Atlas Copco SmartROC T45-11 Guide

AtlasCopco
SmartROCT4511
Maintenance
Originalinstructions
©2015AtlasCopcoAB
20150317|No:871696139.2.9007200127358475enUS

SmartROC T45-11 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 LubricateBoomandFeeder....................................................................................................15
4.2 CheckBoomCondition ...........................................................................................................16
5 FeederUnit .......................................................................................................... 17
5.1 CheckingChainFeedTension................................................................................................17
5.2 CheckJackChainCover .........................................................................................................18
5.3 CheckFeedBeam ....................................................................................................................19
5.4 CheckChainGuide ..................................................................................................................20
5.5 CheckSprocketWheel ............................................................................................................20
5.6 CheckDrillSteelSupport........................................................................................................21
5.7 CheckDrillSteelSupport........................................................................................................22
5.8 CheckChainFeed ....................................................................................................................23
5.9 CheckRodHandling ................................................................................................................24
5.10 CleanBehindSealingDisc......................................................................................................25
5.11 LubricateRodHandling...........................................................................................................26
5.12 LubricateChainFeed...............................................................................................................26
5.13 ReplaceBearingUnit ...............................................................................................................27
5.14 ReplaceSlideRails ..................................................................................................................27
5.15 ReplaceSlidePiecesintheHolder ........................................................................................28
5.16 AdjustingChainFeedTension ...............................................................................................29
5.17 GeneralCheckingGuidelinesforSteelCables .....................................................................29
5.17.1 CheckingCableforWireBreaks ............................................................................................ 30
5.17.2 CheckingCableforStrandBreaks ......................................................................................... 30
5.17.3 CheckingCableforSurfaceWear .......................................................................................... 30
5.17.4 CheckingCableforCorrosion ................................................................................................ 30
5.17.5 CheckingCableforDecreasedDiameter ............................................................................... 31
5.17.6 CheckingCableforReducedElasticity .................................................................................. 31
5.17.7 CheckingCableforHeatExposure ........................................................................................ 31
6 DrillingMachine .................................................................................................. 33
6.1 CheckLubricationOilLevelTank ..........................................................................................33
6.2 DrillLubricationPumps...........................................................................................................33

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7 HydraulicSystem ................................................................................................ 35
7.1 AboutWorkingonHydraulicComponents............................................................................35
7.2 AboutHydraulicWorkshops...................................................................................................35
7.3 AboutReplacingHydraulicHoses .........................................................................................35
7.4 CheckHosesandCouplings...................................................................................................35
7.5 HydraulicFilters .......................................................................................................................36
7.5.1 ReturnOilFilter ...................................................................................................................... 36
7.5.2 CheckBreatherFilter.............................................................................................................. 36
7.5.3 ReplaceReturnOilFilter ........................................................................................................ 37
7.5.4 ReplaceBreatherFilter........................................................................................................... 38
7.6 Tanks.........................................................................................................................................38
7.6.1 DrainCondensatefromHydraulicOilTank ............................................................................ 38
7.6.2 DrainCondensateinPressureTank ...................................................................................... 39
7.6.3 CleanHydraulicTank ............................................................................................................. 39
7.6.4 DrainHydraulicOilTank......................................................................................................... 40
7.6.5 FillHydraulicOil...................................................................................................................... 40
7.7 CheckMountingHydraulicJack.............................................................................................42
8 ElectricalSystem ................................................................................................ 43
8.1 ChargingtheBattery................................................................................................................43
8.2 ChargingBatteryUsing24VCharger.....................................................................................44
8.3 ChargingBatteryUsing12VCharger.....................................................................................45
8.4 StartingwithAuxiliaryBattery................................................................................................46
9 FireFightingEquipment..................................................................................... 47
9.1 CheckFireExtinguishers ........................................................................................................47
9.2 CheckEmergencyStopsandWorkLights............................................................................48
9.3 CheckFireExtinguishers ........................................................................................................49
10 ControlSystemandSensors ............................................................................. 51
10.1 GeneralMaintenanceControlSystemandSensors.............................................................51
10.1.1 RemoteControlBattery .......................................................................................................... 51
10.1.2 CleaningRemoteControl ....................................................................................................... 51
11 CoolingSystem ................................................................................................... 53
11.1 CoolingSystemOverview .......................................................................................................53
11.1.1 CleanRadiators ...................................................................................................................... 54
11.1.2 CheckCoolantLevel .............................................................................................................. 55
11.1.3 AddCoolant ............................................................................................................................ 56
12 Operator'sEnvironment ..................................................................................... 57
12.1 CheckCabin .............................................................................................................................57
12.2 ReplacingAirConditionMainAirFilter .................................................................................58
12.3 ReplacingAirConditionPrefilter ..........................................................................................58
12.4 ReplacingAirConditionCirculationFilters...........................................................................59
12.5 TroubleshootingAC.................................................................................................................59
13 TrackFrames....................................................................................................... 61
13.1 TensioningtheCrawlerTracks...............................................................................................61
13.2 CheckingTrackFramesTorques ...........................................................................................62
13.3 ProceduresforCheckingWear...............................................................................................63
13.3.1 CheckingforFrontWheelWear ............................................................................................. 63

