Atlas Copco SmartROC T45--10 User manual

AtlasCopcoRockDrills
SmartROCT4510
Maintenance
Originalinstructions
©2015AtlasCopcoAB
20150311|No:153418763.2.9007199762240779enUS

SmartROC T45-10 Table of Contents
iii
TableofContents
1 Introduction ........................................................................................................... 9
1.1 SafetyFirst..................................................................................................................................9
1.2 ThePurposeofThisPublication ..............................................................................................9
1.3 TargetGroup ..............................................................................................................................9
1.4 ProductWarranty .......................................................................................................................9
2 AboutMaintenanceManagement ...................................................................... 11
2.1 MaintenancePlanningandCounters .....................................................................................11
2.2 MaintenanceRecords ..............................................................................................................11
3 GeneralMachineCondition................................................................................ 13
3.1 WashMachineExternally ........................................................................................................13
3.2 CheckConditionofSigns .......................................................................................................13
4 BoomUnit ............................................................................................................ 15
4.1 CheckBoomC14......................................................................................................................15
4.2 LubricateBoomC14 ................................................................................................................16
4.3 ReplaceBoomHeadonBoomC14 ........................................................................................17
5 FeederUnit .......................................................................................................... 19
5.1 CheckingChainFeedTension................................................................................................19
5.2 CheckJackChainCover .........................................................................................................20
5.3 CheckFeedBeam ....................................................................................................................21
5.4 CheckChainGuide ..................................................................................................................22
5.5 CheckSprocketWheel ............................................................................................................22
5.6 CheckDrillSteelSupport........................................................................................................23
5.7 CheckDrillSteelSupport........................................................................................................24
5.8 CheckChainFeed ....................................................................................................................25
5.9 CheckRodHandling ................................................................................................................26
5.10 CleanBehindSealingDisc......................................................................................................27
5.11 LubricateRodHandling...........................................................................................................28
5.12 LubricateChainFeed...............................................................................................................28
5.13 ReplaceBearingUnit ...............................................................................................................29
5.14 ReplaceSlideRails ..................................................................................................................29
5.15 ReplaceSlidePiecesintheHolder ........................................................................................30
5.16 AdjustingChainFeedTension ...............................................................................................31
5.17 GeneralCheckingGuidelinesforSteelCables .....................................................................31
5.17.1 CheckingCableforWireBreaks ............................................................................................ 32
5.17.2 CheckingCableforStrandBreaks ......................................................................................... 32
5.17.3 CheckingCableforSurfaceWear .......................................................................................... 32
5.17.4 CheckingCableforCorrosion ................................................................................................ 32
5.17.5 CheckingCableforDecreasedDiameter ............................................................................... 33
5.17.6 CheckingCableforReducedElasticity .................................................................................. 33
5.17.7 CheckingCableforHeatExposure ........................................................................................ 33
6 DrillingMachine .................................................................................................. 35
6.1 CheckLubricationOilLevelTank ..........................................................................................35

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6.2 DrillLubricationPumps...........................................................................................................35
7 HydraulicSystem ................................................................................................ 37
7.1 AboutWorkingonHydraulicComponents............................................................................37
7.2 AboutHydraulicWorkshops...................................................................................................37
7.3 AboutReplacingHydraulicHoses .........................................................................................37
7.4 CheckHosesandCouplings...................................................................................................37
7.5 HydraulicFilters .......................................................................................................................38
7.5.1 ReturnOilFilter ...................................................................................................................... 38
7.5.2 CheckBreatherFilter.............................................................................................................. 38
7.5.3 ReplaceReturnOilFilter ........................................................................................................ 39
7.5.4 ReplaceBreatherFilter........................................................................................................... 40
7.6 Tanks.........................................................................................................................................40
7.6.1 DrainCondensatefromHydraulicOilTank ............................................................................ 40
7.6.2 DrainCondensateinPressureTank ...................................................................................... 41
7.6.3 CleanHydraulicTank ............................................................................................................. 41
7.6.4 DrainHydraulicOilTank......................................................................................................... 42
7.6.5 FillHydraulicOil...................................................................................................................... 42
7.7 CheckMountingHydraulicJack.............................................................................................44
8 ElectricalSystem ................................................................................................ 45
8.1 ChargingtheBattery................................................................................................................45
8.2 ChargingBatteryUsing24VCharger.....................................................................................46
8.3 ChargingBatteryUsing12VCharger.....................................................................................47
8.4 StartingwithAuxiliaryBattery................................................................................................48
9 FireFightingEquipment..................................................................................... 49
9.1 CheckFireExtinguishers ........................................................................................................49
9.2 CheckEmergencyStopsandWorkLights............................................................................50
9.3 CheckFireExtinguishers ........................................................................................................51
10 ControlSystemandSensors ............................................................................. 53
10.1 GeneralMaintenanceControlSystemandSensors.............................................................53
10.1.1 RemoteControlBattery .......................................................................................................... 53
10.1.2 CleaningRemoteControl ....................................................................................................... 53
11 CoolingSystem ................................................................................................... 55
11.1 CoolingSystemOverview .......................................................................................................55
11.1.1 CleanRadiators ...................................................................................................................... 56
11.1.2 CheckCoolantLevel .............................................................................................................. 57
11.1.3 AddCoolant ............................................................................................................................ 58
12 Operator'sEnvironment ..................................................................................... 59
12.1 CheckCabin .............................................................................................................................59
12.2 ReplacingAirConditionMainAirFilter .................................................................................60
12.3 ReplacingAirConditionPrefilter ..........................................................................................60
12.4 ReplacingAirConditionCirculationFilters...........................................................................61
12.5 TroubleshootingAC.................................................................................................................61
13 TrackFrames....................................................................................................... 63
13.1 TensioningtheCrawlerTracks...............................................................................................63
13.2 CheckingTrackFramesTorques ...........................................................................................64

