Atlas Copco Secoroc 7655 User manual

Secoroc 76 Series Rock Drill
Secoroc 7655/7655D Pusher Leg Rock Drill
Operator's instructions / Spare parts list
Secoroc Rock Drilling Tools

2
Foreword
Thank you for selecting the Secoroc pusher leg rock drill 7655/7655D.
These instructions were developed to help you get the best performance and
productivity from the use of your new rock drill.
Please refer to them also for the correct maintenance of the rock drill.

3
Table of Contents
Scope of application ................................................... 4
Specification ....................................................... 4
Safety instructions..................................................... 5
Operation ............................................................ 6
Using the rock drill for the first time.................................... 6
Preparations before starting .......................................... 6
Fitting and removing the drill steel..................................... 7
Before fitting the drill steel .........................................7
Fitting the drill steel ...............................................8
Removing the drill steel............................................8
Attaching the pusher leg to the rock drill ................................ 8
Controls ........................................................... 9
Throttle lever.....................................................9
Feed control .....................................................9
Trigger.........................................................10
Oil regulating valve ..............................................10
Drilling ........................................................... 11
Starting the rock drill .............................................11
Stopping the rock drill ............................................11
Checking the lubrication ..........................................11
Re-positioning the pusher leg .....................................11
Blow-cleaning the drill hole........................................11
When you have finished drilling ....................................12
Maintenance ...................................................... 12
Once a shift (after 8 hours of operation) .............................12
Once a week (after 40 hours of operation) ............................12
Once a month (after 200 hours of operation)..........................12
Selection of spare parts ............................................. 13
Storage .......................................................... 13
Scrapping and waste disposal ....................................... 13
Trouble shooting ..................................................... 14
Spare parts list and exploded drawing ................................... 16

4
Scope of application
Model 7655 is a highly efficient rock drill. It is mainly used in either rock drilling
work such as mining and tunneling, or in railway, water conservancy construction
projects and stone work. It is suitable for wet drilling on hard and medium hard
rock, or for drilling horizontal or inclined blast holes. 7655 can be equipped with
pusher leg FT160A and FY200A lubricator.
Model 7655D is a low energy consumption rock drill based on model 7655. It has
good performance at low air pressure, with long air lines or powered by small sized
air compressor. 7655D is mainly used in the same applications as the 7655. It can be
equipped with pusher leg FT160A and FY200A lubricator.
Specification
Pneumatic rock drills 7655 and 7655D
7655 7655D
Weight 24 24 kg
Dimension (L x W x H) 628 x 232 x 207 668 x 232 x 202 mm
Cylinder diameter 76 70 mm
Piston stroke 55 70 mm
Minimum working pressure 3 3 bar(e)
Impact energy (at 6.3 bar (e)) ≥65 ≥65 J
Impact energy (at 5.0 bar (e)) ≥59 ≥57 J
Impact energy (at 4.0 bar (e)) ≥42 ≥44 J
Air consumption (at 6.3 bar (e)) ≤80 ≤80 l/s
Air consumption (at 5.0 bar (e)) ≤54 ≤52 l/s
Air consumption (at 4.0 bar (e)) ≤50 ≤45 l/s
Impact frequency (at 6.3 bar (e)) ≥37 ≥32 Hz
Impact frequency (at 5.0 bar (e)) ≥36 ≥31 Hz
Impact frequency (at 4.0 bar (e)) ≥34 ≥30 Hz
Torque (at 6.3 bar (e)) ≥18 ≥18 Nm
Torque (at 5.0 bar (e)) ≥15 ≥15 Nm
Torque (at 4.0 bar (e)) ≥12 ≥12 Nm
Water pressure working pressure -1 working pressure -1 bar(e)
Air hose inner diameter 25 19 mm
Water hose inner diameter 13 13 mm
Drilling diameter 34–42 34–42 mm
Max drilling depth 5 5 m
Working temperature -30 to +50 -30 to +50 ºC
Shank size H22x108±1 H22x108±1 mm
Noise level ≤125 dB(A)
Lubricator FY200A
Weight 1.2 kg
Capacity 0.2 litre

