Atlas Copco SMARTROC D65 TIER 4 FINAL Guide

SMARTROC D65 TIER 4 FINAL
Maintenance
Translation of the original instructions
2015-12-17 | No: 713991051.3 en

Reference
!NOTE: Always read the information in the Safety document before starting to use the
rig or starting maintenance work.

SmartROC D65 Tier 4 Final Table of Contents
v
Table of Contents
1 Reference............................................................................................................... 3
2 General................................................................................................................. 11
2.1 General......................................................................................................................................11
2.1.1 Safety .....................................................................................................................................11
2.1.2 Target group and objective..................................................................................................... 11
2.1.3 Contact details........................................................................................................................ 11
2.1.4 Signs for outsourced components .......................................................................................... 16
2.1.5 Dismantling and assembly...................................................................................................... 16
2.1.6 Long-term storage .................................................................................................................. 16
2.1.7 Scaling.................................................................................................................................... 17
2.1.8 Tightening torque in bolted joints............................................................................................ 17
2.1.9 Work on painted surfaces....................................................................................................... 18
2.1.10 Welding...................................................................................................................................18
2.1.11 Welding CAN BUS.................................................................................................................. 19
2.1.12 Diagnostics ............................................................................................................................. 20
2.2 Battery.......................................................................................................................................20
2.2.1 Environmental considerations regarding batteries .................................................................20
2.2.2 Charging the battery ............................................................................................................... 20
2.2.3 Starting with an auxiliary battery............................................................................................. 22
2.3 Steel ropes................................................................................................................................23
2.3.1 Scrapping guidelines for steel cables ..................................................................................... 23
2.4 Air conditioning........................................................................................................................29
2.4.1 Safety .....................................................................................................................................29
2.4.2 Environmental issues when handling refrigerant.................................................................... 29
2.4.3 Changing air filter ...................................................................................................................29
2.4.4 Diagnostics ............................................................................................................................. 30
3 Transport instructions........................................................................................ 33
3.1 Hoisting.....................................................................................................................................33
3.1.1 Single-section boom version ..................................................................................................33
3.2 Transport ..................................................................................................................................34
3.2.1 Before loading the drill rig onto the transport vehicle .............................................................35
3.2.2 Once the drill rig is loaded onto the transport vehicle............................................................. 35
3.3 Towing.......................................................................................................................................36
4 Hardware RCS ..................................................................................................... 39
4.1 Display, application and CCI module .....................................................................................39
4.1.1 Connections............................................................................................................................ 39
4.1.2 Pin configurations ................................................................................................................... 40
4.1.3 LED functions ......................................................................................................................... 40
4.2 Resolver module ......................................................................................................................41
4.2.1 Connections............................................................................................................................ 41
4.2.2 Pin configurations ................................................................................................................... 41
4.2.3 LED functions ......................................................................................................................... 42
4.3 I/O module.................................................................................................................................43
4.3.1 Connections............................................................................................................................ 43
4.3.2 Pin configurations ................................................................................................................... 44
4.3.3 LED functions ......................................................................................................................... 44
4.4 Operator panel..........................................................................................................................46
4.4.1 Connections............................................................................................................................ 46
4.5 Decoder, operator panel..........................................................................................................47
4.5.1 Connections............................................................................................................................ 47
4.5.2 Pin configurations X1 - X6 ...................................................................................................... 47