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13.3.2 CheckingforTrackRollerWear ............................................................................................. 64
13.3.3 CheckingforCarrierRollerWear ........................................................................................... 64
13.3.4 CheckingforTrackShoeWear .............................................................................................. 65
13.3.5 CheckingforWearonTrackShoe ......................................................................................... 65
13.3.6 CheckingforTrackLinkDepthWear...................................................................................... 66
13.3.7 CheckingforBushingWear.................................................................................................... 66
13.3.8 CheckingforTrackChainElongationWear ........................................................................... 67
13.4 CheckTrackFrames ................................................................................................................68
13.5 CheckTrackFrames ................................................................................................................68
13.6 CheckTrackFrames ................................................................................................................69
13.7 ChangeOilonTrackFrames ..................................................................................................70
14 DustCollector...................................................................................................... 71
14.1 CheckingFunctionofDustCollector.....................................................................................71
14.2 CheckDustCollectorFilters ..................................................................................................72
14.3 ReplaceDustCollectorFilters ................................................................................................72
15 DieselEngine....................................................................................................... 75
15.1 CheckMotorOilLevel .............................................................................................................75
15.2 DrainPreFilter .........................................................................................................................76
15.3 FuelQuality...............................................................................................................................76
15.4 DrainingFuelTank...................................................................................................................76
15.5 FillingwithFuel ........................................................................................................................77
15.6 DEFFluid ..................................................................................................................................77
15.7 LocationofDEFTank ..............................................................................................................78
15.8 DrainingDEFTank ...................................................................................................................78
15.9 FillingwithDEFFluid...............................................................................................................79
15.10ReplacePreFilter.....................................................................................................................79
15.11ReplaceSecondaryFuelFilter................................................................................................80
15.12ReplacingDEFTankFilter.......................................................................................................80
15.13Belts ..........................................................................................................................................81
15.13.1 ReplaceMultibelt ................................................................................................................... 81
15.14ReplaceLongtermEffectiveCoolant ....................................................................................82
15.15AirSystem ................................................................................................................................83
15.15.1 AirFilterIndicatorFunction..................................................................................................... 84
15.15.2 ReplacetheFilterCartridge.................................................................................................... 84
16 CompressedAirSystem..................................................................................... 87
16.1 OverviewAirCompressorSystem .........................................................................................87
16.2 CheckCompressorOilLevel ..................................................................................................89
16.3 OilChangeandOilFilterReplacement..................................................................................89
16.4 ReplacingAirCompressorOilandOilFilter .........................................................................89
16.5 ChangeOilonCompressor.....................................................................................................91
16.6 ReplaceSeparatorFilter..........................................................................................................92
16.7 ChangingtoNewTypeofCompressorOil ............................................................................92
16.8 FlushingAirCompressor ........................................................................................................94
16.9 CheckCompressorComponents ...........................................................................................96
16.10DrainCompressor....................................................................................................................96

