, Small/ No/Yes V1a/V1b 20 bar above Pressure gauge
RPCF Reaming normal rotation for rotation Gr
hole pressure during
drilling
Anti-jamming protection, feed Vaj 40 bar above Pressure gauge
return movement normal rotation outlet fitting G3
pressure during
drilling
144
Percussion pump
Safety valve
The percussion pump has a safety valve (CT4) located on valve plate (VB2). This
valve ensures that the system pressure can never exceed 280 bar.
VB2
CT4
1250 0067 58
Figure: Detail of valve plate (VB2)
1. To check the safety valve (CT4), plug the percussion unit hose at the rock drill.
2. Also plug hose XH2 and its nipple at the pump.
3. Start the pump.
4. Remove protective cap (2) for valve (Vhp).
3
4
1
2
1250 0064 77
Figure: Detail of valve (Vhp)

1 Setting the stand-by pressure
2 Setting max. pressure
5. Undo lock nut (3).
6. Screw in the adjusting screw (4) all the way.
145
7. Check that the pressure gauge reads 280 bar. Read the pressure from the pressure
gauge used for the percussion unit (Gh). It is located on the operator panel.
S105 Gr Gh Gf Gdp
Gl
S106
1250 0070 46
Vfl Vfh
Figure: Pressure gauges on the operator panel
Note
Take the following measures if the pressure needs adjusting.
8. Undo lock nut (5) on safety valve (CT4).
6
1250 0067 65
Figure: Detail of valve (CT4)
9. Adjust set screw (6) to provide the desired pressure of 280 bar. Read the pressure
from the pressure gauge used for the percussion unit (Gh). It is located on the
operator panel.
Screw in the screw to increase the pressure.
10. Tighten lock nut (5) which is used for valve (CT4).
11. When the safety valve is set properly, valve (Vhp) must be reset to the high per-
cussion pressure.
12. Then tighten the lock nut on valve (Vhp) and refit the protective cap.
13. Reconnect the hoses to their previous positions.
Sequence valve
The percussion pump has a sequence valve (CT6) that is located on valve plate
(VB2). This valve ensures that the stand-by pressure does not reach the hammer at
the neutral position. It must be set to 50 bar.
146
CT6
VB2
1250 0064 72
Figure: Detail of valve plate (VB2)
Stand-by pressure
Note
This is always set by the pump supplier.
Normally, the stand-by pressure need not be checked or adjusted. If you suspect that
the pump is not supplying a sufficient flow to the system, however, it may be a good
idea to check the stand-by pressure and adjust it if necessary.
1. Plug the percussion unit hose at the rock drill.
2. Connect a 60 bar pressure gauge to the hose (GH).
3. Start the pump.
4. Screw out the set screw all the way for valve (CT6), which is located on valve
plate (VB2).
CT6
VB2
1250 0064 72
Figure: Detail of valve plate VB2
5. Check that the stand-by pressure remains within an 18-25 bar interval.
Note
147
6. Remove protective cap (1) from valve (Vhp).
3 2
4
1250 0067 59
1
7. Adjust set screw (4) so that the pressure stays within an 18-25 bar interval. Read
the pressure from the pressure gauge connected to hose (GH).
8. Screw in the set screw used for valve (CT6) until there is no reading on the pres-
sure gauge. Then screw in the setting screw another half turn.
It will now be impossible for the stand-by pressure to reach the rock drill.
9. Refit protective cap (1) on the set screw used for valve (Vhp).
10. Reconnect the percussion unit hose.
11. Disconnect the 60 bar pressure gauge from hose (GH).
Percussion pressure
Collaring
The pressure is best adjusted during collaring.
1. Remove the protective cap used for valve (V2).
148
2. Undo the lock nut.
V2
Figure: Detail of valve (V2).
3. Start the pump.
4. Set the percussion unit lever (Lh) to its middle position (collaring).
5. Adjust the set screw for valve (V2) until the desired pressure of 130 bar is
attained. The pressure can be read on the pressure gauge for the percussion (Gh)
located on the operator's panel.
6. Tighten the lock nut.
7. Refit the protective cap.
Full drilling
The pressure is best adjusted during full drilling.
149
1. Remove protective cap (2) on valve (Vhp).
3
4
1
2
1250 0064 77

2. Undo the lock nut (3).
3. Start the pump.
4. Activate the percussion lever (Lh) to its front position.
5. Adjust socket head cap screw (4) to attain the desired pressure of 180-230 bar.
Read the pressure from the pressure gauge used for percussion unit (Gh). It is
located on the operator's panel.
6. Tighten the lock nut (3).
7. Refit the protective cap (2).
Positioning pump
Stand-by pressure
Note
This is always set by the pump supplier.
Normally, the stand-by pressure need not be checked or adjusted. If you suspect that
the pump is not supplying a sufficient flow to the system, however, it may be a good
idea to check the stand-by pressure and adjust it if necessary.
1. The anti-inductive protection (Y172) must be disengaged. Remove screw (A) and
pull out the connector.
150
Check that the gasket remains in place at the pin.
A
1250 0064 76
Figure: Detail of anti-inductive protection (Y172)
Note
The anti-inductive protection (Y172) is an electrical connection to the valve. By
removing the protection, the positioning pump will put in stand-by mode.
2. Start the pump.
3. Connect a pressure gauge to pressure test outlet (G1).
4. Make sure the pressure stays in the interval 18-25 bar.
Note
5. Remove the protective cap from setting screw (1) which is used for valve (Vpp).
3 2
4
1250 0067 59
1
Figure: Detail of valve (Vpp)
7. Adjust socket head cap screw (4) to attain the desired pressure of 18-25 bar. Read
the pressure from the pressure gauge connected to pressure test outlet (G1).
9. Refit the protective cap on the adjusting screw (1).
10. Re-engage the anti-inductive protection (Y172) by reconnecting the connector.
151
Check to see that the gasket is still in place.
A
1250 0064 76
Figure: Detail of anti-inductive protection (Y172)
11. Then screw together the anti-inductive protection (Y172) using screw (A).
Positioning pressure
2. Make sure all the control levers on the operator panel are in neutral.
3. Start the pump.
4. Remove the protective cap from adjusting screw (2) which is used for valve
(Vpp).
3
4
1
2
1250 0064 77
Figure: Detail of valve (Vpp)

6. Adjust socket head cap screw (4) to attain the desired pressure of 210-230 bar.
Read the pressure from the pressure gauge connected to pressure test outlet (G1).
8. Refit the protective cap (2).
Pressure reducing function for positioning pump

To prevent needless energy loss during full drilling, there is a pressure reducing func-
tion for the positioning pump.
152
Note
The basic pump settings must be made before setting the pressure reducing function.
2. Undo lock nut (1) which is used for pressure control valve (V4).
V4
2
1
1250 0067 61
Figure: Detail of pressure control valve (V4)
3. Undo lock nut (1) and unscrew set screw (2) for pressure control valve (V4).
4. Undo lock nut (A), used for sequence valve (V5).
V5 A
1250 0067 60 B
Figure: Detail of sequence valve (V5)
5. Screw in setting screw (B), used for sequence valve (V5), all the way.
6. Start the pump.
7. Activate drilling.
8. Adjust the percussion pressure to 160 bar, see section Percussion pressure; Full
drilling.
9. Screw out setting screw (B), used for sequence valve (V5), until the pressure
gauge connected to pressure test outlet (G1) reads 18 bar.
The pressure in question is the stand-by pressure.
10. Adjust setting screw (2), used for pressure control valve (V4), until the pressure
gauge connected to pressure test outlet (G1) reads 160 bar.
11. Lock the valve settings by tightening the lock nuts.
153
12. Re-adjust the percussion pressure to its former value, see section Percussion pres-
sure; Full drilling.
Rotation pump
Setting rotation speed
Small hole bit

1. If the rig is equipped with a special reaming hole kit (option), make sure that lever
(Lrb) is at the small hole position.
2. Start the pump.
3. Set the rotation lever (Lr) to its forward position (rotation drilling).
4. Measure the rotation speed with a rev counter on the drill steel.
Note
Take the following measures if the rotation speed needs adjusting.
5. Undo lock knob (B) on valve (V3a).
V3a
A
B
1250 0064 79
Figure: Detail of valve (V3a)

6. Set adjusting knob (A) until the desired speed is attained.
Screw in the screw to reduce the speed.
7. Tighten the lock knob B.
Reaming hole bit, option

1. Check that lever (Lrb) is in the reaming hole position.
2. Start the pump.
3. Set the rotation lever (Lr) to its forward position (rotation drilling).
154
4. Check the rotation speed using a drill steel rev counter.
Note
Take the following measures if the speed needs adjusting.
5. Undo the lock nut for valve (V3b).

1250 0067 72
V3b
Figure: Detail of valve (V3b)
6. Using a socket head cap screw, adjust the adjusting screw (V3b) to attain the
desired speed, which can be read on the rev counter.
Screwing the screw out reduces the speed.
Rock drill damper pressure

Note
Applies only to drilling system DCS 1800.
2. Start the pump.
3. Check that the pressure is 40 bar. Read the pressure from the pressure gauge used
for damper pressure (Gdp). It is located on the operator panel.
Note
155
4. Undo locking screw (A), used for adjusting knob (B) on valve (Vdp) using a
socket head cap screw.
B
A
1250 0064 80
Vdp
Figure: Detail of adjustable restrictor (Vdp)
5. Set adjusting knob (B) to attain the desired pressure of 40 bar. Read the pressure
from the pressure gauge used for damper pressure (Gdp). It is located on the oper-
ator panel.
6. Tighten locking screw (A).
Setting the pilot pressure and boom positioning pilot pres-

sure
1. Check that the pilot pressure is 35 bar by connecting a pressure gauge to pressure
test outlet (G2). The outlet for the pressure gauge is located at the boom position-
ing block.
Note
2. Undo the lock nut used for valve (V7).
V7
1250 0067 71
Figure: Valve used to adjust pilot pressure and boom positioning pilot pressure
(V7)
3. Adjust the setting screw to provide 35 bar. Read the pressure from the pressure
gauge connected to test pressure outlet (G2).
156
Positioning pressure with diesel power

Make the setting with the pressure control valve (Y203) on the rear frame valve
assembly. This is to be adjusted to 200 bar during diesel operation.
1. Connect a pressure gauge to pressure test outlet (A).
C
B
1250 0067 68 A
Figure: Valve section (Y203)
2. Start the diesel engine and activate the diesel engine positioning pressure.
3. Check that the pressure gauge reads 200 bar.
Note
4. Check that the one-way restrictors (B) are closed (turned all the way to the bot-
tom).
C
B
1250 0067 68 A
5. Remove the protective cap (C).
157
1
2
1250 0067 69
Figure: Detail of valve
7. Adjust setting screw (2) to provide the desired pressure of 200 bar. Read the pres-
sure from a pressure gauge connected to pressure test outlet (A).
Maximum pressure and speed of reeling units

In situations where it is not possible for the slip clutch on the reel gear to unwind the
hose/cable, the reel hydraulic motor can be used for unwinding. The winding-on and
winding-off speed can be adjusted by means of restrictors located beneath valve
(Y414) for the cable reeling unit and (Y415) for the water-hose reeling unit.
1. Connect a pressure gauge (250 bar) to pressure reducing valve (F).
1250 0064 45 A B
Figure: Valve section (Y414) and (Y415)
2. Adjust the pressure to 150 bar with the pressure reducing set screw (B).
3. Start the reeling unit for winding-in and winding-out.
4. Adjust the winding-in/out speed using restrictors (A).
• The speed for reeling in can be adjusted 10-12 rpm ( 1 rev each 5-6 seconds
).
• The speed for reeling out can be adjusted 5-6 rpm ( 1 rev each 10-12 seconds
).
During normal operation, the cable and hose reels must not be operated hydrauli-
cally when being reeled out. The cable and hose must be pulled out via the gear
friction coupling.
158
Setting water pump speed

1. Check that the maximum water pump speed reading is 3000 rpm. Read the speed
from the tachometer on the water pump hydraulic motor coupling.
Note
Take the following measures if the speed needs adjusting.
2. Adjust the water pump speed using flow valve (A) until the tachometer on the
water pump hydraulic motor coupling reads 3000 rpm.
1250 0064 49

Note
The output pressure will vary with the input pressure.
Note
The water pressure must not exceed 25 bar when drilling. If it does, the speed must
be reduced.
Speed control for air flow

1-boom and 2-boom rigs
Standard rig
1. Check that pressure gauge (Ga) on the operator panel reads 3 bar.
Note
Perform the following steps if the air pressure needs to be adjusted.
159
2. Screw out adjusting knob (A) on the flow regulator all the way.
F
A
1250 0066 69
3. Remove protective cap (E).
1
2
1250 0067 69
5. Adjust setting screw (2) until pressure gauge (Ga) reads 3 bar.
6. Tighten lock nut (1).
7. Screw in flow regulator (A) until the pressure begins to drop.
8. Then open the flow regulator a half turn.