SmartROC D65 Tier 4 Final Table of Contents
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4.5.3 Pin configurations X8 - X9 ...................................................................................................... 48
4.5.4 LED functions ......................................................................................................................... 48
5 RCS drilling system ............................................................................................ 49
5.1 Drill system...............................................................................................................................49
5.1.1 RCS ........................................................................................................................................49
5.1.2 Logging in ............................................................................................................................... 51
5.2 Overview of menus ..................................................................................................................52
5.2.1 Menu structure........................................................................................................................ 52
5.3 Settings .....................................................................................................................................54
5.3.1 General and specific settings .................................................................................................54
5.3.2 Parameters ............................................................................................................................. 55
5.3.3 Actuations............................................................................................................................... 56
5.4 Direct selection menus............................................................................................................57
5.4.1 Direct selection menu F1........................................................................................................ 57
5.4.2 Direct selection menu F2........................................................................................................ 59
5.4.3 Direct selection menu F3........................................................................................................ 62
5.4.4 Direct selection menu F4........................................................................................................ 63
5.4.5 Direct selection menu F5........................................................................................................ 64
5.5 System ......................................................................................................................................66
5.5.1 Menu System.......................................................................................................................... 66
5.5.2 System - Modules................................................................................................................... 67
5.5.3 System - Levers...................................................................................................................... 70
5.5.4 System - Monitors................................................................................................................... 72
5.5.5 System - administration .......................................................................................................... 73
5.5.6 Loading new software............................................................................................................. 74
5.5.7 System - Engine status........................................................................................................... 77
5.5.8 System - Service Interval........................................................................................................ 78
5.5.9 System - Configuration ........................................................................................................... 79
5.5.10 System - Rig Options.............................................................................................................. 80
5.6 Logging .....................................................................................................................................81
5.6.1 Logging Menu......................................................................................................................... 81
5.7 Positioning................................................................................................................................88
5.7.1 Positioning menu .................................................................................................................... 88
5.8 Drilling.......................................................................................................................................95
5.8.1 Menu Drilling........................................................................................................................... 95
5.9 Rig ...........................................................................................................................................112
5.9.1 Rig menu .............................................................................................................................. 112
5.10 RHS..........................................................................................................................................122
5.10.1 RHS menu ............................................................................................................................ 122
6 Hydraulic systems ............................................................................................ 135
6.1 Environmental considerations when handling oil ..............................................................135
6.2 General....................................................................................................................................135
6.3 Repairing hydraulic components .........................................................................................136
6.4 Replacement of hydraulic hoses ..........................................................................................136
6.5 Hydraulic workshops.............................................................................................................137
6.6 Filter ........................................................................................................................................137
6.6.1 Return oil filter ......................................................................................................................137
6.6.2 Breather filter ........................................................................................................................ 138
7 Feeder ................................................................................................................ 141
7.1 Feeder chain tension .............................................................................................................141
7.1.1 Feeder chain tension ............................................................................................................ 142
7.2 Tension of hoses on the hose drum ....................................................................................142

SmartROC D65 Tier 4 Final Table of Contents
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7.3 Climbing chain .......................................................................................................................143
7.3.1 Lubricating the sprocket wheel and checking the climbing chain cover. .............................. 143
7.4 Bearing unit and checking the chain guide.........................................................................144
7.4.1 Replacing the bearing unit (chain feed)................................................................................ 144
7.5 Protective plates ....................................................................................................................145
7.6 Checking for wear on the sprockets ....................................................................................145
7.7 Sealing disc ............................................................................................................................146
7.8 Replacing the slide pieces in the holder..............................................................................146
7.9 Replacement of Slide Bars....................................................................................................147
7.10 Lubricating the feeder ...........................................................................................................148
8 Track frames...................................................................................................... 149
8.1 Stretching the crawler tracks................................................................................................149
8.2 Check torques ........................................................................................................................150
8.3 Check for wear .......................................................................................................................151
8.3.1 Procedures ...........................................................................................................................151
8.3.2 Check for wear on the track rollers....................................................................................... 151
8.3.3 Check for wear on the limberoller......................................................................................... 151
8.3.4 Check for wear on the front wheel........................................................................................ 152
8.3.5 Check for wear on the track shoe......................................................................................... 153
8.3.6 Check for wear on the link and bushing ...............................................................................153
8.3.7 Check for wear on the chain................................................................................................. 154
9 Dust collector (DCT) ......................................................................................... 155
9.1 Filter test, dust collector (DCT).............................................................................................155
9.2 Adjust the suction capacity ..................................................................................................156
9.3 Dust collector (DCT) filter change ........................................................................................156
10 Radiator.............................................................................................................. 159
10.1 Environmental issues when handling coolant ....................................................................159
10.2 Coolant....................................................................................................................................159
11 Diesel engine ..................................................................................................... 161
11.1 Safety ......................................................................................................................................161
11.2 Environmental issues when handling oil.............................................................................161
11.3 Oil for the diesel motor..........................................................................................................161
11.4 Maintenance of components.................................................................................................162
11.4.1 Air filter for engine and compressor, service intervals.......................................................... 162
11.4.2 Air filter for engine and compressor, maintenance ............................................................... 163
11.4.3 Fuel system .......................................................................................................................... 164
11.4.4 Environmental issues when handling fuel ............................................................................166
11.4.5 Fuel tank brackets ................................................................................................................ 166
11.4.6 Draining the fuel tank............................................................................................................ 167
11.4.7 Drive belt ..............................................................................................................................167
11.4.8 For further instructions, see separate instructions for the diesel engine. ............................. 169
12 Compressor and air system............................................................................. 171
12.1 Safety ......................................................................................................................................171
12.2 Compressor description........................................................................................................171
12.3 Maintenance ...........................................................................................................................174
12.3.1 Draining the condensate in the pressure tank ...................................................................... 174
12.3.2 Draining the water separator filter ........................................................................................175
12.3.3 Replacing the filter element in the water separator filter ......................................................175