5
Safety instructions
To reduce the risk of serious injury or death to yourself or others, carefully read
through this instruction booklet before putting the rock drill to use. Always follow
the instructions given in this manual.
hAlways wear a safety helmet, impact resistant eye protection with side protection
and ear protectors with CE mark during drilling. Any local regulations that exist
must also be observed.
hWhen drilling in certain minerals, there is a risk of spark generation. Before
starting work, check that the machine is approved (in accordance with local
regulations) for work under such conditions.
hAlways take great care when using the machine. The drill steel is subjected to
heavy loading and can break, with a risk of injury to personnel.
hCheck that the hoses used are of the right quality, and that all hose connections
are in good condition and properly tightened.
hBefore starting work on any of the systems, make sure that the air and water
systems are without pressure.
hMake sure that there are no concealed wires or other sources of electricity. Never
drill near any electric wires or other sources of electricity.
hExposure to crystalline silica (sometimes called 'silica dust') as a result of drilling
in rock may cause silicosis, cancer or death. Never operate the rock drill without
water flushing.
hA compressed air hose that comes loose can lash around and cause personal
injury or death. Check that the compressed air conections are not damaged and
that they are properly attached.

6
Operation
Using the rock drill for the first time
When the rock drill arrives from the factory, the inside of the machine is coated with
heavy oil to prevent corrosion.
After unpacking and installing the machine, pour a small amount of lubrication
oil into the air connection and operate the machine on partial throttle to clean the
interior. Follow this immediately with a liberal amount of air tool oil.
The rock drill and pusher leg are lubricated with oil mixed with compressed air,
which is taken to the parts that need continuous lubrication. Oil is metered into the
compressed air using the FY200A lubricator connected to the air line.
Preparations before starting
1. Check the drilling equipment
hCheck that all of the drilling equipment is in good working order.
hCheck that the impact surface of the drill steel shank is flat with no signs of wear.
hMake sure that the air inlet and exhaust ports are free from obstructions.
hCheck that the flushing holes in the drill steel and drill bit are not blocked and
that the flushing air/water flows through without obstruction.
hEnsure that the fittings are tight and leak-proof.
WARNING
A compressed air hose that comes loose can lash around and cause personal injury or
death. Check that the compressed air conections are not damaged and that they are
properly attached.
2. Blow out the air hose
Every day before using the drill, blow out the air hose to clear it from accumulated
dirt and moisture.
3. Check the lubrication oil level
hFill the lubricator with oil if necessary.
hAlways use a recommended lubricant.
Lubricant recommendation
Use a mineral-based air tool oil
Ambient
temperature ºC
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

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4. Air/water pressure and hose dimensions
Air pressure
Ensure that the compressor can deliver the required air pressure of 5 bar at the
machine.
hHigh pressure (>6.3 bar) causes rough operation and damage.
hLow pressure (<4 bar) results in a slow drilling speed.
Water pressure
Set the water preassure to around 3 bar. Maximum water pressure is 1 bar less
than the working pressure. For example if the air pressure is 5 bar, the water
pressure must be below 4 bar to prevent water entering the impact mechanism.
Air hose dimensions
The air hose diameter for model 7655 must be no less than 25 mm and no less than
19 mm for model 7655D. The inner diameter of connection nipples and hoses must
be no less than 19 mm. The ideal overall air hose length is less than 15m.
Water hose dimensions
The water hose inner diameter for model 7655 and 7655D must be no less than ½".
5. Prevent freezing
In low ambient temperatures, ice can form in the machine. This can be avoided if
the water in the compressed air is removed. This can be done by equipping the air
lines with water separators and drainage points for water condensate.
If the rock drill ices up, it must not be heated to melt the ice. Let the ice thaw at
room temperature.
Do not pour methylated spirits or similar substances into the rock drill, as they will
interfere with the lubrication and lead to increased wear.
Fitting and removing the drill steel
Before fitting the drill steel
hCheck that the drill steel shank is of the correct size and length for the chuck
used.
hThe shank must be clean and the drill steel must be in good condition.
hThe suitable quenching hardness of the shank is HRC48-53. A harder end face will
cause piston damage and breakage of the end face of the piston. If the shank face
is too soft it will be easily deformed by the piston which will result in difficulty in
removing the drill steel.
hThe shank end face shall be flat and perpendicular to the axis.
hRemove sharp edges from the shank's end face. A rough shank surface will cause
premature piston failure.
hInspect the drill steel: A dull drill steel will slow down the drilling speed and
overstrain the drill mechanism. When changing drill steel make sure that the new
one is the correct size to follow your previous bore.