9. Refit protective cap (E).
Rig equipped with air flushing, option
General
Setting the speed regulation used for air flow on a rig equipped with air flushing must
be done in three steps:
• Setting the compressor speed

• Loading and unloading the compressor
• Lubricating air pressure, see section Settings: Adjusting the ECL lubricating sys-
tem; Lubricating air pressure .
160
Compressor speed
1. To check compressor speed, both levers used for flushing (Law) must be moved to
the rear. They are located on the operator panel.
2. Measure the rotation speed using a rev counter on the compressor.
3. Check that the rev counter reads 4000 rpm.
Note
The compressor speed must not exceed 5400 rpm.
Note
Take the following measures if the rotation speed needs adjusting.
4. Screw out adjusting knob (A) on the flow regulator all the way.
F
A
1250 0066 69
Figure: Compressor section (Y171)
5. Remove protective cap (E).
1
2
1250 0067 69
7. Adjust set screw (2) to attain a reading of 4000 rpm on the rev counter.
8. Tighten lock nut (1).
9. Screw in flow regulator (A) until it starts to lower the compressor speed.
10. Open the flow regulator a half turn.
11. Refit protective cap (E).
161
Note
Valve (E) functions by adapting the speed of the compressor to the air pressure in the
tank. When the air pressure in the tank drops (high air consumption during flushing
for example), the speed increases. This causes flow regulator (A) to function as an
overspeed protector when the compressor is unloaded.
Loading and unloading the compressor

Note
The compressor pressure monitor must only be adjusted while the system is pressu-
rised. Otherwise, it can be damaged.
The following settings can be made on the compressor pressure monitor.
• Adjust the unloading pressure (setting knob in upper position)

• Adjust the difference between the unloading and loading pressures (setting knob
in the lower position)
1. Remove the locking pin (1) before adjusting the setting knob (2).
1 2
1250 0067 70
Figure: Compressor pressure monitor

2. Pull up setting knob (2) to the upper position to adjust the unloading pressure.
3. Adjust the compressor unloading pressure to 8 bar by adjusting the setting knob
(2). Read the pressure gauge (Ga) located on the operator panel.
Turning the setting knob clockwise causes the unloading pressure to increase.
Turning it anticlockwise causes the pressure to decrease.
4. Press setting knob (2) down to its lower position in order to adjust the difference
between the unloading and loading pressures.
5. Since the difference between the unloading and loading pressures is to be 2 bar,
setting knob (2) must be adjusted so that the compressor loads at 6 bar. Read the
pressure gauge (Ga) located on the operator panel.
162
Turning the setting knob clockwise causes the difference between the unloading
and loading pressures to increase. Turning it anti-clockwise causes this pressure
difference to decrease.
6. Replace locking pin (1).
Adjusting the ECL lubricating system
Metering lubricating oil

1. Start the pump.
2. Check that the LED (2) on the pulse relay in the electric cabinet indicates that
power is turned on.
ECL
Carlo Gavazzi
Recycler
24 V
Spec 3159
1
T1 T2
2
T1 T2
1250 0067 76
Figure: ECL pulse relay
3. Adjust screw (T1) so that the LED (1) is on for approx. 0.5 seconds.
4. Set the correct lubricating oil dosage using screw (T2) by inducing the LED (1) to
indicate 25-30 pulses/minute.
163
5. After each setting, check the lubrication pump LED (B) to see that the correct
pulse frequency is obtained and that oil is emerging from the front section of the
rock drill.
Gl
ECL
Carlo Gavazzi
Recycler
24 V
Spec 3159
T1 T2
B A
250 0067 77
Figure: ECL lubrication system

A ECL pulse relay
B LED on lubrication pump anti-inductive protection
G1 Pressure gauge for lubricant pressure. Located on operator panel.
Lubricating air pressure, option

Rigs equipped with air flushing have an air regulator that limits the air pressure used
for lubricating the rock drill adapter.
Setting the speed regulation used for air flow on a rig equipped with air flushing must
be done in three steps. See section Settings: Speed control for air flow; 2-boom rig;
Rig equipped with air flushing; General.
Gal
1
1250 0067 66
2
Figure: Pressure regulator with pressure gauge used for lubricating air pressure
164
2. Adjust the lubricating pressure to 3 bar using set screw (2). Read the value from
pressure gauge (Gal).
Lubricant level monitor, option

When the lubricant level monitor lamp (A) is on, it indicates that the lubricant level is
too low.
1250 0071 03
Figure: Lubricant level monitor
If the lubricant tank is not filled, the pumps will be stopped after five minutes.
If the pumps have stopped, it will suffice to fill the lube oil tank before the pumps are
started again.
Feed pressure
General
Note
Only applies to DCS 14/18.
The RPCF valve (V1a) must be disengaged while the feed pressure is adjusted. This
is done by screwing the RPCF valve (V1a) clockwise as far as it will go.
If the rig is equipped with a special reaming hole kit (option), there will be an RPCF
valve for reaming hole (V1b). This must also be disengaged while the feed pressure is
adjusted. (V1b) is to be disengaged in the same way as valve (V1a).
165
Lrb
V1a
V1b 1250 0102 27
Figure: Locations for (V1a) and (V1b) valves on DCS 14/18

V1a RPCF valve, standard
V1b RPCF valve for reaming hole, option
Max. feed pressure

The pressure must not be adjusted when drilling.
1. Place a wooden block (10-20 cm wide) in the feeder in front of the forward drill-
steel support so that the limit switch will not be activated.
3. Start the pump.
4. Run the rock drill towards the wooden block using lever (Lf).
Law Lr Lh Lf Lrb
1250 0102 26
Figure: Lever location (Lf)
166
5. Screw valve (Vfh) clockwise as far as it will go to disengage the valve.
Vfl Vfh
1250 0102 25
Figure: Location of valve (Vfh)
6. Undo the lock nut used for valve (Vfm).
Vfm
1250 0067 79
Figure: Detail of valve (Vfm)

7. Adjust the set screw to 120 bar.
Read the pressure from the pressure gauge used for the feeder (Gf). It is located on
the operator panel.
9. Reset valve (Vfh).
10. Run the rock drill back to its rear end position.
11. Turn off the pump.
12. Remove the wooden block.
167
Feed pressure for collaring

1. The percussion lever (Lh) must be at the middle position (low percussion pres-
sure) and the feed lever (Lf) must be at its forward position.
2. Undo the lock nut used for valve (Vfl).
Vfl Vfh
1250 0102 25
Figure: Location of valve (Vfl)
3. Adjust the collaring feed pressure with the socket head cap screw on valve (Vfl) to
40 bar.
4. Read the pressure from the pressure gauge used for the feeder (Gf). It is located on
the operator panel.
5. Tighten the lock nut used for valve (Vfl).
168
Feed pressure for full drilling in a small hole

Law Lr Lh Lf Lrb
1250 0102 26
Figure: Lever location (Lrb)
2. Loosen the lock knob used for valve (Vfh).
Vfl Vfh
1250 0102 25
3. Adjust the feed pressure for small hole drilling by means of the setting knob for
pressure control valve (Vfh) to 65-120 bar.
Turning the setting knob clockwise increases the feed pressure.
169
the operator panel.
S105 Gr Gh Gf Gdp
Gl
S106
1250 0070 46
Vfl Vfh
Figure: Pressure gauge location (Gf)
5. Tighten the lock knob used for valve (Vfh).
Note
The feed pressure for small holes sometimes has to be adjusted if there are significant
variations in the rock.
Feed pressure for full drilling of reaming holes, option

1. Check that lever (Lrb) is in the reaming hole position.
2. Remove the protective cap on pressure control valve (V6).
3. Adjust the feed pressure used for reaming holes using a socket head cap screw on
pressure control valve (V6) to 50-70 bar. Pressure control valve (V6) is located
beneath selector lever (Lrb).
Lrb
V6
1250 0062 38
Figure: Detail of valve (V6)
Turning the adjusting screw clockwise increases the feed pressure.
the operator panel.
170
Telescope feeder
General
Valve designations in brackets refer to the hydraulics diagram for telescope feeder.
The telescope feeder operates in two steps. Step 1 (lower cylinder) moves both beams
from fully extended position to fully contracted position. Step 2 (upper cylinder)
feeds the rock drill cradle forward on the upper beam.
1250 0072 80
Figure: Two-step operation of telescope feeder
The feed pressure during step 2 (upper cylinder) must be approx. 30-35 bar lower
than the feed pressure during step 1 (lower cylinder). This lower pressure is regulated
by a pressure control valve (31) and does not normally require adjustment.
Feed pressure for rock drill cradle

1. Adjust the feed pressure for the rock drill cradle by means of pressure reducing
valve (Vfh) on the operator panel.
Vfl Vfh
1250 0102 25
171
Turning the adjusting screw clockwise increases the feed pressure.
the operator panel.
Note
The feed pressure for the rock drill cradle sometimes has to be adjusted if there are
significant variations in the rock.
Pressure difference between upper and lower cylinder

The feed pressure for the upper cylinder should normally be approx. 30-35 bar lower
than the feed pressure for the lower cylinder. If the telescope feeder is not operating
satisfactorily, it may be necessary to adjust the pressure difference. A suitable setting
must be determined by trial and error in each individual case.
1. Connect a pressure gauge to pressure test outlet (30).
2. Check that the drill levers are in neutral.
4. Run the rock drill towards the wooden block using the feed lever.
5. Adjust the pressure on valve (31). Turning the valve knob clockwise will increase
the pressure difference.
Feed pressure, reverse

1. Connect a pressure gauge to pressure test outlet (34).
2. Check that the drill levers are in neutral.
4. Activate reverse feed. Read the pressure on the pressure gauge when the rock drill
cradle and upper feed beam are at their rear end positions. The pressure should be
120 bar.
5. Adjust the pressure as necessary on valve (33). Turning the adjusting screw clock-
wise will increase the pressure.
Locking the telescope feeder

The telescope feeder can be locked in collapsed position using the one-way restric-
tors (32) and (35). In this way the telescope feeder can be used as a “normal” feeder
with only the upper stage activated.
172
Anti-jamming protection
Description
There are two types of anti-jamming protection:
• RPCF (feed control)

• Return movement of the feeder, usually only called “anti-jamming”
The anti-jamming protection is integrated and interacts. The following is an example

to show what happens when the protection is activated and what the result is.
If the drill bit tends to jam in the hole due to e.g. joints in the rock, the rotation pres-
sure will start to increase and the feed pressure will drop successively to around 40
bar. If rotation pressure continues to rise, the feed will change direction and the rock
drill will return. As the rotation pressure subsequently drops, the rock drill will
change direction once more. If the drill bit still tends to jam, this procedure will con-
tinue until the bit has passed through the joint in the rock.
RPCF feed control

RPCF (Rotation Pressure Controlled Feed) is an anti-jamming device that is engaged
in the following circumstances:
• the drill bit tends to jam in the rock

• rotation pressure increases
• Broken/worn drill bit
• low hydraulic oil temperature
When RPCF is activated, the feed pressure will gradually drop until it almost reaches
zero.
Feed (rock drill) return movement

If RPCF is activated but the rotation pressure still rises then the second anti-jamming
protection will engage. This means that the feed will change direction so that the rock
drill reverses.
Setting the anti-jamming protection
General
To set the anti-jamming protection, you must make the following settings in the
sequence shown here:
• Setting the feed return movement

• Setting RPCF, small hole
• Setting RPCF, reaming hole (if the optional reaming hole kit is installed)
173
When the RPCF is to be set, there are two ways to proceed:
• Setting RPCF during drilling

• Setting RPCF in a workshop
“Setting RPCF during drilling” provides better adaptation to the state of the local
rock than “Setting RPCF in a workshop”. If, on the other hand, it is impossible to
drill, but you still want to set the RPCF valve/valves, you should choose “Setting
RPCF in a workshop”.
Setting the feed return movement

Note
The hydraulic oil must be at normal operating temperature before setting.
Valve (Vaj) must be used to set the rotation pressure at which the rock drill is to
change direction.
Vaj
1250 0067 53
Figure: Detail of valve (Vaj)
1. Check the rotation pressure during normal drilling. Read the rotation pressure
from pressure gauge (Gr). It is located on the operator panel.
3. Undo the lock nut used for valve (Vaj).
4. Adjust the set screw to 30-40 bar above the normal rotation pressure. Read the
pressure from a pressure gauge connected to pressure test outlet (G3).
Note
If the valve is adjusted too low, the rock drill will change direction too early.
If the valve is adjusted too high, the rock drill will not change direction and the
risk of jamming will increase.
6. Now set RPCF before making any further settings.
174
Setting RPCF during drilling

Note
Normal rotation pressure settings for drilling are 35-50 bar for small holes and 40-50
bar for reaming holes. If the pressure rises above the normal pressure, there is risk
that the drill steel will jam. The RPCF valve must thus be activated if the normal rota-
tion pressure rises by about 20 bar during drilling.
Valve (V1a) affects the rotation pressure at which the feed pressure will start to be
reduced for a small hole drill bit.
Note
If the rig is provided with a special reaming hole kit (option), the following settings
are also to be made for reaming hole valve (V1b).
Valve (V1b) affects the rotation pressure at which the feed pressure will start to be
reduced for a reaming hole drill bit.
Lrb
V1a
V1b 1250 0102 27
Figure: Locations of valves (V1a) and (V1b)
(Lrb) is in the correct position.
To set the small hole valve (V1a), the lever must be in the small hole position. To
set the reaming hole valve (V1b) the lever must be in the reaming hole position.
2. Find some homogeneous rock in the area being drilled.
3. Screw in the adjusting screw used for the RPCF valve all the way.
4. Collar the hole firmly and proceed to full drilling at a suitable feed pressure.
5. Read the rotation pressure from the pressure gauge used for rotation (Gr). It is
located on the operator panel.
175
6. Screw out the adjusting screw used for the RPCF valve until the feed pressure
starts to drop
7. Screw in the adjusting screw used for the RPCF valve about one turn.
One turn corresponds to about 20 bar of rotation pressure.
In other words, a 20 bar increase in the normal rotation pressure is needed during
full drilling before the RPCF function will start to reduce the feed pressure.
8. Tighten the RPCF valve lock nut.
Setting RPCF in a workshop
Setting
Note
Normal rotation pressure settings for drilling are 35-50 bar for small holes and 40-50
bar for reaming holes. If the pressure rises above the normal pressure, there is risk
that the drill steel will jam. The RPCF valve must thus be activated if the normal rota-
tion pressure rises by about 20 bar during drilling.
Lrb
V1a
V1b 1250 0102 27
Figure: Locations of valves (V1a) and (V1b)
reduced for a small hole drill bit.
Note
If the rig is provided with a special reaming hole kit (option), the following settings
are also to be made for reaming hole valve (V1b).
Valve (V1b) affects the rotation pressure at which the feed pressure will start to be
reduced for a reaming hole drill bit.
176
1. If the rig is equipped with a special reaming hole kit (option), make sure that the
lever is at the correct position.
To set the small hole valve (V1a), the lever must be in the small hole position. To
set the reaming hole valve (V1b) the lever must be in the reaming hole position.
2. Read the normal rotation pressure during drilling on the pressure gauge used for
rotation (Gr). It is located on the operator panel.
3. Run the rock drill back to is rear position on the feeder.
4. Screw out the adjusting screw all the way for the RPCF valve.
5. For “Setting RPCF in a workshop” jamming must be simulated.
One way to simulate jamming is to disengage the rock drill rotation hoses (RRR4)
and (RRL4), and then connect the hoses together with a cock/needle-valve (A).
RRR4
RRL4
1250 0067 73
Figure: Rock drill rotation hoses
RRR4
A
1250 0067 74 RRL4

Figure: Connecting the rotation hoses together with a needle valve
6. Set the rotation lever (Lr) to the forward position (rotation drilling).
7. Screw in needle valve (A) until the pressure gauge used for rotation (Gr) reads 60
bar. It is located on the operator panel.
8. Set the feed lever (Lf) to its forward position (forward feed).
9. Screw in the adjusting screw on the RPCF valve until the rock drill cradle starts to
move forward on the feeder.
10. Then screw out the adjusting screw used for the RPCF valve until the cradle stops.
11. Tighten the lock nut used for the RPCF valve.
12. Now check the functioning of the anti-jamming protection (before making any
further settings).
177
Setting
Note
Normal rotation pressure settings for drilling are 35-50 bar. If the pressure rises
above the normal pressure, there is risk that the drill steel will jam. The RPCF valve
must therefore be activated if the normal rotation pressure rises by about 20 bar dur-
ing drilling.
reduced.
Lr Lh Lf Vfl Vfh
Law
V1a
1250 0006 00
Figure: Operator panel

1. Read the normal rotation pressure during drilling on the pressure gauge used for
rotation (Gr). It is located on the operator panel.
2. Run the rock drill back to is rear position on the feeder.