SmartROC D65 Tier 4 Final Table of Contents
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12.3.4 Checking the oil level............................................................................................................ 175
12.3.5 Changing oil and oil filter ...................................................................................................... 176
12.3.6 Changing to new type of oil .................................................................................................. 177
12.3.7 Cleaning the oil cooler .......................................................................................................... 179
12.3.8 Test pressurising the safety valve ........................................................................................ 179
12.3.9 Checking the pressure sensor B456 ....................................................................................180
12.3.10 Checking the start protection................................................................................................ 180
12.3.11 Checking the minimum charge pressure .............................................................................. 180
12.4 Control system .......................................................................................................................180
12.4.1 System description ............................................................................................................... 180
12.4.2 Setting the percussion pressure ........................................................................................... 181
13 Oil and fuel......................................................................................................... 183
13.1 Environmental issues when handling fuel ..........................................................................183
13.2 Filling fuel ...............................................................................................................................183
13.3 DEF (Diesel Exhaust Fluid) ...................................................................................................184
13.3.1 Filling DEF (Diesel Exhaust Fluid)........................................................................................ 184
13.3.2 Storing DEF (Diesel Exhaust Fluid)...................................................................................... 184
13.4 Environmental considerations when handling oil ..............................................................185
13.5 Compressor oil.......................................................................................................................185
13.6 Oil sampling............................................................................................................................186
13.7 Hydraulic oil............................................................................................................................186
13.8 Lubrication..............................................................................................................................187
13.9 For engine oil and fuel, see chapter "Diesel engine". ........................................................188
13.10Draining the fluids..................................................................................................................188
13.10.1 Draining DEF (Diesel Exhaust Fluid).................................................................................... 189
13.11Recommended oils and lubricants.......................................................................................189
13.11.1 Engine oil.............................................................................................................................. 189
13.11.2 Hydraulic oil .......................................................................................................................... 189
13.11.3 Lubricating oil tank (ECL) (ECG) (HECL) ............................................................................. 190
13.11.4 Grease nipples and CLS ......................................................................................................190
13.11.5 Rotation unit .........................................................................................................................190
13.11.6 Traction gears, carrier rollers................................................................................................ 191
13.11.7 Oil recommendations for two-stage compressor .................................................................. 191
13.11.8 Coolant ................................................................................................................................. 191
14 Options............................................................................................................... 193
14.1 GPS..........................................................................................................................................193
14.1.1 General................................................................................................................................. 193
14.1.2 General data......................................................................................................................... 193
14.2 Service equipment .................................................................................................................195
14.2.1 Service tool bag RCS ........................................................................................................... 195
14.2.2 Checking the power supply and the CAN network ............................................................... 196
14.2.3 I/O module ............................................................................................................................ 198
14.2.4 Resolver module................................................................................................................... 203
14.2.5 Replacing the module........................................................................................................... 205
14.3 RC - Reverse Circulation .......................................................................................................205
14.3.1 General................................................................................................................................. 205
14.3.2 Lubrication ............................................................................................................................206
14.3.3 Maintenance of components ................................................................................................208
14.3.4 Blow adapters....................................................................................................................... 214
14.3.5 Metzke Blowdown Valve....................................................................................................... 214
14.3.6 Fault finding in the event of air leakage................................................................................ 215
14.3.7 Conversion to normal drilling ................................................................................................ 215
14.4 Fire suppression system.......................................................................................................216

SmartROC D65 Tier 4 Final Table of Contents
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14.4.1 Daily checks and maintenance............................................................................................. 216
14.4.2 Annual maintenance............................................................................................................. 216
14.4.3 Electric Welding, Steam Cleaning and High Pressure Cleaning .......................................... 216
14.5 Service Winch.........................................................................................................................216
14.5.1 Cleaning ...............................................................................................................................216
14.5.2 Transmission ........................................................................................................................ 217
14.5.3 Disengagement device ......................................................................................................... 217
14.5.4 Adjusting - Drum brake......................................................................................................... 218
14.5.5 Cable ....................................................................................................................................218