8
hBefore drilling check that the flushing hole in the drill steel is not blocked.
Fitting the drill steel
1. Push the retainer outwards in the direction of the arrow (see picture below),
until the front portion of the retainer is able to accommodate the drill steel
collar.
2. Insert the drill in the chuck.
3. When the drill bottoms, push back the retainer to lock it.
Removing the drill steel
1. Push the retainer outwards in the direction of the arrow until the drill steel
collar disengages from the front of the retainer.
2. Pull the drill steel out.
3. Push back the retainer.
Attaching the pusher leg to the rock drill
hMount the pusher leg (1), lock sleeve (2), rubber pad (3), washer (4) and locking
nut (5) in the order shown in the picture below.
hTurn the locking nut clockwise with a wrench until you hear a "click".

9
Controls
Throttle lever
The rock drill is equipped with a throttle lever for regulating both the compressed
air to the percussion mechanism and the flushing water.
A. Extra blowing, water flushing off, impact and rotation off.
B. Stop position, air and water off
C. Low throttle, air to pusher leg, water flushing
D. Medium throttle
E. Full throttle
Feed control
Adjust the feed force using the feed control lever.
A. Pushing the lever in this direction will increase feed force.
B. Pulling the lever in this direction will decrease feed force

10
Trigger
When the trigger (A) is pushed in, the feed force stops abruptly and the setting
on the feed control lever is overridden. The piston rod in the pusher leg retracts
automatically. This function is used for example to adjust the height of the rock
drill, when rigging up the pusher leg, or when there is a tendency to jam. When the
trigger is released, the feed control setting is activated again.
Oil regulating valve
Oil dosing is controlled using a screwdriver. Tighten the nut after regulation.
Check that sufficient lubrication is obtained by putting your hand in front of the
exhaust port while adjusting the regulating valve. If the hand is covered by a thin
film of oil after a few seconds, the lubricator has been correctly adjusted. Too much
oil will have negative effects on the operation whilst too little will result in damage
to parts as the temperature rises during operation.
The amount of oil going into the rock drill increases when turning the valve counter
clockwise, and it decreases when turning the valve clockwise. Oil consumption is
2.5–6 ml/minute.

11
Drilling
Starting the rock drill
1. Open the main valve for compressed air.
2. Open the cock for the flushing water.
3. Adjust the feed control lever to give a suitable feed force for collaring the hole.
4. Align the rock drill so that the drill steel touches the desired collaring point.
5. Move the throttle lever forward a little, which will start water flushing,
percussion and rotation.
6. Collar the hole with reduced feed force.
7. Move the throttle lever fully forward once the drill steel has gained a secure
footing in the rock.
8. Adjust the feed force using the control lever so that the maximum penetration
rate is obtained.
Note! Do not bend the drill steel as this will increase wear of the shank bushing and
piston. It can also affect drilling efficiency and increase the risk of drill steel
breakage.
Stopping the rock drill
Pull the throttle lever backwards, which will stop percussion, rotation and flushing
water.
Checking the lubrication
The chuck and drill steel shank must allways be covered by a film of oil.
Re-positioning the pusher leg
1. Switch off the rock-drill percussion and flushing using the throttle lever.
2. Press the trigger, whereupon the piston rod is pulled back into the pusher-leg
cylinder automatically.
3. Re-position the pusher leg.
4. Release the trigger, whereupon the piston rod will move outwards again.
5. Move the throttle lever forward into the working position.
Note!The feed control lever does not need to be touched throughout this operation.
Blow-cleaning the drill hole
CAUTION
When blow-cleaning, particles and dirty flushing water can emerge at speed from
the drill hole.
hMove to the side and cover your eyes before starting to blow-clean the drill
hole.
hAlways wear impact resistant eye protection with side protection to avoid
injury.
hMake sure that no co-workers are in range when blow-cleaning.
If powerful blow-cleaning of the drill hole is required, turn the throttle lever fully
backwards beyond the stop position for extra blowing whereupon the rock drill