3. Screw out the adjusting screw all the way for the RPCF valve.
4. For “Setting RPCF in a workshop” jamming must be simulated.
178
One way to simulate jamming is to disengage the rock drill rotation hoses (RRR4)
and (RRL4), and then connect the hoses together with a cock/needle-valve (A).
RRR4
A
1250 0067 74 RRL4

5. Set the rotation lever (Lr) to the forward position (rotation drilling).
6. Screw needle valve (A) in until the pressure gauge used for rotation (Gr) reads 60
bar. It is located on the operator panel.
7. Set the feed lever (Lf) to its forward position (forward feed).
8. Screw in the adjusting screw on the RPCF valve until the rock drill cradle starts to
move forward on the feeder.
9. Then screw out the adjusting screw used for the RPCF valve until the cradle stops.
10. Tighten the lock nut used for the RPCF valve.
11. Check the function of the anti-jamming protection before making any further set-
tings.
Function check
2. Open needle valve (A) slowly.
RRR4
A
1250 0067 74 RRL4

The rock drill must now start to move forward slowly while the rotation pressure
starts to drop.
3. Close needle valve (A) slowly.
The rock drill cradle must stop when the rotation pressure reaches about 65 bar.
179
4. Continue to close needle valve (A) slowly.
The anti-jamming protection is to be activated and the rock drill cradle is to

reverse direction when the rotation pressure reaches about 80 bar.
5. Set lever (Lrb) to the reaming hole position and repeat steps two to four.
6. Conclude by moving the rotation lever and feed lever to their neutral positions.
180
10. Compressor
10. Compressor
Safety
WARNING
• Hazardous system pressure and system
voltage.
• Never carry out maintenance while the rig
is in operation.
• Make sure that the hydraulic, water and
air systems are depressurised and that
the electrical system is without current
before starting any work on these
systems.
Compressor instructions
Compressor GAR 5
The rig compressor is a single-stage, hydraulic screw compressor. The compressor
starts when one of the rig's hydraulic pumps starts.
Compressed air from the compressor goes to an air reservoir that also acts as an oil
separator. In the air reservoir, most of the oil found in the oil and air mixture will be
removed through centrifugal force. The remaining oil is separated in an oil separation
element in the air reservoir. The separated oil collects in the bottom of the air reser-
voir, which acts as an oil tank.
181
10. Compressor
111
23(B366) 24
6 18 103
25
21 (Y210)
17 104
5
15
1250 0148 45
2 110
Figure: Compressor GAR 5 with air reservoir
Table: Compressor components

Locations Description Locations Description
2 Adjusting screw, belt drive 103 Minimum pressure valve
5 Drive belts 104 Oil level indicator
6 Air filter 110 Oil filler plug
15 Hydraulic motor 111 Safety valve
17 Oil cooler
18 Oil filter
21 Solenoid valve, loading
23 Temperature switch
24 Shunt valve
25 Intake valve
Checking oil level

Always check the oil level during operation. The compressor must be idling.
1. Unscrew and lift off the electrical connector from valve (Y210) to reduce the load
on the compressor.
2. Check the oil level on the level indicator (104).
Note
The oil level is sufficient when the black line on the level indicator is in the green
zone.
182
10. Compressor
Oil and oil filter
Safety
WARNING
• Hot fluids.
• Use goggles and suitable protective
clothing when handling hot fluids.
Changing oil and oil filter

1. It is easier to drain the old oil if it is warm. Therefore, always start by running the
compressor warm.
2. Stop the compressor and wait a few minutes. The compressor can be stopped by
stopping all the hydraulic pumps on the rig.
3. Ensure the air reservoir is depressurised by carefully disconnecting the hose

(CPAP) on the air reservoir.
18
CPAP
1250 0148 46
110
OD
Figure: Compressor and air reservoir
4. Drain the oil by opening the drain valve located at the end of hose (OD). Collect
the oil in a receptacle.
5. Unscrew the oil filter (18) located on the compressor.
6. Clean the filter seat and lubricate the new filter gasket.
183
10. Compressor
7. Screw the filter in place and tighten it by hand.
8. Remove the filler plug (110) from the air reservoir and fill up with fresh oil
(approx. 4.8 litres). For recommended oil. see maintenance instructions Lubri-
cants, coolants and propellants.
9. Replace the filler plug and tighten it.
10. Check the oil level, see section Checking oil level above. Top up with oil if nec-
essary.
Air reservoir
Safety
WARNING
• Hazardous air pressure in air reservoir.
• Danger of serious personal injury.
• Release the pressure from the air
reservoir before opening it.
Changing the separator element

1. Stop the compressor. The compressor can be stopped by stopping all the hydraulic
pumps on the rig.
184
10. Compressor
2. Ensure the air reservoir is depressurised by carefully disconnecting the hose

(CPAP).
x6
117
113
CPAP
1250 0148 47
Figure: Changing the separator filter
3. Unscrew the cap on the air reservoir (117).
4. Remove the separator element (113) and replace it with a new one.
5. Screw on the cap (117) on the air reservoir.
Changing air filter

1. Stop the compressor by stopping all the hydraulic pumps on the rig.
2. Remove the air filter (6). Discard the filter element if damaged.
3. Fit a new filter element.
4. Clean the dust separator in the air reservoir cap.
185
10. Compressor
Adjusting drive belts

1. Undo the cover.
2. Undo the hydraulic motor bolts (A).
1250 0099 07
Figure: Compressors without drive belt cover.
3. Adjust the belts with the belt tensioner nut (B).
Note
If correctly adjusted, it should be possible to press down the belt 5 - 6 mm with a
force of 25N half way between the two belt pulleys.
Safety valve
The air reservoir (oil separator) has a safety valve (111). If the rig is not fitted with
the air flushing option (with an extra compressed air tank), there will be an additional
safety valve for protecting the rock drill(s) against excess pressure.
The safety valve setting, part number and pressure setting are stamped on the valves.
Adjustments are not allowed. Never run the compressor without safety valve(s).
186
10. Compressor
Fault finding
Fault finding, compressor

111
23(B366) 24
6 18 103
25
21 (Y210)
17 104
5
15
1250 0148 45
2 110
Figure: Compressor GAR 5 with air reservoir
187
10. Compressor
23 24
18
1250 0148 48
Figure: Compressor GAR 5

18 Oil filter
23 Temperature switch
24 Shunt valve
Some possible faults and causes follow below. If in doubt, get in touch with Atlas
Copco.
Compressor will not start

• Temperature switch (23) triggered, temperature exceeding value (approx. 115ºC)
set with screw in centre of monitor.
Compressor starts but does not load

• Solenoid valve (Y210) faulty. Check the valve and replace if necessary.
• Intake valve (25) stuck closed.
• Leak in control air lines.
• Minimum pressure valve (103) leaking (after circuit has been vented).
Compressor will not unload, safety valve blowing

188
10. Compressor
• Intake valve (25) will not close.
Compressor air delivery or pressure lower than normal

• Air leak in connected equipment. Check and rectify.
• Air filter (6) blocked. Change filter element.
• Intake valve (25) will not open completely.
• Oil separator element clogged. Depressurise the air reservoir and change the sepa-
rator element.
• Safety valve (111) leaking. Change valve.
• Compressor element faulty.
Abnormal oil consumption or oil in outlet line

• Oil level too high. Depressurise the air reservoir and drain the oil to the correct
level.
• Incorrect oil causing frothing. Change to correct oil. Change oil separator element.
• Faulty oil separator element. Check element and change if necessary.
Oil in the air filter

• A faulty intake valve can result in oil being forced back into the air filter housing.
Replace the intake valve.
Safety valve blowing after loading

• Intake valve (25) faulty.
• Minimum pressure valve (103) faulty.
• Oil separator element clogged. Depressurise the air reservoir and change the ele-
ment.
• Faulty safety valve (111). Change safety valve.
Air outlet temperature higher than normal

• Air filter (6) blocked. Change filter element.
• Oil level too low. Top up with oil.
• Oil cooler (17) blocked. Clean cooler.
• Defective shunt valve (24). The shunt valve acts as a thermostat and admits oil to
the oil cooler at a certain temperature. The shunt valve should start to open at
approx. 65 °C and should be fully open at approx. 80 °C.
189
10. Compressor
• Faulty compressor element.
190
11. Air and water systems
Technical data
Hose dimensions
Incoming water line
Rigs with drilling system DCS 1200

Hose dimension, 1-boom rig 25 mm
1 inches
1 1/4 inches
1 1/2 inches
Rigs with drilling system DCS 1800

1 inches
Hose dimension, 2-boom rig 38mm
1 1/2 inches
2 inches
191
Safety
WARNING
• Hazardous water pressure.
• Make sure the system has been
depressurised before starting any
maintenance work.
Water pump
General
The water pump is hydraulically driven. The input water pressure should be at least 2
bar. The input pressure is regulated with a safety valve to a maximum 16 bar.
Checking the rotation direction

Note
The direction of rotation of the water pump must be checked after working on the
hydraulic circuit.
1. Check that the direction of rotation of the water pump corresponds with the arrow
(A) on the pump.
1250 0070 37
Figure: Direction of rotation of water pump
2. If the direction of rotation is incorrect, the delivery and return hoses on the motor
and/or valve must be switched.
192
Setting flow switches.

The flow switches (B141) monitor the flow of water during drilling, and also start the
water pump.
1250 0056 70 B141

Figure: Flow switches B141
1. Open the black plastic cover from the guard.
2. Undo the screw on top of the switch.
3. Adjust the sensor body (A) according to the adjustment interval (B).
1250 0061 57
Figure: Adjusting the flow

There are two triangles on the sensor body: one white and one red.
• A white triangle indicates adjustment interval for making contact.

• A red triangle indicates adjustment interval (B) for breaking contact.
Flow switch (B141) should be set as a making contact.
4. Once adjusted, tighten the screw and refit the plastic cover.
Note
The water flow switch must be adjusted so that the water pump always starts on drill-
ing.
193
Cleaning the water strainer

The strainer must be cleaned regularly to prevent the pressure from dropping too
much.
1. Connect a water supply to the water inlet (4) on the rig
Note
Connect the water supply to the water-hose reeling unit if the rig is equipped with
one.
5
6
3
1
4
2
1250 0137 14
Figure: Cleaning the water strainer

2. Make sure the connections are not fouled.
3. Open the main stop cock (3).
4. Open the cock (1) and let water run through the water strainer (5).
5. If the water strainer is severely soiled, undo the end piece (6).
6. Remove the strainer drum.
7. Clean the strainer drum or replace with a new one.
Freeze prevention measures
Draining the water system

1. Make sure the diesel engine and hydraulic pumps are turned off to avoid the risk
of damaging the water pump.
194
2. Connect air to water inlet (2).
5
6
3
1
4
2
1250 0137 14
Figure: Water inlet

3. Open cocks (1) and (3) to blow the water out through the reeling unit.
4. Close cock (3).
5. Move the lever (Law) forward, so that the water valve opens and the compressed
air expels the water from the system.
Law Lr Lh Lf Lrb
1250 0102 26
Figure: Section of operator panel
6. Repeat the above procedure for the other boom.
195
12. Electrical system, IEC and Australia
Safety
WARNING
• Dangerous voltage.
• Make sure the system is deenergised
before starting any maintenance work.
The electrical system may only be
serviced by an authorised electrician.
General
Safety standard
The electrical system complies with current Swedish regulations regarding high ten-
sion. Applied directives and standards are specified in Safety.
Low-voltage circuit
Low voltage refers to an alternating current with a voltage greater than 50 V and
less than or equal to 1000 V.
The rig's low-voltage circuit is a high-current circuit.
• Cable on reeling unit and collector

• Electric cabinet
• Electric motor(s) for hydraulic pump(s)
• Lighting (and extra low voltage)
• Operating circuits
• Service outlet
• Battery charger for carrier (also extra low voltage)
• Indicator lamps on electric cabinet
196
Extra low-voltage circuit