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16.11CleanCompressorOilCooler .................................................................................................97
17 AutomaticCentralLubricationSystemCLS..................................................... 99
17.1 CentralLubricationSystemPump .........................................................................................99
17.2 SettingLubricationandIntervalTime..................................................................................100
17.3 CheckConditionofCLSpump .............................................................................................101
17.4 SettingLubricationPump .....................................................................................................102
17.5 FillingLubricant .....................................................................................................................103
17.6 BleedingLubricationPump ..................................................................................................103
17.7 LubricationPumpProgramDisplayAlarmList ..................................................................104
17.8 TroubleshootingCLS.............................................................................................................104
18 WaterMistSystem ............................................................................................ 107
18.1 CheckSealsonWaterMistPump ........................................................................................108
18.2 FillingWaterMistTank ..........................................................................................................109
18.3 DrainingWaterMistSystem..................................................................................................110
18.4 StartingUpWaterMistSystemfromDry.............................................................................111
18.5 CleanFilterinWaterMistTank.............................................................................................112
19 Welding .............................................................................................................. 113
19.1 AboutWelding........................................................................................................................113
19.2 CANBusSystemDisconnectionBeforeWelding...............................................................113
20 Downtime ........................................................................................................... 115
20.1 PreparationsBeforeLongPeriodofDowntime ..................................................................115
20.2 RestoringAfterLongPeriodofDowntime ..........................................................................115
20.3 InspectionandMaintenanceDuringPeriodofDowntime..................................................116
21 StartUp .............................................................................................................. 117
21.1 AboutSpecialStartUp ..........................................................................................................117
21.2 PerformingSpecialStartUp .................................................................................................117
21.3 FlushingofHosesandPipes ................................................................................................117
21.4 AboutTestingPressureReleaseValves..............................................................................118
22 Options............................................................................................................... 119
22.1 Winch ......................................................................................................................................119
22.1.1 CheckAttachmentofWinchCable....................................................................................... 119
22.1.2 CheckWinchUnitAttachment.............................................................................................. 120
22.1.3 LubricateWinch .................................................................................................................... 121
22.1.4 CheckWinch ........................................................................................................................ 122
22.1.5 CheckSmallRemoteControl ............................................................................................... 122
22.2 ServiceToolBagRCS ...........................................................................................................123
22.3 CheckingCANNetwork .........................................................................................................124
22.4 CheckingCANPowerSupply ...............................................................................................124
22.5 CheckingCANCable .............................................................................................................124
22.6 CheckingDigitalInputsonI/OModule ................................................................................125
22.7 CheckingDigitalOutputsVoltageonI/OModule ...............................................................126
22.8 CheckingDigitalOutputsCurrentonI/OModule ...............................................................127
22.9 CheckingPWMOutputsCurrentonI/OModule..................................................................128

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22.10CheckingAnalogInputsonI/OModule ...............................................................................129
22.11EncoderInputs .......................................................................................................................129
22.12CheckingResolverModuleResolverInputs .......................................................................130
22.13CheckingResolverModuleEncoderInputs ........................................................................131
22.14CheckingResolverModuleAnalogInputs ..........................................................................131
22.15ReplacingaRCSModule.......................................................................................................133
23 Specifications.................................................................................................... 135
23.1 StandardTighteningTorquesBoltedJoints .......................................................................135
23.2 SignsforOrderingSpareParts ............................................................................................136
Maintenancetable ............................................................................................. 137

SmartROC T45-11 Table of Contents
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SmartROC T45-11 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 T45-11 1 Introduction
10

SmartROC T45-11 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 T45-11 2 About Maintenance Management
12

SmartROC T45-11 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 T45-11 3 General Machine Condition
14

SmartROC T45-11 4 Boom Unit
15
4 BoomUnit
4.1 LubricateBoomandFeeder
nPumpgreaseinto21greasenipples(A).

SmartROC T45-11 4 Boom Unit
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4.2 CheckBoomCondition
nCheckmountingonboomhead(A).Tighteningtorque73Nm(54lbf.ft).
nCheckclearancebetweenfeedandfeedbracket(B).Clearance24mm.
nCheckmountingonthefeedbracket(C).Tighteningtorque185Nm(136Ibf.ft).
nCheckclearancebetweenbushes,shaftandholder(D).Ifnecessarychangebushes
andperhapsalsotheshaft.
nCheckclearanceonthebearingsincylinderlugs(E).Maximumclearance1mm.
nCheckmounting,damage.9platesonlockingplates(F).Tighteningtorque73Nm(54
lbf.ft).

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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).

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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.

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5.3 CheckFeedBeam
Thefeedbeamisfittedwithblackprotectiveplasticcovers(A).Thecoversisdesignedto
preventthechainandbeamfromdamagingeachother
1. Checkcoversforwear.
Result èIfcoversareworn,theymustbereplaced.

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5.4 CheckChainGuide
nCheckthechainguide(B)forwear.Ifchainguideisdamagedoroverlyworn,replace
it.
5.5 CheckSprocketWheel
Asageneralrule,replacethedriveoneverythirdchainchange.
AWornSprocketWheel
nCheckwhetherthereareunevenpatches.
nCheckthatthechainrunssmoothlywhenthechainiscoupledinandoutofthe
sprocketwheel.
nInspecttheteethforreducedareasandsharppoints.