12
stops. This can be done during drilling. When the drill hole is clean, turn the throttle
lever forwards again to re-start the rock drill.
When you have finished drilling
Run the rock drill at medium speed when retracting the drill steel from the drilled
hole.
Lay down the rock drill on a stone, wooden plank or similar object, so as to prevent
drill cuttings and other foreign matter from entering the chuck.
Turn off the water pressure before the air pressure. Run the rock drill for a few
seconds to clean out water and moisture after the water has been shut off.
Maintenance
Regular maintenance is a prerequisite for machine safety. Replace damaged and
worn components in good time.
Check the machine and drill steel for wear and damage at regular intervals. Do not
use a very worn or damaged drill steel.
When cleaning mechanical parts with a solvent, make sure that you comply with
current health and safety regulations and ensure that there is sufficient ventilation.
Daily maintenance, regular checking of wearing parts and carrying out repairs in
good time prevents breakdowns and increases the service life of the machine.
hMake sure that no foreign matter enters the machine.
hAlways hose down and wipe clean the rock drill and pusher leg after use.
Once a shift (after 8 hours of operation)
hCheck the wear in the chuck bushing. If the wear limit has been exceeded, the
drill steel shank will wear more quickly, or become deformed. This will lead to
stoppages and increased drill steel consumption.
hCheck the rock drill's connection to the pusher leg.
hCheck the hoses, couplings and controls for leakage and damage.
hCheck that the rock drill and pusher leg are receiving enough lubrication. Fill the
lubricator as necessary.
hEvery day before using the drill, blow out the air hose to clear it from
accumulated dirt and moisture.
hDrain the water separator.
hCheck the air and water pressure. Make sure that the water pressure is at least 1
bar lower than the air pressure.
Once a week (after 40 hours of operation)
Carry out a basic check of all functions of the drilling equipment.
Once a month (after 200 hours of operation)
hSend the rock drill to a workshop for inspection. The local operating conditions
will determine whether or not this is a suitable interval for overhauling the drill.
hDismantle and clean the lubricator.

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hClean out the water separator.
Selection of spare parts
Use only genuine parts for replacement, to ensure stable performance. Do
not use pattern parts, which not only have a short working life but also cause
consequential damage to other parts, due to differing measurements and methods
of manufacturing.
Storage
hAlways oil the rock drill and pusher leg well before you put them into storage.
hStore the rock drill and pusher leg in a clean and dry place.
hIn the case of long-term storage, pour a quantity of oil directly into the rock-drill's
air intake and then turn on the air briefly. This will protect the machine from
corrosion.
hProtect the chuck using a wooden plug or a clean piece of cotton waste.
Scrapping and waste disposal
Used and worn-out machines must be disposed of in such a way that as much of
the material as possible can be recycled and the impact on the environment is kept
to a minimum.

14
Trouble shooting
Problem Cause Solution
Decreased
penetration rate
Air leakage in hoses,
couplings
Change packings, and where
required, change parts in the
throttle valve
Shank sleeve Check the shank sleeve for
excessive wear. Replace if
necessary.
Air leakage due to worn
piston/cylinder
Replace the piston and/or cylinder
Air leakage due to worn
guide sleeve/pilot guide
Change the worn part
Insufficient feed
force
Piston rod seal (in pusher
leg) worn or deformed
Change the seal
O-rings on pusher leg
coupling worn or deformed
Change the o-ring
Poor rotation Splines of the rifle nut worn Replace the rifle nut if the splines
are worn
Splines of the rifle bar worn
down
Replace the rifle bar when needed
Splines on the piston worn
down
Replace the piston when needed
The toothing in the ratchet
housing is worn out
Replace the ratchet housing if the
tooth housing is so worn that the
pawls have difficulty catching
The toothing in the ratchet
wheel is worn out
Replace the ratchet wheel if the
toothing is so worn that the pawls
have difficulty catching
Chuck nut worn out Replace the chuck nut if the splines
have been worn to 1/2 of the spline
width
Pawls worn Replace all pawls, all pawl springs
and all pawl pins
Uneven running Piston has seized in the
guide sleeve or the piston
guide
Replace the guide sleeve/piston
guide. If required, polish the piston.
Check the piston for heat damage
such as blue colouring and/or
fissures. If it is damaged in this
way, replace the piston as well
Dirty or damaged main
valve. Caused by impurities
or foreign matter entering
the drill with the compressed
air
Clean and polish the valve so that
it seals against the corresponding
cylindrical and plane sealing
surfaces. If this is not possible
because the defects are too serious,
the valve must be replaced
Freezing. Caused by leakage
in the flushing system or
by excess water in the
compressed air or by
excessive water pressure
Check the flushing tubes and seals
and the water pressure. Drain water
from the compressed air system. If
the problem continues,
fit a water separator in the airline
system.

