Atlas Copco Secoroc YSP Series User manual

Secoroc YSP Series Rock Drill
Secoroc YSP 45 Stoper
Operator's instructions / Spare parts list
Secoroc Rock Drilling Tools

2
Foreword
Thank you for selecting the Secoroc stoper YSP45.
These instructions were developed to help you get the best performance and
productivity from the use of your new stoper.
Please refer to them also for correct maintenance of the stoper.

3
Table of Contents
Scope of application ................................................... 4
Specification ....................................................... 4
Safety instructions..................................................... 5
Operation ............................................................ 6
Using the stoper for the first time...................................... 6
Preparations before starting .......................................... 6
Before fitting the drill steel ........................................... 7
Controls ........................................................... 8
Throttle lever.....................................................8
Feed control knob.................................................8
Exhaust valve button ..............................................9
Oil regulating valve ...............................................9
Drilling ............................................................ 9
Starting the stoper ................................................9
Stopping the stoper ..............................................10
When you have finished drilling ....................................10
Maintenance ...................................................... 10
Once a shift (after 8 hours of operation) .............................10
Once a week (after 40 hours of operation) ............................11
Once a month (after 200 hours of operation)..........................11
Selection of spare parts ............................................. 11
Storage .......................................................... 11
Scrapping and waste disposal ....................................... 11
Trouble shooting ..................................................... 12
Spare parts list and exploded drawing ................................... 14

4
Scope of application
Model YSP45 is a high frequency stoper. The blast hole angle range is from
60º–90º. YSP45 is mainly used for production drilling, raise driving and bolting. It is
equipped with FY500 lubricator.
Specification
Stoper YSP45
Weight 44 kg
Dimension (L x W x H) 1420x390x160 mm
Cylinder diameter 95 mm
Piston stroke 47 mm
Pusher leg stroke 750 mm
Pusher leg inner diameter 74 mm
Working pressure 4–6.3 bar(e)
Impact energy (at 6.3 bar(e)) ≥73.5 J
Impact energy (at 5 bar(e)) ≥70 J
Impact energy (at 4 bar(e)) ≥57 J
Air consumption (at 6.3 bar(e)) ≤113.3 l/s
Air consumption (at 5 bar(e)) ≤83 l/s
Air consumption (at 4 bar(e)) ≤80 l/s
Drilling frequency (at 6.3 bar(e)) ≥46 Hz
Drilling frequency (at 5 bar(e)) ≥45 Hz
Drilling frequency (at 4 bar(e)) ≥42 Hz
Torque (at 6.3 bar(e)) ≥21
Torque (at 5 bar(e)) ≥18
Torque (at 4 bar(e)) ≥15
Water pressure working pressure -1 bar(e)
Air hose inner diameter 25 mm
Water hose inner diameter 13 mm
Drilling diameter 34–42 mm
Max drilling depth 6 m
Working temperature -30 to +50 ºC
Shank size H22x108±1 mm
Lubricator FY500
Weight 2.5 kg
Capacity 0.52 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 stoper 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 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 stoper 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 stoper for the first time
When the stoper 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 stoper is 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 FY500 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

7
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 must be no less than 25 mm. The inner diameter of
connection nipples and hoses must be no less than 20 mm. The ideal overall air
hose length is less than 15m.
Water hose dimensions
The water hose inner diameter 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 stoper 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 stoper, as they will
interfere with the lubrication and lead to increased wear.
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.
hBefore drilling check that the flushing hole in the drill steel is not blocked.

8
Controls
Throttle lever
The stoper is equipped with a throttle lever (T) for regulating both the compressed
air to the percussion mechanism, the blowing and the water flushing. The seven
positions (A to G) of the throttle lever are explained in detail in the table below.
Position Rotation and
percussion
Water flushing Blowing Air to pusher
leg
A off off on (extra strong) off
B off off on on (low)
C off off on on
D on (slight) off on on
E on (low) on (low) on on
F on (medium) on (full) on on
G on (full) on (full) on on
Feed control knob
The pressure regulating valve is located in the back head. It regulates the feed force
of the pusher leg. Increase the feed force by turning the feed control knob (P) in the
direction of the arrow, i.e. counter clockwise.