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13.3 ProceduresforCheckingWear...............................................................................................65
13.3.1 CheckingforFrontWheelWear ............................................................................................. 65
13.3.2 CheckingforTrackRollerWear ............................................................................................. 66
13.3.3 CheckingforCarrierRollerWear ........................................................................................... 66
13.3.4 CheckingforTrackShoeWear .............................................................................................. 67
13.3.5 CheckingforWearonTrackShoe ......................................................................................... 67
13.3.6 CheckingforTrackLinkDepthWear...................................................................................... 68
13.3.7 CheckingforBushingWear.................................................................................................... 68
13.3.8 CheckingforTrackChainElongationWear ........................................................................... 69
13.4 CheckTrackFrames ................................................................................................................70
13.5 CheckTrackFrames ................................................................................................................70
13.6 CheckTrackFrames ................................................................................................................71
13.7 ChangeOilonTrackFrames ..................................................................................................72
14 DustCollector...................................................................................................... 73
14.1 CheckingFunctionofDustCollector.....................................................................................73
14.2 CheckDustCollectorFilters ..................................................................................................74
14.3 ReplaceDustCollectorFilters ................................................................................................74
15 DieselEngine....................................................................................................... 77
15.1 CheckMotorOilLevel .............................................................................................................77
15.2 DrainPreFilter .........................................................................................................................78
15.3 FuelQuality...............................................................................................................................78
15.4 DrainingFuelTank...................................................................................................................78
15.5 FillingwithFuel ........................................................................................................................79
15.6 DEFFluid ..................................................................................................................................79
15.7 LocationofDEFTank ..............................................................................................................80
15.8 DrainingDEFTank ...................................................................................................................80
15.9 FillingwithDEFFluid...............................................................................................................81
15.10ReplacePreFilter.....................................................................................................................81
15.11ReplaceSecondaryFuelFilter................................................................................................82
15.12ReplacingDEFTankFilter.......................................................................................................82
15.13Belts ..........................................................................................................................................83
15.13.1 ReplaceMultibelt ................................................................................................................... 83
15.14ReplaceLongtermEffectiveCoolant ....................................................................................84
15.15AirSystem ................................................................................................................................85
15.15.1 AirFilterIndicatorFunction..................................................................................................... 86
15.15.2 ReplacetheFilterCartridge.................................................................................................... 86
16 CompressedAirSystem..................................................................................... 89
16.1 OverviewAirCompressorSystem .........................................................................................89
16.2 CheckCompressorOilLevel ..................................................................................................91
16.3 OilChangeandOilFilterReplacement..................................................................................91
16.4 ReplacingAirCompressorOilandOilFilter .........................................................................91
16.5 ChangeOilonCompressor.....................................................................................................93
16.6 ReplaceSeparatorFilter..........................................................................................................94
16.7 ChangingtoNewTypeofCompressorOil ............................................................................94
16.8 FlushingAirCompressor ........................................................................................................96
16.9 CheckCompressorComponents ...........................................................................................98