SmartROC D65 Tier 4 Final Table of Contents
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SmartROC D65 Tier 4 Final 2 General
11
2 General
2.1 General
2.1.1 Safety
When maintenance work is carried out on the rig, observe the following points:
nNever carry out service or maintenance work while the drill rig is running.
nTo prevent personal injury during service and maintenance work, all components that
can be brought into motion or fall down must be thoroughly secured.
nEnsure that the hydraulic and pneumatic systems are depressurised before starting
work on them.
nAll controls must be inactivated during service and maintenance.
nWhen changing hydraulic hoses, ensure they are replaced with hydraulic hoses fitted
with the correct crimp couplings of correct quality and dimension. All pressurised hy-
draulic hoses have crimped couplings and should therefore be purchased ready made
from Atlas Copco. Quality classes and hose dimensions are specified in the spare
parts catalogue. Ensure also that all hose connections are clean, undamaged and se-
curely tightened.
2.1.2 Target group and objective
!NOTE: This chapter (General) contains general recommendations for maintenance of
the drill rig and its peripheral equipment. This means that certain sections may not be
fully adapted to individual components.
The maintenance instructions are intended for mechanics and personnel in maintenance
and service. The user should have undergone Atlas Copco's training courses for the equip-
ment concerned.
The objective of these maintenance instructions is to detect and rectify faults at an early
stage so that breakdowns, costly secondary damage and accidents can be 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.
2.1.3 Contact details
Country Address Phone and fax number
Argentina Estados Unidos 5335
B1667JHQ Malvinas Argentinas
Buenos Aires
Phone: +54 - (0) 3327 43 18 00
Fax: +54 - (0)3327 - 43 18 66
Australia P O Box 6134 Delivery Centre
Blacktown
NSW 2148
Phone: + 61 - (0)2 - 9621 9700
Fax: + 61 - (0)2 - 9621 9813
Austria Postfach 108 A-1111 Wien Phone: + 43- (0)1 -76 01 20

SmartROC D65 Tier 4 Final 2 General
12
Country Address Phone and fax number
Fax: + 43 - (0)1 - 76 01 24 16
Bolivia P.O. Box 290 Santa Cruz de la
Sierra
Phone: + 591 - (0)2 - 211 20 00
Fax: + 591 - 0(2) - 211 78 01
Brazil P O Box 1080 Barueri - SP
06460-970
Phone: + 55 - (0)11 - 41 96 87
00
Fax: + 55 - (0)11 - 41 95 37 22
Bulgaria 7, Iskarsko Shousse Blvd. Build-
ing 3, Office 4
1528 Sofia, Bulgaria
Phone: + 359 - (0) - 2 489 31 78
Fax: + 359 - (0) - 2 999 97 64
Canada 1025 Tristar Drive Mississauga
Ontario, L5T 1L8
Phone: + 1 - 289 - 673 67 11
Fax: + 1 - 289 - 562 01 00
Chile Panamericana Norte 5001 -
Conchali
Santiago, Chile 6553935
Conchali
Phone: + 56 - (0)2 - 442 36 00
Fax: + 56 -(0)2 - 623 44 60
China 1 No 2 HengTai Road Nanjing
Economic &
Technological Development
Zone Nanjing
Postal code 210038
Phone: + 86 -(0) 25 - 85 75 75
00
Fax: + 86 - (0) 25 - 85 75 75 30
China 2 No. 12 Kun Ming Hu Street
Shenyang
Economic & Technological De-
velopment Zone
CN-Shenyang 110027
Phone: + 86 -(0) 24 - 25 81 17
19
Fax: + 86 - (0) 24 - 25 81 18 67
CMT International S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00
Fax: + 46 - (0)8 - 702 21 29
Colombia A.A. 95310 Santafé de Bogotá,
D.C.
Phone: +57 - (0)1 -419 92 00
Fax: +57 - (0)1 - 419 92 22
Czech Republic Prumyslova 10 Praha 10, Post
Code 102 00
Phone: + 420 - (0)2 - 25 43 42
20
Fax: + 420 - (0)2 - 25 43 42 22
Egypt 520 El-Obour Market Cairo Phone: + 20 - (0)2 - 461 00 337
Fax: + 20 - (0)2 - 461 00 341
Finland Tuupakankuja 1 SF-01740
Vantaa
Phone: + 358 - (0)2 - 07 18 94
35
Fax: + 358 - (0)2 - 07 18 94 02
France BP 27055 Saint Ouen l'Aumône
FR-95052
Phone: + 33 - (0)1 - 39 09 30 00
Fax: + 33 - (0)1 - 39 09 30 22