15
Problem Cause Solution
Uneven running
(continued)
The side bolts are unevenly
or insufficiently tightened.
Can cause the various parts
to lose their alignment,
resulting in the seizure
of the movable parts.
Abnormal strains on the
side bolt may result in
fracture at the threads.
Check and repair any damage to
the contact points and tighten the
bolts with the correct tightening
torque
The drill gets
hot
Lack of oil Add oil and check that it runs
through. It is not sufficient that
there is oil in the exhaust air.
There must also be an oil coating
on the shank of the drill steel.
Freezing High level of humidity in the
compressed air
Use water traps
Water pressure higher than
the air pressure
Lower the water pressure
Water pipe
breakage
Misalignment of the shank Change drill steel or shank sleeve
or both
Damaged flushing hole in
the shank
Change drill steel
Chipping of the
piston tip
Misalignment of the shank Change the drill steel or shank
sleeve or both
Excessive wear of the
piston tip
Change piston
Spline breakage Lack of lubrication Lower the water pressure if it is
the same as or greater than the
air pressure
Increase lubrication or change oil
Dirt intrusion (specially
when drilling upwards)
Increase service intervals
Piston breakage Lack of lubrication Lower the water pressure if it is
the same as or greater than the
air pressure
Increase lubrication or change oil
Uneven tension in the side
bolts
Tighten the bolts correctly
Worn guide sleeve/piston
guide (can be confirmed by
the cushion test)
Change the worn part
Side bolt
breakage
Uneven tension on the bolts Tighten the bolts correctly

16
Spare parts list and exploded drawing

17
No. Description Quantity Product no. Product code
7655 7655D
1 Handle 1 1 96000819 9600-1-3312310016
2 Roll pin 1 1 96000527 9605-1-3312310708
3 Trigger 1 1 96000820 9600-1-3312310017
4 Circlip 1 1 96000183 9605-1-3312310173
5 Spring cap 1 1 96000169 9605-1-3312310159
6 Spring 1 1 96000170 9605-1-3312310160
7 O-ring 3 3 96000482 9605-1-3312310627
8 Water valve 1 1 96000173 9605-1-3312310163
9 O-ring 2 2 96000489 9605-1-3312310642
10 Rubber pad 1 1 96000175 9605-1-3312310165
11 Water valve body 1 1 96000171 9605-1-3312310161
12 O-ring 1 1 96000181 9605-1-3312310171
13 Water tube sleeve - 1 96000835 9601-1-3312310035
13 Water tube sleeve 1 - 96000822 9600-1-3312310019
14 Air tube - 1 96000837 9601-1-3312310037
15 Back head - 1 96000834 9601-1-3312310034
15 Back head 1 - 96000829 9600-1-3312310026
16 Lock pin 1 1 96000180 9605-1-3312310170
17 Spring 1 1 96000179 9605-1-3312310169
18 Ratchet pawl 4 4 96000166 9605-1-3312310155
19 Conical spring 4 4 96000167 9605-1-3312310156
20 Lock pin 1 1 96000177 9605-1-3312310167
21 Operation handle 1 1 96000178 9605-1-3312310168
22 Standard spring pad 1 1 96000534 9605-1-3312310716
23 Hexagon thin nut 1 1 96000524 9605-1-3312310704
24 Rifle bar - 1 96000102 9602-1-3312310075
24 Rifle bar 1 - 96000810 9600-1-3312310005
25 Ratchet 1 1 96000805 9600-1-3312310000
26 Lock pin - 1 96000839 9601-1-3312310039
26 Lock pin 1 - 96000809 9600-1-3312310004
27 Valve chest - 1 96000840 9601-1-3312310040
27 Valve chest 1 - 96000806 9600-1-3312310001
28 Valve - 1 96000841 9601-1-3312310041
28 Valve 1 - 96000807 9600-1-3312310002
29 Valve sleeve - 1 96000842 9601-1-3312310042
29 Valve sleeve 1 - 96000808 9600-1-3312310003
30 Rifle nut 1 1 96000814 9600-1-3312310009
31 Piston - 1 96000843 9601-1-3312310044
31 Piston 1 - 96000811 9600-1-3312310006