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16.10DrainCompressor....................................................................................................................98
16.11CleanCompressorOilCooler .................................................................................................99
17 AutomaticCentralLubricationSystemCLS................................................... 101
17.1 CentralLubricationSystemPump .......................................................................................101
17.2 SettingLubricationandIntervalTime..................................................................................102
17.3 CheckConditionofCLSpump .............................................................................................103
17.4 SettingLubricationPump .....................................................................................................104
17.5 FillingLubricant .....................................................................................................................105
17.6 BleedingLubricationPump ..................................................................................................105
17.7 LubricationPumpProgramDisplayAlarmList ..................................................................106
17.8 TroubleshootingCLS.............................................................................................................106
18 WaterMistSystem ............................................................................................ 109
18.1 CheckSealsonWaterMistPump ........................................................................................110
18.2 FillingWaterMistTank ..........................................................................................................111
18.3 DrainingWaterMistSystem..................................................................................................112
18.4 StartingUpWaterMistSystemfromDry.............................................................................113
18.5 CleanFilterinWaterMistTank.............................................................................................114
19 Welding .............................................................................................................. 115
19.1 AboutWelding........................................................................................................................115
19.2 CANBusSystemDisconnectionBeforeWelding...............................................................115
20 Downtime ........................................................................................................... 117
20.1 PreparationsBeforeLongPeriodofDowntime ..................................................................117
20.2 RestoringAfterLongPeriodofDowntime ..........................................................................117
20.3 InspectionandMaintenanceDuringPeriodofDowntime..................................................118
21 StartUp .............................................................................................................. 119
21.1 AboutSpecialStartUp ..........................................................................................................119
21.2 PerformingSpecialStartUp .................................................................................................119
21.3 FlushingofHosesandPipes ................................................................................................119
21.4 AboutTestingPressureReleaseValves..............................................................................120
22 Options............................................................................................................... 121
22.1 Winch ......................................................................................................................................121
22.1.1 CheckAttachmentofWinchCable....................................................................................... 121
22.1.2 CheckWinchUnitAttachment.............................................................................................. 122
22.1.3 LubricateWinch .................................................................................................................... 123
22.1.4 CheckWinch ........................................................................................................................ 124
22.1.5 CheckSmallRemoteControl ............................................................................................... 124
22.2 ServiceToolBagRCS ...........................................................................................................125
22.3 CheckingCANNetwork .........................................................................................................126
22.4 CheckingCANPowerSupply ...............................................................................................126
22.5 CheckingCANCable .............................................................................................................126
22.6 CheckingDigitalInputsonI/OModule ................................................................................127
22.7 CheckingDigitalOutputsVoltageonI/OModule ...............................................................128
22.8 CheckingDigitalOutputsCurrentonI/OModule ...............................................................129

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22.9 CheckingPWMOutputsCurrentonI/OModule..................................................................130
22.10CheckingAnalogInputsonI/OModule ...............................................................................131
22.11EncoderInputs .......................................................................................................................131
22.12CheckingResolverModuleResolverInputs .......................................................................132
22.13CheckingResolverModuleEncoderInputs ........................................................................133
22.14CheckingResolverModuleAnalogInputs ..........................................................................133
22.15ReplacingaRCSModule.......................................................................................................135
23 Specifications.................................................................................................... 137
23.1 StandardTighteningTorquesBoltedJoints .......................................................................137
23.2 SignsforOrderingSpareParts ............................................................................................138
Maintenancetable ............................................................................................. 139

SmartROC T45-10 Table of Contents
viii

SmartROC T45-10 1 Introduction
9
1 Introduction
1.1 SafetyFirst
AlwaysreadtheinformationintheSafetydocumentbeforestartingtousetheproductor
startingmaintenancework.
1.2 ThePurposeofThisPublication
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prevented.
Regularmaintenanceisapreconditionforplanningnecessaryinterruptionsinoperation
suchasreconditioningandrepairs.Thisallowsmaintenancetobecarriedoutwhenmost
suitablewithregardtoproductioninsteadofcausingcompletebreakdown.
1.3 TargetGroup
Theinformationinthispublicationisintendedforeveryoneinvolvedintheapplication,op
eration,andmaintenanceofthemachineandrelatedequipment.Allreadersareexpected
topossessbasiccompetenceregardingminingmethods,constructionmethods,andthe
machinesusedforthatkindofoperation.
AtlasCopcoisnotliableforanydamage,injuries,ordeathscausedbyuserswhomisun
derstandthepublishedinformationand/oruseitincorrectly.
1.4 ProductWarranty
Theproductwarrantyreliesoncorrectuse,maintenanceandrepairofthemachineandits
componentsatalltimes.
nUseonlyAtlasCopcooriginalparts.Anydamageoroperationalinterruptionscaused
byusingsparepartsofothermanufacturethanAtlasCopcowillnotbecoveredby
warranty.
nAtlasCopcoisnotliableforanydamagecausedbyunauthorisedmodificationtothe
machineanditsequipment.
nAtlasCopcoisnotliablefordamagecausedbyinappropriateuse.
nOverloadingthemachinecanresultindamagetothestructurewhichisnotnoticed
duringnormalusage.Suchdamageisnotcoveredbythewarranty.
nDamagethatoccursasaresultofinadequatemaintenance,substandardrepairs,or
damagetoequipmentthatisattributabletoolderunrepaireddamage,isnotcovered
bythewarranty.