Extra low-voltage refers to an alternating current with a voltage less than or equal
to 50 V and direct current with a voltage less than or equal to 120 V.
• Guards in the system
• Battery charger for carrier (also low voltage)
• Lighting (and low voltage)
• Oil level switch
Before starting
Check, before starting, all high-current connections in the electric cabinet and the
collector, as well as the electric motors. Also, check that the plug is plugged in prop-
erly.
Cable marking
All the cables are marked with cable numbers corresponding to the wiring diagram.
Replacement of components
Whenever changing components, make sure the new component has the same Atlas
Copco part number as the old one. Mark new components with the same marking as
the ones they replace.
Electric cabinet, high-current
Indicator lamps
For information on the electric cabinet indicator lamps, see operator's instructions
Electrical system.
197
IEC standard
Inside
F01 F01 K51 P01 F25

1250 0104 10
K50 Q01
Figure: Electric cabinet A10, IEC standard

F01 Motor protection relay (one for each hydraulic pump unit)
F25 Earth fault breaker (personal protection)
K50 Phase sequence switch
K51 Earth fault relay (fire protection)
P01 Voltmeter, ammeter and hour counter
Q01 Main switch
198
Australian standard
Inside
1250 0106 46
1F01 3F01 2F01 K51 P01 F25 F20
K50 Q01
Figure: Electric cabinet A10, Australian standard

1F01 Motor protection relay, hydraulic pump 1
2F01 Motor protection relay, hydraulic pump 2
3F01 Motor protection relay, drain pump
K51 Earth fault relay (fire protection)
P01 Voltmeter, ammeter and hour counter
Q01 Main switch
Voltmeter, ammeter and hour counter

P01
1250 0104 12
V A1 A2 A3 T
Figure: Combined voltmeter, ammeter and hour counter
Gauge (P01) is a combined voltmeter, ammeter and hour counter. With the five dif-
ferent buttons, you can select what to display in the gauge's window. The LEDs under
the buttons indicate what buttons are activated.
Press button (V) to check that the input voltage to the rig complies with the rated
voltage specified on the rig's data plate.
199
Buttons (A1-A3) display current consumption of the hydraulic pump electric motors.
How many buttons to push varies from rig to rig and depends on how many hydraulic
pump units are fitted on the rig. When the rig is in operation, you can make sure the
motors are not overloading by comparing the value shown on the gauge with the
rated current specified on the electric motor data plate.
Button (T) is used to show the operating hours of the percussion. The operating hours
that are shown in the display window (for which hydraulic pump unit) depends on
what buttons (A1-A3) are activated.
Electrical system protection
Main switch
General
The main switch (Q01) is on the 3-phase circuit in the electric cabinet. It has a knob
for on and off. The main switch has as standard under-voltage protection, thermal
overload protection and magnetic short-circuit protection.
The switch can be reset after being triggered by turning the knob to position 0 (OFF)
and then back to position 1 (ON).
Note
On rigs with the Australian standard electrical system, the main switch does not have
under-voltage protection.
200
Main circuit breaker dip switches
0.4 L OFF I TEST

0.5 1.5 15V dc
0.6 2
0.7 I1 4 In= 400 A +
I3
0.8 6
8
_
0.9 InN= In/2
0.95 10
x In
1 x In 12
A 3s
1250 0006 75
B 6s t1
C 12s
D 18s I=6I1 SACE PR211
Q01
Figure: Main circuit breaker Q01

I1 Dip switches for setting overload protection
t1 Dip switches for setting overload duration
I3 Dip switches for setting short circuit protection
Overload protection
The overload protection setting is dependent on the supply voltage and total electric
motor output.
The setting is made with DIP switches (I1) on the main circuit breaker. Next to the
DIP switches is a mark indicating the different setting alternatives. Check the follow-
ing table to see what setting to use.
The duration (t1) should be set to 18 seconds in all cases.
Table: Setting, main switch overload protection

Power supply Electric motors Setting
380 - 690 V 1 x 55 kW 0.4 x 400 A
380 - 690 V 1 x 75 kW 0.4 x 400 A
380 - 400 V 2 x 55 kW 0.6 x 400 A
201
Power supply Electric motors Setting

380 - 400 V 2 x 75 kW 0.8 x 400 A
440 V 2 x 55 kW 0.5 x 400 A
440 V 2 x 75 kW 0.7 x 400 A
500 V 2 x 55 kW 0.5 x 400 A
500 V 2 x 75 kW 0.6 x 400 A
550 V 2 x 55 kW 0.4 x 400 A
550 V 2 x 75 kW 0.5 x 400 A
660 - 690 V 2 x 55 kW 0.4 x 400 A
660 - 690 V 2 x 75 kW 0.4 x 400 A
1000 V 2 x 55 kW 0.4 x 320 A
1000 V 2 x 75 kW 0.4 x 320 A
Short circuit protection

The settings for the short-circuit protection depend on the method of starting.
The setting is made with DIP switches (I3) on the main circuit breaker. Next to the
DIP switches is a mark indicating the different setting alternatives.
For rigs with Y/D start, the short-circuit protection should be set to 4 x the switch's
rated current (In).
For rigs with direct start, the short-circuit protection should be set to 10 x the switch's
rated current (In).
Phase sequence switch

If the phase sequence fault indicator lamp comes on, the following measures must be
taken by a qualified electrician.
The electrical system has a phase sequence switch (K50) to prevent the electric
motors from starting if the power supply has the wrong phase sequence. If there is a
phase sequence problem, an indicator lamp on the electric cabinet will come on, see
operator's instructions Electrical system.
1. Turn off the main switch for the input cable and pull out the plug.
2. Switch two of the phases in the consumer mains source.
Earth fault equipment

IEC standard
The electrical system has an earth fault relay (K51) and an earth fault breaker (F25).
202
The purpose of the earth fault relay (K51) is to protect the rig from fires in the main
circuit. This breaker is set by the supplier to 300 mA and 0.5 seconds.
The earth fault breaker (F25) provides personal protection. It is included in the trans-
former circuit for the work lighting and service outlet 230 V AC. This breaker is set
to 30 mA and max. 40 ms.
The earth fault equipment should be tested regularly by a qualified electrician.
The earth fault equipment settings are checked prior to delivery and the equipment
sealed.
Australian standard
The electrical system has an earth fault relay (K51) and an earth fault breaker (F25).
The earth fault relay (K51) protects the outlet for the submersible pump. This breaker
is set by the supplier to 30 mA and max. 40 ms.
former circuit for the work lighting and service outlet 230 V AC and for feed to the
power supply cubicle (A40). This breaker is set to 30 mA and max. 40 ms.
The earth fault equipment should be tested regularly by a qualified electrician.
The earth fault equipment settings are checked prior to delivery and the equipment
sealed.
203
Motor protection
Electronic motor protection relay

1 2 3 4
6
7 5
1250 0104 15
Figure: Electronic motor protection relay (F01)

1 Indicator for overheating
2 Indicator for phase loss and phase error
3 Indicator for overcurrent and thermal overload
4 Indicator for motor protection in operating position
5 Reset button
6 Setting rated current
7 Setting triggering time
Each hydraulic pump motor has an electronic motor protection relay (F01), which is
equivalent to a thermistor relay and a thermoelectric relay.
The motor protection has a green LED (4) that indicates that the power supply is on
and that the output relay is in operating position. If the engine protection is triggered,
the LED goes out.
The motor protection has three LEDs (1, 2 and 3) to indicate which type of fault has
triggered the protection.
LED (1) comes on when the permitted motor temperature is exceeded (overheating).
LED (2) comes on in the event of a phase loss or a phase error.
LED (3) flashes when the permitted engine current is exceeded (overcurrent). If this
continues for a long period of time, the LED will shine constantly and the motor pro-
tection will trigger due to motor overload (thermal overload).
If the motor protection has been triggered

1. Check which LED (1, 2 or 3) is on and rectify the cause of the stoppage.
a. LED (1) is on. Check that the electric motor is properly cooled.
b. LED (2) is on. Turn off the main switch for the input cable and pull out the plug
from the wall socket. Then check the cables in the motor circuit and the electric
motor.
204
c. If LED (3) flashes, this indicates that the motor current exceeds the set rated
current and that the motor protection can soon be triggered.
If the LED starts to shine constantly and the motor protection is triggered,
check that the power supply complies with the rated voltage on the rig's data
plate. If the voltage is correct, check the motor circuit, see item b above.
2. Once the cause of the stoppage has been rectified, reset the motor protection with
button (5).
Setting rated current

The motor protection must be set to the rated current of the motor unless the motor
has a service factor (SF) higher than 1.0.
• If the service factor is 1.15, the motor protection must be set to a value 15% higher
than the rated current.
• If the service factor is 1.3, the motor protection must be set to a value 30% higher
than the rated current.
The rated current and service factor are specified on the motor's data plate.
The motor protection has a basic setting of 20A that must be taken into consideration
when setting. The setting must consequently be 20A lower than the rated current or
20A lower than the rated current x the service factor (1.15 or 1.3).
Adjust settings using the DIP switches on the motor protection. Two examples fol-
low .
205
1. Electric motor with rated current of 85 A. Rated current - basic value = 85 - 20 =

65 A.
OFF ON
+1
1
+2
2
+3
3
+5
4
+10
5
6 +20
+40
7
+80
8
1250 0104 16
Figure: Setting, example 1
2. Electric motor with rated current of 81 A and service factor 1.15. Rated current x
service factor - basic value = (81 x 1.15) - 20 = 73 A.
OFF ON
+1
1
+2
2
+3
3
+5
4
+10
5
+20
6
+40
7
+80
8
1250 0104 17
Figure: Setting, example 2
206
Setting triggering time

The triggering time for the motor protection should be set to 18 seconds. Set using
the DIP switches on the motor protection.
OFF ON
+2
1
+4
2
+8
3
+16
4
1250 0104 18
Figure: Setting triggering time, 18 seconds
Power supply cubicle
General
The power supply cubicle (A40) supplies the rig's 24 V system. The cubicle has room
for three power supply units (1, 2 and 3). The number of power supply units depends
on the number of power consumers on the rig.
The supply voltage to the power supply units must be 220-240 V AC ± 10%, 44-66
Hz.
207
POWER-ONE POWER-ONE POWER-ONE
POWER ON POWER ON POWER ON
O.V. SHUTDOWN O.V. SHUTDOWN O.V. SHUTDOWN
7 8
ALARM ALARM ALARM
1 2 3
1 2 + - - -
F124
K107
F100 15A
F101 15A
F102 15A
F104 15A
F105 15A
10 10 11 11 3 4 5 23 52 0
K110
N109
1250 0133 56
1 2 + - - -
F124
F100 15A
F101 15A
F102 15A
F104 15A
F105 15A
10 10 11 11 3 4 5 23 52 0
Figure: Power supply cubicle A40
Each power supply unit has three indicator lamps. If none of these lamps are on, it is
likely that the fuse (A) on the back of the unit needs changing.
POWER-ONE
POWER ON
O.V. SHUTDOWN
A
ALARM
1250 0133 58
Figure: Fuse, back of power supply unit
Check regularly that the cooling fan in the power supply cubicle is working. If the fan
ceases to work, there is a great risk of the power supply unit overheating and ceasing
to work.
Setting charge voltage

If one of the power supply units (1, 2 or 3) has been changed, the charge voltage must
be set on the new unit. Measure the set voltage between 7(+) and 8(-) using a voltme-
ter, see the illustration above. The set voltage should lie between 26.6 - 26.8 V DC.
1. Unscrew and remove the other power supply units, if there is more than one unit.
208
2. Use a long screwdriver to adjust the charge voltage for each unit as follows.
a. Power supply unit 1, adjust on potentiometer P11.
b. Power supply unit 2, adjust on potentiometer P21.
c. Power supply unit 3, adjust on potentiometer P31.
P11
P21
POWER-ONE
PL20
POWER-ONE
P31
POWER ON POWER ON
O.V. SHUTDOWN O.V. SHUTDOWN
ALARM ALARM
POWER-ONE POWER-ONE
POWER ON POWER ON
O.V. SHUTDOWN O.V. SHUTDOWN
ALARM ALARM
1 3
1 3
K107
K110
N109
1 2 + - - -
F124
1250 0133 57
F100 15A
F101 15A
F102 15A
F104 15A
F105 15A
10 10 11 11 3 4 5 23 52 0
Figure: Setting charge voltage
3. Refit the other power supply units.
Cable recommendations
Table: Recommended cables for different rated voltages
Rated voltage (V) Cable type Dimension (mm2) Diameter (mm) Length (m)
400 H07RN-F 4G150 67 60
440 H07RN-F 4G120 60 75
440 BUFLEX 3x150+3G25 52 100
460 - 500 H07RN-F 4G120 60 75
460 - 500 BUFLEX 3x150+3G25 52 100
500 - 550 H07RN-F 4G95 55 90
500 - 550 BUFLEX 3x120+3G25 46 135
660 - 700 H07RN-F 4G70 49 110
660 - 700 BUFLEX 3x95+3G16 42 155
1000 BUFLEX 3x50+3G10 32 275
209
Fault finding
Before starting fault finding, check that:
• all fuses are intact and turned on.