18

19
No. Description Quantity Product no. Product code
7655 7655D
32 Spring fixing ring 1 1 96000831 9600-1-3312310028
33 Change valve 1 1 96000827 9600-1-3312310024
34 Expansion ring 1 1 96000830 9600-1-3312310027
35 Pressure regulating valve 1 1 96000828 9600-1-3312310025
36 O-ring 2 2 96000486 9605-1-3312310633
37 Control valve - 1 96000090 9601-1-3312310048
37 Control valve 1 - 96000824 9600-1-3312310021
38 Pad 1 1 96000174 9605-1-3312310164
39 Check ring 1 1 96000182 9605-1-3312310172
40 Air tube nut 1 1 96000823 9600-1-3312310020
41 Pad 1 1 96000184 9605-1-3312310174
42 Air tube swivel 1 1 96000825 9600-1-3312310022
43 Water tube connector 1 1 96000826 9600-1-3312310023
44 Silencer 1 1 96000137 9603-1-3312310125
45 Hoop 1 1 96000542 9605-1-3312310725
46 Cylinder - 1 96000838 9601-1-3312310038
46 Cylinder 1 - 96000812 9600-1-3312310007
47 Guide sleeve - 1 96000844 9601-1-3312310045
47 Guide sleeve 1 - 96000813 9600-1-3312310008
48 Side bolt - 2 96000151 9603-1-3312310140
48 Side bolt 2 - 96000832 9600-1-3312310029
49 Hexagon thick nut 2 2 96000518 9605-1-3312310697
50 Rotation sleeve - 1 96000089 9601-1-3312310047
50 Rotation sleeve 1 - 96000816 9600-1-3312310011
51 Shank sleeve 1 1 96000168 9605-1-3312310157
52 Front head - 1 96000845 9601-1-3312310046
52 Front head 1 - 96000815 9600-1-3312310010
53 Hexagon lock nut 2 2 96000531 9605-1-3312310713
54 Retainer spring 2 2 96000818 9600-1-3312310013
55 Retainer bolt 2 2 96000634 9600-1-3312311820
56 Retainer 1 1 96000635 9600-1-3312311821
57 Water tube - 1 96000836 9601-1-3312310036
57 Water tube 1 - 96000821 9600-1-3312310018
58 Air tube pad - 1 96000176 9605-1-3312310166
59 Small seal 2 2 96000543 9605-1-3312310726
60 Large seal 1 1 96000544 9605-1-3312310727
61 Hoop 1 1 96000540 9605-1-3312310723
62 Wing nut - 1 96000218 964H-1-3312310213
62 Wing nut 1 - 96000185 9605-1-3312310175
63 Conical hose nipple - 1 96000222 9605-1-3312310219
63 Conical hose nipple 1 - 96000186 9605-1-3312310176
64 Pipe connector - 1 96000223 9605-1-3312310220
64 Pipe connector 1 - 96000187 9605-1-3312310177

Atlas Copco Secoroc AB
Box 521, SE-737 25 Fagersta, Sweden
Phone: [phone]
E-mail: [email protected]
www.atlascopco.com
9852 3029 01 2012.06