SmartROC T45-10 1 Introduction
10

SmartROC T45-10 2 About Maintenance Management
11
2 AboutMaintenanceManagement
2.1 MaintenancePlanningandCounters
Maintenanceisorganisedatscheduledintervals.
Scheduledintervalssupplementeachother.Longerintervalcontainsmaintenancetasks
supplementarytotasksfromshorterinterval.Maintenanceschedulingshouldbeapplied
periodicallytounit/function'sshortestinterval(whichevercomesfirstduringoperation).
Operationalmaintenanceisplannedbasedonthefollowingcounters:
nHourmetersfortherockoperationsystem
nHourmeterfortheengineormotor
nCalendarbasedmaintenanceappliestoallrubberdetails,lubricantsthatrisksbreak
ingupduringstandstills,pressurevessels.Corrosionandsuchwhereage,substance
regressionandenvironmentalexposurearevitaltomaintenancefactors.
2.2 MaintenanceRecords
Correctrecordsenablemaintenancepersonneltoidentifyandevaluateproblemsand/or
highcostareas.Allmaintenanceproceduresshouldbecheckedoffastheinspectionor
procedureiscompleted.Quantitiesofrefilledlubricantsandfluids,andpressureandflow
readings,shouldberecorded.Anyfaultsordeviationsshouldberecordedirrespectiveof
whethertheyhavebeenrectifiedorarewaitingforrectification.

SmartROC T45-10 2 About Maintenance Management
12

SmartROC T45-10 3 General Machine Condition
13
3 GeneralMachineCondition
3.1 WashMachineExternally
nRinsethemachinewithwateratleastonceadaytoremovedrillcuttings,mudand
dirt.
Thefeeder,frontpartoftheboomandtrackframesareparticularlyimportanttokeep
clean.
3.2 CheckConditionofSigns
nMakesureallsignsareintact,cleanandfullyreadable.
nMakesureallsignsareinplace.Comparewiththedrawing.
nAlwaysreplacedefectormissingsigns.

SmartROC T45-10 3 General Machine Condition
14

SmartROC T45-10 4 Boom Unit
15
4 BoomUnit
4.1 CheckBoomC14
nCheckmountingofthefeedbrackets(A).Checktheplaybetweenfeederandfeed
bracket,itshouldbe24mm.
nCheckmountingofthefeedextensioncylinder'sattachment(B).Checkforplayon
thebearingsincylinderlugs,maximumis1mm.
nCheckmountingoftheboomhead(C).
nCheckmountingfnthefeedholder(D).Checktheclearance,itshouldbe24mm.
nCheckforplaybetweenbushes,shaftandholder.
IfCentralLubricationSystem(CLS)isinstalled,thefunctionsandconnectionsofCLS
mustbechecked.

SmartROC T45-10 4 Boom Unit
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4.2 LubricateBoomC14
nFillgreaseintothegreasenipples(A).
IfCentralLubricationSystem(CLS)isinstalled,thefunctionsandconnectionsofCLS
mustbechecked.

SmartROC T45-10 4 Boom Unit
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4.3 ReplaceBoomHeadonBoomC14
nReplacetheboomhead(A).

SmartROC T45-10 4 Boom Unit
18

SmartROC T45-10 5 Feeder Unit
19
5 FeederUnit
5.1 CheckingChainFeedTension
C Feedbeam
D Chain
Condition p Apoorlytensionedchaincausesincreasedwearonthechainandassociatedparts.
nCheckthatthechainfeediscorrectlytensioned.
Result èWhenthechainfeediscorrectlytensioned,itshouldcomeintocontactwiththeinner
edgeonthelowerprismonthefeedbeamatpoint(B)whenthefeedisplacedina
horizontalposition(transportposition).

SmartROC T45-10 5 Feeder Unit
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5.2 CheckJackChainCover
nCheckifthechainlinkschafeagainstthejackchaincover(A).
Result èReplacethejackchaincoverifworn.