• the correct power supply is connected to the rig (see voltmeter).
• all warning lamps on the electric cabinet are in working order (lamp test).
210
13. Electrical system, Canada
Safety
WARNING
General
Safety standard
The electrical system complies with current regulations. Applied directives and
standards are specified in the Safety chapter. See chapter Safety.
Low-voltage circuit
Low voltage refers to an alternating current with a voltage greater than 50 V and
less than or equal to 1000 V.
The rig's low-voltage circuit is a high-current circuit.
• Cable on reeling unit and collector

• Electric cabinet
• Electric motor(s) for hydraulic pump(s)
• Lighting
• Service outlet
• Battery charger for carrier (also extra low voltage)
• Indicator lamps on electric cabinet
211
Extra low-voltage circuit

Extra low-voltage refers to an alternating current with a voltage less than or equal
to 50 V and direct current with a voltage less than or equal to 120 V.
• Guards in the system
• Battery charger for carrier (also low voltage)
• Lighting
• Oil level switch
Before starting
Check, before starting, all high-current connections in the electric cabinet and the
collector, as well as the electric motors. Also, check that the plug is plugged in prop-
erly.
Cable marking
All the cables are marked with cable numbers corresponding to the wiring diagram.
Whenever changing components, make sure the new component has the same Atlas
Copco part number as the old one. Mark new components with the same marking as
the ones they replace.
212
Electric cabinet, high-current
Front
SH06 H04 H03 SH02
Q01
P01 1P01 2P01
1P02 2P02
1250 0106 44
S11 S12
Figure: Electric cabinet A10, front

Q01 Main switch
SH06 Indicator lamp, main power
H04 Indicator lamp, low hydraulic oil level
H03 Indicator lamp, phase sequence fault
SH02 Indicator lamp, motor overload
P01 Voltmeter
1P01 Ammeter, electric motor 1
2P01 Ammeter, electric motor 2
1P02 Hour counter, percussion 1
2P02 Hour counter, percussion 2
S11 Motor switch, electric motor 1
S12 Motor switch, electric motor 2
213
Inside
1Q02 2Q02 F25 K50 1K04 2K04
Q01
1F01 2F01
1250 0107 06
Figure: Electric cabinet A10, inside

1F01 Electric overload protector, electric motor 1
2F01 Electric overload protector, electric motor 2
F25 Earth fault breaker
1K04 Thermistor relay, electric motor 1
2K04 Thermistor relay, electric motor 2
Q01 Main switch
1Q02 Circuit breaker, electric motor 1
2Q02 Circuit breaker, electric motor 2
Electrical system protection
Main switch
General
The main switch (Q01) is on the 3-phase circuit in the electric cabinet. It has a knob
for on and off. The main switch has as standard under-voltage protection, thermal
overload protection and magnetic short-circuit protection.
The switch can be reset after being triggered by turning the knob to position 0 (OFF)
and then back to position 1 (ON).
Main circuit breaker short-circuit protection

The short circuit protection should be set to 10 x the breaker's rated current (In).
214
Phase sequence switch

The electrical system has a phase sequence switch (K50) to prevent starting the elec-
tric motor in the event of a phase fault in the user's power socket. In case of a phase
sequence fault, the indicator lamp on the electric cabinet will come on, see section
Electric cabinet, high-current.
If the phase sequence fault indicator lamp comes on, the following measures must be
taken by a qualified electrician.
1. Turn off the main switch for the input cable and pull out the plug.
2. Switch two of the phases in the consumer mains source.
Earth fault breaker

former circuit for the work lighting and service outlet 230 V AC. This breaker is set
to 30 mA and max. 40 ms.
The earth fault breaker should be tested regularly by an authorised electrician.
Motor protection
Electronic overload protection

Each hydraulic pump motor has electric overload protection (F01).
The overload protection must be set to the electric motor's rated current x 1.15 by
turning the knob (1) to the correct position. The rated current is specified on the elec-
tric motor data plate.
The overload protection is reset with the RESET button (2).
215
TRIP = 125% PWR
135
10 20 105
CLASS 90
75 45
TRIP 60
1250 0107 10
2
Figure: Electronic overload protection
Circuit breaker
Each hydraulic pump motor has a circuit breaker (Q02).
The circuit breaker short-circuit current must be set to 875A with the know (A) as
illustrated in the figure.
An activated circuit breaker is reset by moving switch (B) to position 0.
1400 A
1200 A 1550 A
1000 A 1650 A
Min Max
875 A 1750 A
Min Max
I
250 A
0 250
600 V ~
I
1400 A
1200 A 1550 A
B
1000 A 1650 A
Min Max
875 A
0 250
1750 A
Min Max
1250 0107 39
Figure: Circuit breaker
216
Power supply cubicle
General
The power supply cubicle (A40) supplies the rig's 24 V system. The cubicle has room
for three power supply units (1, 2 and 3). The number of power supply units depends
on the number of power consumers on the rig.
K110
1 2 3
1250 0104 85
7 8
Figure: Power supply cubicle A40

Each power supply unit has three indicator lamps. If none of these lamps are on, it is
likely that the fuse (A) on the back of the unit needs changing.
POWER ON
A
O.V. SHUT-DOWN
ALARM
1250 0104 86
Figure: Fuse, back of power supply unit
217
Setting charge voltage

If one of the power supply units (1, 2 or 3) has been changed, the charge voltage must
be set on the new unit. Measure the set voltage between 7(+) and 8(-) using a voltme-
ter, see the illustration above. The set voltage should lie between 26.6 - 26.8 V DC.
1. Unscrew and remove the other power supply units, if there is more than one unit.
2. Use a long screwdriver to adjust the charge voltage for each unit as follows.
a. Power supply unit 1, adjust on potentiometer P11.
b. Power supply unit 2, adjust on potentiometer P21.
c. Power supply unit 3, adjust on potentiometer P31.
P21 P31
POWER ON
O.V. SHUT-DOWN
POWER ON
O.V. SHUT-DOWN
ALARM
ALARM
1
1
1250 0104 20
P11
Figure: Setting charge voltage

3. Refit the other power supply units.
Fault finding
Before starting fault finding, check that:
• all fuses are intact and turned on.

• the correct power supply is connected to the rig (see voltmeter).
• all warning lamps on the electric cabinet are in working order (lamp test).
218
14. Component locations
Component locations
Electric and hydraulic components
Electrical cabinets and electric boxes
A74
A52 A40 A50 A55 A58 A72 A59 A72
A51
A57
A54
A41
A62
A10
A61
A71 A73
1250 0051 15
A70
Figure: Location of electrical cabinets and electric boxes
219
Guards
1250 0102 17
Figure: Location of monitors
Table: Guards
Designation Description Designation Description
B138 Percussion hour pressure switch B145 High temperature switch
B141 Water flow monitor B186 Automatic boom lubrication
B143 Pressure switch (low oil level) B188 Air pressure switch
220
Electrically controlled valves

1250 0102 16
Figure: Location of electrically controlled valves
Table: Electrically controlled valves

Valves Description Valves Description
Y106 ECL pump Y411 Front left jack
Y114 Cease drilling without water flushing Y412 Front right jack
Y156:5 Idling pump Safe Bolting System Y414 Cable reel winding/unwinding speed
Y162 Water pump speed Y415 Water-hose reel winding/unwinding
speed
Y171 Speed control for air flow Y423 Extended front jacks
Y172 Loaded positioning pump Y436 Protective roof pillar, left
Y174 Water by-pass Y437 Protective roof pillar, right
Y203 Positioning pressure with diesel power Y450 Anti-parallel
Y210 Compressor charging Y531 Swellex pump
Y410 Rear jacks
221
Hydraulically controlled valves
Vfm Vaj V3b V6 V7
DCS 1200 DCS 1800

V2 V2
1250 0102 23
Vhp Vpp Vdp VB2 V3a V4 V5
Figure: Location of hydraulically controlled valves
Table: Hydraulically controlled valves

Valves Description Valves Description
Vhp Percussion pump stand-by pressure V3b Rotation speed, reaming bit
and max pressure
Vpp Positioning pump stand-by pressure V4 Positioning pressure reduction
and maximum pressure
Vdp Rock drill damper pressure V5 Positioning pressure reduction
Vfm Max feed pressure for full drilling V6 Feed pressure for full drilling, reaming
hole
Vaj Rotation pressure, jamming V7 Pilot pressure and boom positioning
pilot pressure
V2 Percussion pressure, collaring VB2 Percussion pump valve block
V3a Rotation speed for small hole bit
222
Pressure gauges and test outlets
G1 G3 G2
Gal
G1 G3
Gal
G1, G2, G3
1250 0064 71
Figure: Location of pressure gauges and test outlets
Table: Pressure gauges and test outlets

Component Component
designation Description Function designation Description Function
G1 Test outlet Positioning G3 Test outlet Rotation
pressure pressure, feed
return
G2 Test outlet Pilot pressure and Gal pressure gauge Lubricating air
boom positioning pressure
pilot
223
15. Reeling units
15. Reeling units
Cable reeling unit
B
1250 0146 20
Figure: Cable reeling unit

A Gear with motor
B Collector
C Drive chain
224
15. Reeling units
Hose reeling unit
1250 0148 49
A
Figure: Hose reeling unit
A Gear with motor
General
The reeling unit is controlled by a hydraulic motor. Unwinding from the reel while
travelling takes place by allowing the clutch on the reel gear to slip. The unwinding
control should be left in neutral. Winding is done with the help of a hydraulic motor.
The slip clutch must be adjusted so that it is able to wind up the cable/hose hydrauli-
cally but can still slip when the cable is being unwound during travel.
Reeling unit gear

B
C
A
1250 0148 51
D
Figure: Reeling unit gear
A Oil level glass
B Set key for adjusting reel torque.
C Set screw for adjusting drive chain (not direct drive)
D 4 bolts, attachment for reeling unit gear.
225
15. Reeling units
1. Check the oil level through the level glass (A) regularly. Top up when necessary.
See maintenance schedule Diesel engine hours.
Adjusting reeling unit drive chain

1. Undo the four bolts (D) holding the gear.
B
C
1250 0148 51
D
2. Adjust the chain using the set screw (C). The chain slack should be 10-15 mm.
3. Tighten the four bolts (D).
Adjusting the reeling unit slip clutch

The slip clutch should slip when winding in the electric cable or water hose. The
torque, which is conveyed by oil in the gear, should be measured in operation while
the clutch is slipping and is only to be adjusted hard enough to lift and wind the cable
or hose without any slack.
For fault-free operation and retained torque, the oil in the gear must be changed regu-
larly.
The setting is done with small adjustments to the spring package, 1/6 of a turn at a
time, after which the operation is tested and adjusted again if necessary.
The following torque is recommended.
Cable reeling unit: Torque in operation on drum periphery to be adjusted so that it

corresponds to 25-30 kg (max 40-50 kg).
Hose reeling unit: Torque in operation on drum periphery to be adjusted so that it

corresponds to 10-15 kg (max 15-20 kg).
226
15. Reeling units
N.B.
The gear and chain can be damaged while winding out the cable or hose if the
clutch is set too hard. Always turn off the hydraulics when not using the reeling
units.
1. Screw out the set key (B).
B
C
D 1250 0148 51
2. Insert the set key upside down into the gear housing.
3. Rotate the drum slowly until the set key falls into locked position.
4. The torque will increase as the drum is turned half a turn clockwise and decrease if
turned half a turn anticlockwise.
5. Remove the set key.
6. Check the torque. Repeat the procedure if further adjustment is required.
227
15. Reeling units
Collector, cable reeling unit
Collector F460/1 and K4122/1
A
1250 0020 33
Figure: Changing collector

A Collector
Checking the collector
WARNING
The location of the collector depends on the type of rig. On some rigs, the collector is
located inside the cable reeling unit protected by a cover plate that must be removed
during inspection. On other rigs, the collector is located in a protective box mounted
on the outside of the reeling unit.
After about a week's use, the nuts on all the cable terminals on a new or reconditioned
collector must be retightened. The collector slip rings must be retightened according
to the torque table.
228
15. Reeling units
1. Make sure the collector housing and collector rings are dry, clean and free from
oil, copper deposits and other impurities.
2. Use a vacuum cleaner, clean cloth and a brush for cleaning.
Note
NEVER USE WATER OR COMPRESSED AIR.
3. Replace damaged components with new ones.
4. Make sure the protective cable stocking is fitted properly.
Settings
See maintenance instructions Hydraulic system: Settings for setting the speed of the
reeling units.
Limit switch, option
Description
The task of the limit switch is to:
• warn when there are only three turns left on the drum of the cable reeling unit.
• activate the parking brake when there is one turn left on the drum of the cable reel-
ing unit.
Adjusting
Adjust the limit switch contactors if the cable on the reel is changed or if their set-
tings are inadvertently changed.
229
15. Reeling units
1. Remove the limit switch cover (1).
Figure: Limit switches
2. Slacken the lock screw (A).
A B C
E
1250 0113 97
Figure: Lock screw, set screw and contactors
3. Run out the cable until there are three turns left on the drum of the cable reeling
unit.
230
15. Reeling units
4. Adjust screw (C) until contactor (D) activates warning lamp (H209) on the control
panel.
- +
H208 H206 H219 H205 H203 H209 H207 H220 H210 H204 H202 H200 H201
N
1 1
2 2
1 1/1 3 3
S138 S178
0 0 0 0 0 1
FILTER
P110 P111
S137
0 0
S186 S304 H101
1250 0063 72
S308 S307
S139
S145 S146
A70
Figure: Control panel
5. Run out the cable until there is one turn on the drum.
6. Adjust screw (B) until contactor (E) activates the parking brake. Parking brake
activation is indicated by lamp (H208) on the control panel.
7. Tighten locking screw (A).
8. Refit the limit switch cover (1).
231
16. Exhaust filtering
Safety
WARNING
• Make sure the engine is turned off for all
maintenance work.
• Take care when draining hot oil and
fluids.
Scrubber
General
A
1250 0146 08
C
Figure: Exhaust filtering
A Level cock
B Cock, water connection
C Drain cocks
Ensure the water level in the scrubber is sufficient by frequently filling up with water.
232
Filling up with water

1. Make sure stopcock (1) is closed and stopcock (3) is open.
5
6
3
1
4
2
1250 0137 14
Figure: Water inlet
2. Connect a water supply to (4).
Note
If the rig has a hose reel, connect the water to reel, as this in turn is connected to
connection (4).
3. Open cock (A).
A
1250 0146 08
C
Figure: Scrubber
4. Open cock (B) until water runs from cock (A).
5. Close cock (B) and then cock (A).
6. Turn off the water.
233
7. The water line must be depressurised before it can be disconnected. Therefore,

open cock (1) and close cock (3).
5
6
3
1
4
2
1250 0137 14
Figure: Water inlet
8. Disconnect the water from (4).
Note
If the rig has a hose reel, disconnect the water from this.
9. Close cock (1).
Freeze prevention measures
Draining
1. Open water cock (C) and empty the system.
A
1250 0146 08
C
Figure: Draining the scrubber
2. Close water cock (C).
234
Catalytic converter
General
The catalytic converter is effective for cleaning only once the engine has warmed up.
Changing the catalytic converter