9
Exhaust valve button
The exhaust valve button (E) controls the exhaust valve which is located in the
cylinder handle. When the exhaust valve button is pushed, the feed force ceases
abruptly, thus overriding the setting on the feed control. The facility is used e.g. to
adjust the height of the stoper, setting up the stoper or to help releasing a jammed
drill steel.
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 stoper increases when turning the valve counter
clockwise, and it decreases when turning the valve clockwise. Oil consumption is
2.5–6 ml/minute.
Drilling
Starting the stoper
1. Open the main valve for compressed air.
2. Open the cock for the flushing water.
3. Adjust the feed control knob to give a suitable feed force for collaring the hole.
4. Align the stoper so that the drill steel touches the desired collaring point.
5. Move the throttle lever downward a little, which will start water flushing,
percussion and rotation.
6. Collar the hole with reduced feed force.
7. Move the throttle lever fully downward once the drill steel has gained a secure
footing in the rock.
8. Adjust the feed force by means of the feed control knob so that the maximum
penetration rate is obtained.

10
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 stoper
Pull the throttle lever upwards, which will stop percussion, rotation and flushing
water.
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
upwards whereupon the stoper stops. This can be done during drilling. When the
drill hole is clean, turn the throttle lever downwards again to re-start the stoper.
When you have finished drilling
Run the stoper at medium speed when retracting the drill steel from the drilled
hole.
Lay down the stoper 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 stoper 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 stoper 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 hoses, couplings and controls for leakage and damage.
hCheck that the stoper is receiving enough lubrication. Fill the lubricator if
necessary.

11
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 stoper 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.
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 stoper well before you put it into storage.
hStore the stoper in a clean and dry place.
hIn the case of long-term storage, pour a quantity of oil directly into the stoper'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.

12
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-rings
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.

13
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

14
Spare parts list and exploded drawing

15
No. Description Quantity Ordering No. Product code
1 Front head 1 96000288 962A-1-3312310293
2 Rotation sleeve 1 96000289 962A-1-3312310294
3 Shank bush 1 96000291 962A-1-3312310296
4 Rotation nut 1 96000290 962A-1-3312310295
5 Silencer 1 96000282 962A-1-3312310287
6 Cylinder 1 96000285 962A-1-3312310290
7 Air cylinder 1 96000287 962A-1-3312310292
8 Valve sleeve 1 96000280 962A-1-3312310285
9 Valve 1 96000279 962A-1-3312310284
10 Ratchet 1 96000277 962A-1-3312310282
11 Small seal 3 96000543 9605-1-3312310726
12 Back head 1 96000292 962A-1-3312310298
13 Air tube 1 96000296 962A-1-3312310302
14 Water tube 1 96000297 962A-1-3312310303
15 O-ring 1 96000485 9605-1-3312310632
16 Yx seal ring 1 96000320 962A-1-3312310329
17 Outer pipe 1 96000314 962A-1-3312310320
18 Lower pipe seat 1 96000315 962A-1-3312310324
19 Guide sleeve 1 96000316 962A-1-3312310325
20 Dust sleeve 1 96000317 962A-1-3312310326
21 Spring pad 1 96000535 9616-1-3312310718
22 Foot 1 96000355 9616-1-3312310385
23 center 1 96000326 9605-1-3312310337
24 Piston rod 1 96000318 962A-1-3312310327
25 Ring 1 96000319 962A-1-3312310328
26 Elastic ring 1 96000333 9616-1-3312310344
27 Water tube nut 1 96000300 962A-1-3312310306
28 Fixing screw 1 96000525 9605-1-3312310705
29 O-ring 1 96000196 962A-1-3312310191
30 Water tube sleeve 1 96000301 962A-1-3312310307
31 Air tube seat 1 96000302 962A-1-3312310308
32 Air tube pad 1 96000176 9605-1-3312310166
33 Valve chest 1 96000278 962A-1-3312310283
34 Rifle nut 1 96000814 9600-1-3312310009
35 Rifle bar 1 96000283 962A-1-3312310288
36 Piston 1 96000284 962A-1-3312310289
37 Guide sleeve assembly 1 96000286 962A-1-3312310291
38 Large rubber pad 1 96000308 962A-1-3312310314
39 O-ring 1 96000481 9605-1-3312310623
40 Water valve 1 96000309 962A-1-3312310315
41 O-ring 2 96000483 9605-1-3312310628
42 Rubber pad 1 96000310 962A-1-3312310316
43 Aluminum plug 1 96000313 962A-1-3312310319