1. Loosen the clamps around the catalytic converter.
2. Change the catalytic converter.
235
17. Fire fighting equipment
Fire fighting systems
Description
The rig is equipped with an Ansul 101 or Forrex fire fighting system to extinguish
any engine fires.
The system consists of:
• a triggering system
• an N 2 cartridge
• extinguishing medium
• nozzles over the engine and hydraulic transmission
The chemical agent in Ansul 101 is FORAY (based on monoammonium phosphate)

while Forrex contains a water-based agent. These extinguishants are effective on
class A, B and C fires.
There are also different types of fire fighting equipment, manual and automatic. The
automatic systems are controlled from a central unit.
Ansul
• Manual system
Consists of only one fire fighting system. In case of fire the fire fighting system
must be activated manually.
• Automatic system (Checkfire).
Consists of a system with a sensor that automatically activates the fire fighting
system in case of fire. It can also switch off the engine, cut off the supply of petrol
and lock the brakes if an alarm situation arises.
Forrex
• Manual system - M.
Consists of only one fire fighting system. In case of fire the fire fighting system
must be activated manually.
• Automatic system -EAA
Comprises an extinguisher system and a fire alarm.
236
Activates the fire fighting system automatically when the fire alarm starts. Stops
the engine, cuts off the fuel and turns off the battery switch at the same time
(option).
Automatic operation can be disengaged from the central unit whenever necessary.
Locations
Figure: Location of extinguishing installation for M2/L2/L1

1 Tank with actuating device
2 Activators
3 Nozzles
Manual triggering
1. Pulling out the pin (A) and pressing button (B) activates the fire fighting system
and the contents are spread through the nozzles over the engine and transmission.
2. If the system has been used, it is important that the nozzles are changed and the
pipes cleaned.
237
1250 0020 63
Figure: Activators
Maintenance of fire fighting system
Safety measures
Be sure to avoid the accumulation of flammable items in the machine such as leftover
oil and fuel that could intensify the fire or help spread it to places which otherwise do
not in themselves constitute a fire hazard.
Most important of all for avoiding fires in the machine are:
Periodic inspection and preventive service at those points where fire can most easily
break out - engine bay, electrical system, turbo, manifolds and brake system.
Regular cleaning of all areas where flammable materials like oil, grease, hydraulic
fluids and other waste can accumulate.
Modification of the machine

If the machine is modified, an authorised fitter must check over the fire-extinguishing
system when the modification has been completed.
Service
It is essential that the fire fighting system is inspected at least once a year by an
authorised service company. Contact Atlas Copco's sales company in your country
for information regarding authorised service companies.
238
Steps to take after a fire or activation of the fire-fighting sys-

tem
Do not start the machine until it has been cleaned and serviced. Water can be used to
remove chemicals. Neither should you start the machine until the cause of the fire has
been found and eliminated. Recharge the fire-fighting system before you start to use
the machine again. You needed it once, you may need it again.
239
18. Service platform
HL 210-300 MB, HL 210-300 MBC, HL SP2 MBC
1250 0070 42
Figure: Service platform
Technical data
HL 210 MB/MBC
Maximum loads
for platform without protective roof 400kg
for platform with protective roof 350kg
Working radius, swing angle and lifting range

Largest working radius 10250mm
Smallest working radius 6250mm
Swing angle 45°
Lifting range Up 60°
Down 35°
Weights
Weight for platform without protective roof 1625kg
Weight for platform with protective roof 1675kg
Other
Working pressure 200bar
240
HL 230 MB/MBC
Maximum loads

Swing angle 45°
Down 35°
Weights
Other
HL 300 MB/MBC
Maximum loads

Swing angle 45°
Down 35°
Weights
241
Other
HL SP2 MBC
Maximum loads

Swing angle 45°
Down 35°
Weights
Other
242
Safety
CAUTION
control system is depressurised before
starting work.
Slinging
To avoid damage and accidents, it is essential that great care be taken when slinging
and lifting the service platform.
Distance to centre of gravity when slinging

Note
The following applies for slinging and lifting:
• A new service platform is delivered in transport position. If this is not the case,
make sure that the telescope is completely contracted and that the service plat-
form is in the horizontal position.
• Make sure to lift directly above the centre of gravity.
• Lift slowly and carefully. Make sure the slings do not slip or become damaged
and that the service platform does not start to swing.
1250 00 70 44
Figure: Distance to centre of gravity in relation to attachment plate (telescope con-

tracted)
243
Table: Distance to centre of gravity in relation to attachment plate.

Distance to centre of HL 210 MB/ HL 230 MB/ HL 300 MB/ HL SP2
gravity (g) MBC MBC MBC MBC
Telescope contracted 2995 mm 3040 mm 2330 mm 2751 mm
Supporting the service platform

Note
In connection with all forms of service and maintenance work the service platform
must be supported on stands.
1250 0070 43
Figure: Supporting the service platform
Tools
The following tools will be required when carrying out maintenance on the service
platform and are available on special order:
1. Hexagon hole spanners 3, 4, 5, 6 and 10 mm.
2. Hexagon spanners, width across flats 10, 13, 17, 19, 24, 36 and 36 mm.
3. Screw tap, M8.
4. Drills 6 and 8 mm.
5. Screwdriver.
6. Hook spanner, SKF HN7, HN8, HN13 and HN15.
7. Adjustable pin spanner, Belzen no. 4310.
244
Adjusting play in telescope tube guide

1. Undo bolts 1.
2. Screw in or out set screws 2 until the opening between the guide heel and tele-
scope tube is approximately 0.5 mm.
3. Tighten bolts 1.
1 2
0,5 mm
1250 0070 45
Figure: Adjusting play in telescope tube guide
Bleeding the hydraulic system

Note
Air in the hydraulic system can be detected if one or more hydraulic cylinders give or
operate jerkily.
The hydraulic system must be bled if air enters the system.
1. Check the oil level in the hydraulic oil tank before bleeding.
2. Operate the cylinders several times between their end positions. (This will force
the aerated oil back to the hydraulic tank where the air can be separated.)
Rear boom link
Checking clearances
1. Lower the service platform to the ground to relieve the boom link.
245
2. Draw a line (C) with a marker pen on the boom bracket (A) and the boom link (B).
See illustration below.
C
A
B
1250 0004 09
Figure: Marking on boom bracket and rear boom link
3. Raise the service platform form the ground and measure the distance between the
lines on the boom bracket and the boom link.
If the play exceeds 2.5 mm, the shaft must be disassembled and the bushings
replaced.
Lubricating before start

When starting a newly delivered, newly reconditioned or seldom used service plat-
form, it is essential that the lubrication is effective from the beginning. See mainte-
nance interval Operating hours.
Function check
1. Check the service platform for transport damage.
2. Make sure no threaded joints or hoses have been shaken loose.
3. Make sure there are no oil leaks while performing all operative movements.
4. Check that the entire service boom movement pattern can be performed (all the
hydraulic cylinders should be operated to their end positions) without any hoses
getting jammed or pinched.
246
Menus in the RCS system
General
This section applies only to rigs with the RCS computerised control system.
Menu Lever
Figure: Menu Lever
The Lever menu shows the lever actuation in X-axis (forward-back) and Y-axis
(right-left) and the actuation of the lever button. Actuation is shown as a percentage
where the maximum position in one direction is 100% and in the other direction -
100%.
Calibration
1. Activate the calibration function by marking the box to the right of Calibration
mode .
2. Confirm by pressing Enter.
3. Calibrate the lever by moving the lever to its end position forward-backward (X-
axis) and right-left (Y-axis). Then press the lever button fully.
4. Mark Calibration mode again.
5. Confirm by pressing Enter.
247
Actuations menu
Figure: Actuations menu
Use the Actuations menu to manually actuate a certain function or to test a certain
function during troubleshooting components for example.
Parameters menu
Figure: Parameters menu
248
The speed of the service platform cylinders is set from this menu.
First, select the desired cylinder from the options list at the top right-hand corner of
the menu.
Lowest valve current is the opening value required to start moving the cylinder. High-
est valve current is the maximum speed required of the cylinder.
Long-term storage
If the service platform is not to be used for a long period, the following measures
must be taken:
1. Clean the boom by spraying it with de-greasing agent. Then flush with warm
water and blow dry with compressed air.
2. Lubricate according to the lubrication schedule, see maintenance intervals Oper-

ating hours.
3. Apply anti-rust oil on unpainted surfaces such as piston rods, sliding surfaces, etc.
4. Keep the service platform in a dry place.
Transport
The following applies if the service platform is to be removed to facilitate transport:
1. Remove the axle holding the hydraulic cylinder for the service platform from the
boom side.
2. Bind the loose cylinder at the service platform to prevent it from being damaged.
3. Detach one of the cylinder ends for parallel holding. Lash the loose cylinder end to
the boom body.
249
4. Detach hydraulic hoses LK3, LK4 and LT1from the service platform's valve block
and attach them to a closed circuit to the tank.
LK3
LK4
1250 0094 48
LT1
Figure: Connecting hydraulic hoses
Note
Connecting the hoses together prevents pressure build-up in the parallel cylinder
circuit.
5. The remaining hoses of the service platform are detached and plugged.
6. Remove the axle holding the service platform.
7. Dismantled shafts and bushes from cylinder lugs must be protected against corro-
sion with anti-corrosion agent and suitably wrapped.
8. When the service platform is refitted and the hydraulic hoses reattached, it is
important to bleed the hydraulic system.
250
19. Directional control equipment
FAM
The FAM (Feed Angle Measurement) directional control system has the following
main components:
• Two angle sensors for each boom, positioned in the rear boom joint (boom swing)
and in the front boom joint (feed swing).
• One inclination sensor for each boom, located on the feed holder (feed inclina-
tion).
• One resolver module for each boom.
• One display screen for each boom.
• One fuse box.
• One ON/OFF switch.
In addition on systems with hole depth measuring (option):
• One length sensor for each boom located on the feed beam.
B307
B370
B371 B372
1250 0062 91
Figure: Location of sensors on the boom

B370 Angle sensors, boom swing
B371 Angle sensors, feed swing
B372 Inclination sensor, feeder inclination
B307 Length sensor, hole depth measurement (option)
Technical data
Directional control FAM

Power supply 24 V DC
Fuses 10 A
251
Communications system CAN

Working range Horizontal angle +/-180
degrees
Vertical angle +/-45 degrees
Component designations
Display screen Boom 1: D501
Boom 2: D503
Boom 3: D505
Resolver module Boom 1: D120
Boom 2: D220
Boom 3: D320
Angle sensors, boom swing Boom 1: B370
Boom 2: B370
Boom 3: B370
Angle sensors, feed swing Boom 1: B371
Boom 2: B371
Boom 3: B571
Inclination sensor, feeder inclination Boom 1: B372
Boom 2: B372
Boom 3: B372
Length sensor, hole depth (option) Boom 1: B307
Boom 2: B307
Boom 3: B307
Fuse box Rig: D551
Menus
The system menus and menu structure are described in the operator's instructions.
See operator's instructions, Directional control: Operating.
Password
N.B.
A password is required to access some menus.
252
1. Go to the password menu.
******
1250 0061 90
Figure: Menu for password
2. Enter the password using the arrow keys as illustrated in the following figure.
Confirm with Enter.
1250 0060 89
Figure: Password for calibrating
3. Press the Escape key to access the main menu.
Note
The password is active until the system is turned off or another password is
entered.
4. Once calibration is complete, you can log in again as the user to prevent unauthor-
ised persons from accessing the calibration menus. Enter the user password using
the arrow keys as illustrated in the following figure and confirm with Enter.
1250 0071 49
Figure: Password for user
253
Connections
Single-boom and dual-boom systems
D551
65
D120
25
55 35
10
X3 X1 X4
0 1
D501 X5
55
X5 X4 X3 X1
D501
D120: X3-X5, X11-X12 D120: X1

D501:X3-X5 D551: F1-F5 D501: X1
1250 0060 69
Figure: Single-boom system
254
D551
65 30
65
D120 D220
25
55 35 40 60
10 15
X3 X1 X4 X4 X1 X3
20
D501 X5
55 0 1
D503 X5
60
X5 X4 X3 X1 X5 X4 X3 X1
D501 D503
D120, D220: X3-X5, X11-X12 D120, D220: X1

D501, D503:X3-X5 D551: F1-F5 D501, D503: X1
1250 0059 58
Figure: Dual-boom system
Table: Connections, single-boom and dual-boom systems

Pos. no. Description Connection
10 CAN cable D501 (X3) - D120 (X4)
15 CAN cable D503 (X3) - D220 (X4)
20 CAN cable D501 (X4) - D503 (X4)
25 Power supply cable, 24 V DC D120 (X1) - D551 (F1)
45 Power supply cable, 24 V DC D551 - Switch (W50:1)
50 Power supply cable, 24 V DC Switch (W50) - A2 cabinet (W50)
55 ID plugs (9106 1324 90) D120 (X5)
D501 (X5)
60 ID plugs (9106 1324 91) D220 (X5)
D503 (X5)
255

65 Terminating resistor (9106 1324 D120 (X3)
38) D220 (X3)
Three-boom system
D120 D220 D320
D501 D503 D505
D501 D503 D505
D120, D220, D320: X3-X5, X11-X12

D501, D503, D505: X3-X5
1250 0062 88
Figure: CAN connections, three-boom system
256
D551
D120 D220 D320
D501 D503 D505
D501 D503 D505
D120, D220, D320: X1 D551: F1-F5
1250 0062 87
Figure: Power supply connections, three-boom system
Table: Connections, three-boom system

10 CAN cable D501 (X3) - D120 (X4)
15 CAN cable D501 (X4) - D503 (X3)
20 CAN cable D503 (X4) - D505 (X3)
25 CAN cable D220 (X3) - D320 (X4)
30 CAN cable D120 (X3) - D220 (X4)
35 Power supply cable, 24 V DC D551 (F1) - D120 (X1), D501 (X1)
60 ID plugs (9106 1324 90) D120 (X5)
D501 (X5)
65 ID plugs (9106 1324 91) D220 (X5)
D503 (X5)
70 ID plugs (9106 1324 92) D320 (X5)
D505 (X5)
75 Terminating resistor (9106 1324 D120 (X3)
38) D220 (X3)
257
Sensor connections
B307
D120, D220, D320

B371
X10 X1
X9 X3
X8 X4
X5
X7 X11 B372
X6 X12
1250 0059 59
B370
Figure: Sensor connections
D120 Resolver module, boom 1
B307 Length sensor, hole depth measurement (option)
B370 Angle sensors, boom swing
B371 Angle sensors, feed swing
B372 Inclination sensor, feeder inclination
Power supply circuit, 24 V DC

Note
It is important for the system to be connected to a power source that provides a stabi-
lised 24 V DC supply.
258
D551
A2
1250 0059 63
Figure: Power supply circuit, 24 V DC

D551 Fuse box
S Switch
A2 A2 cabinet
Sensor calibration
Conditions
The following is required to calibrate the sensors:
• Digital spirit level

• Tape measure
The sensors must be calibrated in the order specified below. The rig must be level
when calibrating.
The lookout cylinder MUST always be run to the bottom and the feeder and rotation
axis must be parallel for the aligning instrument to work properly.
Adjusting the lookout cylinder

1. Raise the rig on its jacks and level it using a spirit level. Precision +/- 0.1 degrees.
2. Run in the lookout cylinder to bottom. Lock it with the button on the panel.
259
3. Position the rotation axis so that the lookout axis is horizontal (+/- 5 degrees) with
the rock drill upwards.
ON/OFF HOLD
1250 0058 75
Figure: Lookout axis horizontal.
4. Run the rock drill all the way to the rear of the feeder.
5. Run the feed telescope all the way to the back.
6. Position the rotation axis horizontally. Check with a spirit level. Precision +/- 0.1
degrees.
ON/OFF
HOLD
1250 0058 77
Figure: Rotation axis horizontal
7. Check that the feeder is horizontal using a spirit level. Precision +/- 0.1 degrees.
8. If the feeder is not level, the feed telescope must be run forward to see if the fault
disappears (vary the load on the feed holder). If the feeder is still not level, the
lookout cylinder must be adjusted mechanically until it is. Precision +/- 0.1
degrees.
260
Feeder inclination sensor
Calibration menu
=0 xC
+1 -11.2 X6
-1 -11.2 X7
-123 23.6 X12
1250 0059 17
Figure: Menu (2.2) sensor calibration
Adjusting inclination sensor

1. Go to the Calibration menu, see illustration above.
2. Level the feeder roughly (+/- 5 degrees).
3. Reset the inclination sensor by activating the "reset button" for inclination of feed.
4. Set the inclination of feed coefficient to 1200 or -1200. The angle must be positive
when the front of the feeder is raised.
5. Set the boom so that feed rotation can be run to its mechanical end positions.
261
6. Position the rotation axis so that the lookout axis is approximately level (+/- 5
degrees) with the rock drill up.
ON/OFF HOLD
1250 0058 75
7. Run the feeder down until it is roughly horizontal and read off the angle.
8. Rotate 180 degrees so that the feeder is now standing on the other side of the
boom.
Note
NOTE: Operate only with the rotary actuator.
9. Read off the angle for the inclination of feed again. This angle must not differ by
more than 0.4 degrees from the previous reading.
10. If the difference between the angle readings is more than 0.4 degrees, the tilt sen-
sor on the feed holder must be adjusted. In order to adjust the tilt sensor, the bolts
must be loosened slightly (perhaps only one of them) and the box changed so that
the angle on the screen is in between the two readings (as A in illustration below).
262
Example : If the first reading gives 0.0 degrees and the second 1.2 degrees, then
the angle should be 0.6 degrees after adjustment. Tighten the bolts.
B
1250 0061 64
Figure: Adjusting inclination sensor
11. Read off the angle of the inclination of feed and run the feeder back 180 degrees to
the other side of the boom. NOTE: Operate rotation only. Read off the angle again
and check that the difference is less than 0.4 degrees. Repeat steps 6-10 if the dif-
ference is too great.
12. Position the rotation axis so that the lookout axis is approximately level (+/- 5
degrees) with the rock drill up.
ON/OFF HOLD
1250 0058 75
13. Set the feeder so that it is approximately horizontal and read off the angle.
14. Then operate the feeder 90 degrees with rotation so that it is above the boom and
read off the angle for inclination of feed. The difference must not be greater than
0.4 degrees.
263
15. If the difference is greater than 0.4 degrees, the box must be adjusted with shims
(B below). Place a 0.4 mm shim at the front to increase the angle (more positive)
by one tenth of a degree.
B
1250 0061 64
Figure: Adjusting inclination sensor
16. Operate the feeder rotation to and fro and check that the angle for inclination of
feed does not change more than 0.4 degrees between ends. Repeat steps 12-15 and
possibly 6-10 if this is not the case.
Resetting inclination sensor

1. Position the rotation axis so that the lookout axis is horizontal (+/- 5 degrees) with
the rock drill upwards.
ON/OFF HOLD
1250 0058 75
3. Level the feeder roughly. Precision +/- 0.05 degrees.
4. Run in the lookout cylinder to bottom. Lock it with the button on the panel.
264
5. Go to the Calibration menu.
6. Reset the inclination sensor by activating the "reset button" for inclination of feed.
Setting coefficient for inclination sensor

1. Raise the front of the feeder about 30 degrees. Measure the angle of the feeder
with a spirit level.
2. Change the coefficient for inclination of feed so that the angle on the display
screen is the same as the measured value and has a plus sign. Accuracy +/- 0.1
degrees.
3. Calibrate the inclination sensor for all the booms before calibrating the side
angles.
Rear and front side angles
Calibration menu
=0 xC
+1 -11.2 X6
-1 -11.2 X7
-123 23.6 X12
1250 0059 17
Figure: Menu (2.2) sensor calibration
Setting coefficient for rear and front side angles

1. Level the rig.
2. Set the coefficient for the rear side angle so that it increases when the boom is
moved to the right.
3. Set the coefficient for the front side angle so that it increases when the feeder is
moved to the right.
4. Repeat steps 2 and 3 for all the booms and then position them about straight ahead
and roughly the same height.
265
Resetting rear side angle

1. Level the feeders and rotate them so that they are as close as possible to each
other. The best position is if the feeders fit between the booms but if this is not
possible, they can be underneath the booms.
2. Adjust one boom at a time so they are pointing straight ahead. Check that the rear
boom cylinders are extended equal lengths using a rule. (Applies only to “straight”
boom plates, another method must be used to check that the booms are parallel to
the rig if boom plates are angled for a wider target surface.)
3. Go to the Calibration menu, see illustration above.
4. Reset the rear side angle by activating the "reset button".
5. Repeat steps 1-4 for all booms.
Resetting front side angle

1. The side angles must now be calibrated so the rear cylinders must not be operated.
2. Adjust boom 1 so that the feeder is parallel with the boom. Use a rule to measure
the front boom cylinders to check that they have been run out by an equal amount.
4. Reset the front side angle for boom 1 by activating the "reset button".
5. Now position the feeders for the other booms parallel to boom 1. Measure with a
tape measure or rule. Precision +/- 5 mm.

7. Reset the front side angle for the other booms by activating their "reset button".
Rock drill position (option - hole depth measurement)

266
2. Open the menu for calibrating the length sensor.
=0
xC
+10 4 cm X10
1250 0062 90
Figure: Menu (3.2) for calibration of the length sensor.
3. Reset the sensor by activating the “reset button” on the menu.
4. Run the rock drill from the rear end position to the front end position on the feeder.
5. Measure the distance between both end positions with a tape measure.
6. Change the coefficient (xC) in the menu so that the length for the hole depth corre-
sponds with the measured value.
Replacement of angle sensors

1. Clean the area where the sensor is built into the boom joint.
267
2. Undo the four hexagon socket screws (A) on the existing sensor.
1250 0042 93
Figure: Angle sensors
3. Disconnect the cable from the cable connector (B).
4. Remove the sensor and bellows coupling. The bellows coupling consists of two
parts. One part (1) is mounted on the sensor by means of a hexagon socket screw.
The other part (2) is mounted in the boom joint by means of a hexagon socket
screw in the bottom of the coupling.
1250 0059 28
Figure: Bellows coupling
268
5. Fit part 2 of the new bellows coupling into the boom joint and tighten the hexagon
socket screw in the bottom. Check that the correct mounting dimension is
obtained, see following illustration.
B A
1
14 mm
1250 0059 64
Figure: Mounting dimensions, angle sensors
6. Fit part 1 of the bellows coupling onto the new sensor.
7. Fit the sensor in place in the boom joint. Make sure the splines of the bellows cou-
pling (on the part mounted on the sensor) are in the correct groove on the part
mounted in the boom joint. Fit the sensor so that its connector is pointing in the
correct direction with regard to the run of the cable.
8. Press down the sensor while tightening the four hexagon socket screws (A).
9. Connect the cable to the cable connector (B).
10. Calibrate the sensor, see the section Sensor calibration.
Replacement of inclination sensors

1. Rotate the feeder to one of the end positions.
2. Disconnect the cable from the existing sensor.
3. Undo the locking screws on the sensor protection and pull the sensor out of the
protection.
4. Fit the new sensor in the protection with the connector facing forwards (towards
the drill bit).
5. There is stop screw (A) on the rear end face of the sensor. Turn the sensor so that
the stop screw is down.
269
Note that the end positions for feed rotation vary depending on how the feeder is
fitted on the boom. However, the sensor must always be fitted with the stop screw
down, irrespective of the type of boom and feeder.
A
1250 0152 58
Figure: Feed holder viewed from the operator position.
6. Lock the sensor in place by means of the locking screws on the protection.
7. Connect the cable to the new sensor.
8. Calibrate the sensor, see the section Sensor calibration.
270
Replacement of length sensor
Rock drill mode
A A
B
3 B
5 C
2
C
1
Figure: Length sensor for rock drill mode

1 Sensors
2 Wire pulley
3 Rear wire attachment
4 Front wire attachment
5 Spring
1. Make sure the sensor (1) is filled with grease before screwing it to the beam. Note
that the lubricating nipple lubricates the seal only.
2. Lay the wire one turn around the wire pulley. Note the direction of the coil (2), the
spring side of the wire must be closest to the beam.
3. Adjust the wire length so the spring is 100 mm. The spring is 70 mm unloaded.
4. Run the feed cylinder in/out and check that the wire does not stick anywhere.
5. Note that the wire attachment (3) is in two parts when assembling.
Replacement of resolver module

1. Detach all the connections from the resolver module.
2. Remove the address plug and termination resistor and connect them to the corre-
sponding contacts on the new resolver module.
3. Once the new resolver module has been fitted in place, be sure to connect the sup-
ply voltage, display screen module and sensor to the correct contacts.
271
4. Calibrate the sensors. See the section Sensor calibration.
Fault finding
Fault indication
System
The system indicates a fault by displaying a warning triangle in the lower right-hand
corner of the display screen. This warning triangle is only shown in the main menu
and the working menu.
A fault indication may be caused by:
• defective cable between resolver module and sensor

• defective sensor
• defective resolver module
• defective display screen module
The cause of the fault can be found using the fault finding menus.
CAN communication
If a fault arises in CAN communication, a warning is shown on the display screen.
1250 0060 86
Figure: Warning. CAN communication fault
The warning indicating a CAN communication fault can only be shown if the display
screen and resolver module have contact. It is not shown if a problem has arisen
between the I/O and resolver modules.
When the warning is shown on the display screen, check:
272
• CAN cables (contact check)

• that the system's ID plugs and termination resistors are correctly connected
Function check
-11.2 X6
-11.2 X7
23.6 X12
1250 0059 16
Figure: Menu (2.1) for sensor angles
By studying the angles in the menu for sensor angles while making different feeder
and boom movements, you can see whether the different sensor units seem to give
realistic values.
Fault-finding menus
If the system fails to function correctly, the fault-finding menus can be used to find
the cause of the fault.
OK
1250 0061 88
Figure: Menu (5.1) for fault finding of the display screen
The menu for fault finding of the display screen shows the status of the display
screen module.
• OK
• Fault (crossed-out OK)
273
If the display screen has the status Fault, the display screen module should be
replaced.
OK X6
OK X7
OK
OK X12
1250 0061 96
Figure: Example. Menu for fault finding of the sensor and resolver module
The menu for fault finding of the sensor and resolver module shows the status of the
resolver module contacts that are connected to a sensor. Should one of the contacts
have the status Fault (crossed-out OK), further fault finding can lead to the cause of
the fault. Possible causes are:
• defective cable between resolver module and sensor

• defective sensor
• defective resolver module
Angle sensors
By measuring the winding resistances of the sensor, it is possible to determine
whether the sensor and the cable between resolver module and sensor are in working
order. First, disconnect the cable from the contact on the resolver module. Take read-
ings across the cable pins as follows:
• Across pins 1 and 2. The resistance should be approx. 36 ohms.