16

17
No. Description Quantity Ordering No. Product code
44 Water hose swivel 1 96000311 962A-1-3312310317
45 Nut 1 96000312 962A-1-3312310318
46 Water valve spring 1 96000305 962A-1-3312310311
47 Water valve body 1 96000298 962A-1-3312310304
48 Control valve 1 96000293 962A-1-3312310299
49 Lock ring 1 96000294 962A-1-3312310300
50 Air hose nut 1 96000295 962A-1-3312310301
51 O-ring 1 96000488 9605-1-3312310640
52 O-ring 1 96000487 9605-1-3312310635
53 Spring 1 96000179 9605-1-3312310169
54 Lock pin 1 96000180 9605-1-3312310170
55 Expansion ring 1 96000830 9600-1-3312310027
56 O-ring 1 96000482 9605-1-3312310627
57 Dowel pin 1 96000560 9605-1-3312311043
58 Pressure regulating valve 1 96000306 962A-1-3312310312
59 Fixing pin 1 96000177 9605-1-3312310167
60 Hexagon thin nut 1 96000524 9605-1-3312310704
61 Spring pad 1 96000534 9605-1-3312310716
62 Control handle 1 96000307 962A-1-3312310313
63 Hexagon nut 2 96000517 9605-1-3312310695
64 Side bolt 2 96000299 962A-1-3312310305
65 Hexagon thick nut 4 96000518 9605-1-3312310697
66 Handle 1 96000869 962A-1-3312311027
67 Exhaust valve 1 96000325 9605-1-3312310336
68 O-ring 1 96000484 9605-1-3312310629
69 Exhaust valve spring 1 96000324 9605-1-3312310335
70 Exhaust valve body 1 96000322 9605-1-3312310333
71 Exhaust valve button 1 96000323 9605-1-3312310334
72 Fixing pin 1 96000281 962A-1-3312310286
73 Conical spring 4 96000167 9605-1-3312310156
74 Ratchet pawl 4 96000166 9605-1-3312310155
75 Air hose swivel 1 96000303 962A-1-3312310309
76 Connector nut 3 96000304 962A-1-3312310310
77 Rubber tube connector 3 96000186 9605-1-3312310176
78 Wing nut 3 96000185 9605-1-3312310175
79 Hoop 3 96000540 9605-1-3312310723
80 Bolt 2 96000321 962A-1-3312310331
81 Hexagon nut 2 96000523 962A-1-3312310703
82 Spring pad 2 96000536 962A-1-3312310719
83 Water valve 1 96000555 962A-1-3312311026
84 Retainer bolt 2 96000634 9600-1-3312311820
85 Retainer spring 2 96000818 9600-1-3312310013
86 Retainer 1 96000635 9600-1-3312311821
87 Locking nut 2 96000531 9605-1-3312310713
88 Dust ring 1 96000870 962A-1-3312312013

NOTES

NOTES

Atlas Copco Secoroc AB
Box 521, SE-737 25 Fagersta, Sweden
Phone: [phone]
E-mail: [email protected]
www.atlascopco.com
9852 3032 01 2012.06