274
5 6 1
4 2
3
1250 0060 28
Figure: Sensor connection
If any of the measurements should indicate a value that deviates greatly, the same
measurement should be made on the sensor pins. Detach the cable from the sensor
contact and measure across the pins as above. If the same fault is obtained as when
measuring on the cable, the sensor should be changed. Otherwise, it can be assumed
that the fault is in the cable.
Should fault finding show that both cable and sensor are intact and free from faults,
the fault probably lies in the resolver module.
Inclination sensor
Check that the sensor is supplied with current. Disconnect the cable from the sensor
and take a reading on the cable.
• If the sensor is supplied with current it may be assumed to be defective.
1 4
5
2 3
1250 0059 65
Figure: Inclination sensor cable connector

1 Earth
2 Power supply 15 V DC
3 Signal
• If there is no supply of current, the fault could be in the cable. Take the same read-
ing on the resolver module contact to check that the resolver module is supplying
current.
If current is supplied by the resolver module, the fault is probably in the cable.
275
Length sensor, rock drill

Check that the sensor is supplied with current. Disconnect the cable from the sensor
and take a reading on the cable.
• If the sensor is supplied with current it may be assumed to be defective.

• If there is no supply of current, the fault could be in the cable. Take the same read-
ing on the resolver module contact to check that the resolver module is supplying
current.
If current is supplied by the resolver module, the fault is probably in the cable.
5 6 1
4 2
3
1250 0060 32
Figure: Sensor connection
A B
5 1 1 5
6 6
4 2 2 4
3 3
1250 0060 33
Figure: Sensor cable connections
Table: Sensor cable connection

Contact A (pin) Contact B (pin) Signal
1 1 5V supply
2 2 5V supply
3 3 Signal A
4 4 Earth
5 5 Signal B
6 6 Earth
276
20. Safe Bolting System
Introduction
SBS (Safe Bolting System) is a product intended for use on Atlas Copco's Boomer
rigs. The system is used to avoid working under unsecured rock by angling the feeder
up to 180° using the lookout axis and parallel cylinders. Two ranges of use are possi-
ble:
• changing drill bit and/or drill steel

• bolting with Split Set
The equipment is intended for the following rig models:
• Boomer M2/L2
• Rocket Boomer M2/L2
The equipment is intended for the following booms:
• BUT 32
• BUT 35
Rigs can be equipped with DCS or RCS drilling systems with protective roof or cab.
Description
SBS has a function that prevents the operator inadvertently moving the drill bit, drill
steel or bolt towards the operator's station and avoid causing serious personal injury
and damage to property. It comprises a warning lamp, a three-way switch with “dead
man's grip” located on the control panel beside the operator's station, and an induc-
tive sensor mounted on the rotary actuator.
The three-way switch makes the operator take part actively in all boom and feeder
movement when the feeder has a lookout angle greater than 90°.
277
A B
1250 0106 37
Figure: Control panel SBS

A Button with “dead man's grip”
B Warning lamp
Function
An inductive sensor located on the lookout axis is active when the lookout angle is
less than 90°. When the sensor is inactivated (i.e. when the feeder lookout angle is
greater than 90°), the holding voltage will activate a relay. The relay will in turn cut
the voltage to:
• valve to diesel positioning.

• loading of positioning pump.
• rotation flow discharge valve(s)
The relay is closed when:
• the inductive sensor is active (lookout angle is less than 90°).

• when the three-way switch is pressed to middle position (while the lookout angle
is greater than 90°).
In order to move the boom and feeder as well as operate the rock drill rotation, the
three-way switch must bypass the inductive sensor. This is done by holding the three-
way switch in its middle position. The sensor is activated when the switch is com-
pletely depressed and completely released.
A back-pressure valve which opens at approx. 30 bar is used prevent the stand-by
pressure from escaping into the system.
If the rig is fitted with a telescope feeder, there will be another pilot-controlled non-
return valve. This valve confines the pressure in the feed cylinders so that the oil is
not drained, thereby allowing movement.
Component parts
The following components are included in the Safe Bolting System (for each boom):
278
• Feed holder with increased stick angle (+90°).

• Inductive sensor.
• Flag that activates the inductive sensor.
Activates the inductive sensor within the lookout area less than 90°.
• Three-way switch with “dead man's grip” on control panel.
• One relay.
• One warning lamp on control panel.
The lamp comes on when the lookout angle is greater than 90° and the three-way
switch is released or completely depressed.
• Electrical connections in power supply cubicle.
Controls the shut-off valve for loading the positioning pump.
• Electrical connections in chassis.
Shuts the valve to diesel positioning.
• Shut-off valve for rotation flow on rotation hose between rotation pump and rota-
tion valve.
When the shut-off valve is active, oil is sent to the rotation valve and when it is
inactive, oil is sent to the tank.
• Back-pressure valve on positioning pump.
Prevents the stand-by pressure from escaping into the system.
• Pilot-controlled non-return valve (applies to telescope feeder only).
Prevents inadvertent feed with telescope feeder due to its own weight.
• Working platform directly connected to the operator's station, option.

Functional extra platform for Safe Bolting.
Locations
• The inductive sensor is mounted on the knob at the end of the stick axle and the
flag on the end of the stick axle.
• The pilot-controlled non-return valve is mounted between the branching to the
piston rod side of the upper member's feed cylinder and the pressure reduction
valve to the piston side of the lower member's feed cylinder.
The pilot pressure is taken from the piston side of the upper member's feed cylin-
der.
279
21. Rod handling equipment, option
Rod adding system

Manual rod adding system
Manual RAS
RAS
B C D
A 1250 0141 69
Figure: Rod handling equipment, RAS

A RAS arm with gripper claw
B Splicing rod
C Drilling rod
D Hydraulic drill-steel support, BSH 110
The Rod Adding System (RAS) is a system for handling drill rods for extension drill-
ing. The equipment comprises two arms with gripper claws mounted on the feed
beam, and a hydraulic front drill-steel support.
The RAS arms can be positioned to two positions: parked position and drilling cen-
tre. The gripper claws can assume three positions: closed, guide position and open.
The guide position means that the gripper claws hold the drill rod gently allowing the
rod to rotate.
The drill-steel support can either be open or closed. These positions are adapted to
the diameter of the drill rod (closed position) and the diameter of the rod joint (open
position).
280
Settings
Valve block
G5
CT14 CT15 CT16
CT13
G2
CT17
CT18
1250 0075 96 G6
Figure: Detail of valve plate
G2 Pressure gauge outlet
CT13 Valve
CT14 Valve
CT15 Valve
CT16 Valve
CT17 Valve
CT18 Valve
281
Inductive sensors
Position indication for RAS
1250 0070 92
Figure: Position indication for RAS on LED box.

0 Rock drill shank adapter free from drill rod
1 Front join free
2 Drill rod joins in support
3 Drill-steel support can be closed
4 Drill-steel support must be opened
5 Rock drill in forward end position
6-7 RAS arms in drilling centre
282
1250 0156 53
Figure: Location of inductive sensors on the feeder.

0 Sensor B127: Splicing rod unthreaded at both ends.
1 Sensor B161: Splicing rod unthreaded front.
2 Sensor B162: Sleeve in correct position, drill-steel support.
3 Sensor B163: Drill-steel support can be closed.
4 Sensor B168: Drill-steel support is opened.
5 Sensor B121: Front position, rock drill.
6 Sensor B108: Front RAS arm in drill centre.
6 Sensor B110: Front RAS arm in parked position.
7 Sensor B107: Rear RAS arm in drill centre.
7 Sensor B109: Rear RAS arm in parked position.
283
22. Air conditioning
Safety
WARNING
• Refrigerants under pressure.
• Service of refrigerant system must be
carried out by authorised personnel.
Note
Do not use the system with too little refrigerant, leakage or any other fault until it is
rectified. Otherwise, there is risk of the compressor breaking down.
Technical data
Refrigerant R134a
Amount of refrigerant 1,6 kg
Refrigerating capacity (35 °C, Rh 50%) 8.5 kW
Heating capacity, from diesel engine 12 kW
Heating capacity, electric heater 3 kW
Air flow 1300 m 3 /h
Adjusting compressor speed

The speed for the air conditioning compressor must be adjusted to 2200 rpm using
the flow valve at Y553.
284
Adjusting compressor V-belts

A B
D
C
1250 0006 86
Figure: Adjusting V-belts
• Unscrew the cover under the driver's seat in the operator cab.
• Undo the nut (A) and adjust the belts (D) by turning the tensioner (B) towards or
away from the motor (C).
• Tighten the nut (A) and refit the cover under the driver's seat.
Fresh air filter and recirculation filter

The fresh air filter (1) and the recirculation filters (2) are both kept in place by a
metal plate (3). The metal plate is held in place with two screws (4).
285
4
1250 0052 57
Figure: Fresh air filter and recirculation filter

1 Fresh air filter
2 Recirculation filter
3 Metal plate
4 Screws
The fresh air filter should be inspected regularly and cleaned as necessary. How often
the filter needs cleaning or changing depends on the prevailing operating conditions.
If the air conditioning efficiency becomes impaired despite cleaning the filter regu-
larly, it is probably time to change the filter.
The recirculation filter cleans purer air than the fresh air filter and therefore will not
need cleaning as often. Regular inspections of the recirculation filters are recom-
mended, however.
286
Electric heater
1
2
1250 0063 62
Figure: Electric heater
If the automatic circuit breaker has been tripped it can be reset with the reset button
(1).
An output of 2 or 3kW can be selected using the knob (2). A suitable setting is 3 kW.
The screw (3) can be used to check that the pump has not become jammed, which can
happen if the heater has not been used for some time.
Fault finding
No heating
Check for air in the diesel engine cooling system. For bleeding the system, see main-
tenance instruction Engine.
No cooling
Check the following points:
• Fuses, electric connections, compressor earth, electromagnets, switches and pres-

sure switches
• V-belt and compressor
• Expansion valve and temperature control valve
• Coolant hoses
Poor cooling
287
• Fresh-air fan and V-belt tension

• That the air does not evade the evaporator in the unit
• That the evaporator and condenser are not clogged by rubbish and the filter in the
air intake is not dirty
• That the expansion valve capillary tube is firmly against the evaporator outlet pipe
• That the thermostat does not cut out too early
Uneven cooling
• That connections to switches, magnetic coupling or pressure switch are not loose
• That the expansion valve is not clogged
• That the system is filled and the thermostat is not defective
Abnormal noise
• That the V-belts for the compressor are properly tensioned and that compressor
retaining bolts are tight.
• That the system is filled sufficiently and not overfull
• That the expansion valve is in working order
• That the airflow across the evaporator is sufficient
• That the condenser is clean and the airflow is sufficient
Abnormal system noise is often connected to incorrectly assembled components. If

the compressor is noisy at a certain speed, for instance, and the noise disappears
when the speed increases or decreases, there is probably nothing wrong with the
compressor itself.
Each individual vehicle has so-called critical frequencies where vibration of different
types can generate noise. The speed at which these frequencies arise can differ from
vehicle to vehicle. It is often possible to eliminate such vibration by increasing or
reducing the belt tension. If the belt tension is to high, it will cause excessive wear on
compressor bearings, belts and belt pulleys. You should therefore avoid tensioning
the belts too much.
There is seldom any point in changing the compressor due to noise when the belts
"jump". Adjusting the belt tension or changing to another belt length is better. Chang-
ing the length of the delivery hose to the compressor can also reduce noise.
The difference between the pressure on the suction side and the pressure side also
affects the level of noise. A compressor with low suction makes more noise than a
compressor with high suction. Likewise, a compressor with high high-pressure
makes more noise because it puts more load on bearings, etc.
288

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9852 1752 01 Drill Rig Maintenance Instructions

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Atlas Copco

Boomer & Rocket Boomer L1/L2 D

PM No. 9852 1752 01

Special attention must be paid

Only use genuine Atlas Copco parts.

© Copyright 2005, Atlas Copco Rock Drills AB, Sweden

Atlas Copco Rock Drills AB

2. Lubricants, coolants and propellants...................................................................... 30

Boom telescope ..................................................................................................... 61

Tensioning belts ................................................................................................ 99

7. Brake system ........................................................................................................ 119

Checking brake pressure...................................................................................... 120

8. Drill system .......................................................................................................... 129

9. Hydraulic systems ................................................................................................ 130

Percussion pump ............................................................................................. 145

Function check ........................................................................................... 179

10. Compressor ........................................................................................................ 181

11. Air and water systems ........................................................................................ 191

12. Electrical system, IEC and Australia ................................................................. 196

Electric cabinet, high-current .............................................................................. 197

13. Electrical system, Canada .................................................................................. 211

Electronic overload protection ................................................................... 215

14. Component locations.......................................................................................... 219

15. Reeling units....................................................................................................... 224

16. Exhaust filtering ................................................................................................. 232

17. Fire fighting equipment...................................................................................... 236

Manual triggering ................................................................................................ 237

18. Service platform ................................................................................................. 240

19. Directional control equipment............................................................................ 251

Feeder inclination sensor ................................................................................ 261

20. Safe Bolting System ........................................................................................... 277

21. Rod handling equipment, option ........................................................................ 280

22. Air conditioning ................................................................................................. 284

Electric heater ...................................................................................................... 287

• Think of the environment!

• Think of the environment!

• Think of the environment!

• Think of the environment!

• Think of the environment!

Country Address Phone and fax number

Country Address Phone and fax number

Country Address Phone and fax number

Target group and objective

The objective of these maintenance instructions is to detect and rectify faults at an

operation such as reconditioning and repairs. This allows maintenance to be carried

Repairing hydraulic components

• Suitable premises for hydraulic repairs to be arranged at the workplace. Repairs to

Replacement of hydraulic hoses

• with correct crimped couplings

The following must be observed when welding:

• Turn off the supply of current to the unit.

• Alterations and reinforcements must not be made without previous consultation

Table: Electrode recommendations

Table: MIG electrodes

If in any doubt, contact Atlas Copco for advice.

Tightening torque in bolted joints.

Table: Atlas Copco Standard 4369:01 K.

Markings and plates

Dismantling and assembly

Starting with an auxiliary battery

For this reason, proceed as follows:

Figure: Starting assistance

2. Lubricants, coolants and propellants

• Never mix oils of varying type and grade.