SmartROC D65 Tier 4 Final 2 General
13
Country Address Phone and fax number
Cergy Pontoise Cedex
Germany Postfach 10 02 25 D-46002 Es-
sen
Phone: + 49 - (0)201 - 217 70
Fax: + 49 - (0)201 - 21 77 360
Ghana P O B 10071 Accra North Phone: + 233- (0) 302 77 45 12
Fax: + 233 - (0) 302 77 61 47
Great Britain Swallowdale Lane Hemel
Hempstead
Herts. HP2 7EA
Phone: + 44 - (0) 1442 - 26 12
01
Fax: + 44 - (0)1442 - 23 35 06
Greece 93, Koropiou - Varis, Avenue
Thesi
Klossari, GR-194 00 Koropi
Phone: + 30 - (0)210 - 349 96
00
Fax: +30 - (0)210 - 345 47 83
Hong Kong P O Box 1516 Shatin Central
Post Office
New Territories
Phone: + 852 - 27 97 66 00
Fax: + 852 - 23 41 43 13
India Sveanagar Bombay Pune Road
Dapodi
Pune 411 012
Phone: + 91- (0)20 -39 85 24 15
Fax: + 91 - (0)20 - 27 14 59 48
Indonesia P O Box 7021/JKS CCE Jakarta
12075
Phone: + 62 - (0) 21 780 10 08
Fax: +62 - (0)21 780 18 37
Iran PO Box 13145-1311 Tehran
1345654551
Phone: + 98 - (0) 21 -669 377
11
Fax: +98 - (0)21 - 669 273 14
Ireland Kylemore Road Bluebell Dublin
12
Phone: +353 - (0)1 - 450 59 78
Fax: +353 - (0)1 - 456 7686
Italy Casella Postale 77 IT-20092
Cinisello
Balsamo MI
Phone: + 39 - (0)2 - 61 79 91
Fax: + 39 - (0)2 - 61 79 95 20
Japan Sumitomo Fudosan Shipa Bldg
4 11F 2-13-4
Shiba, Minato-ku, Tokyo
105-00014
Phone: + 81 - (0)3 - 57 65 78 07
Fax: + 81 - (0)3 - 57 65 31 95
Kazakhstan Floor 2, 8A Kurmangaliyev
Street.
050010 ALMATY
Phone: + 7 - (0)727 - 258 85 34
Fax: + 7 - (0)727 - 258 85 35
Kenya PO Box 400 90 - 00100 Nairobi Phone: + 254 - (0) 70 - 305
4000
Fax: + 254 - (0) 20 - 82 54 72 /
(0) 20 - 82 52 15

SmartROC D65 Tier 4 Final 2 General
14
Country Address Phone and fax number
Korea 3rd Floor, Seowon Build-
ing1515-4
Seocho 3-dong, Seocho-ku
Seoul
Phone: + 82 - (0)2 - 21 89 40 00
Fax: + 82 - (0)2 - 522 82 39
Malaysia 26, Jalan Anggerik Mokara
31/47 Kota
Kemuning, Section 31 40460
Shah Alam,
Selangor West Malaysia
Phone: + 60 - (0)3 - 5123 88 88
Fax: + 60 -(0)3 - 51 23 89 49
Mexico Apartado Postal Box 104 54000
Tlalnepantla
Edo. De Mexico
Phone: + 52 - (0) 55 - 22 82 06
00
Fax: + 52 - (0) 55 - 53 90 15 20
Morocco P O Box 13 844 20 100 Casab-
lanca
Phone: + 212 - (0) 522 -63 40
00
Fax: + 212 - (0) 522 - 60 05 22
Mongolia Building BP9, Tavan Erdene
(MISHEEL)
Center, 2nd Khoroo, Khan Uul
District,
Chinggis Avenue, Ulaanbaatar,
Mongolia
Phone: + 976 - (0)11 - 34 49 91
Fax: + 976 - (0)11 - 70 13 02 23
Norway P O Box 334 N-1401 Ski Phone: + 47 - (64) 86 03 00 00
Fax: + 47 - 64 - 86 03 30 30
Peru Apartado 662 Lima 100 Phone: + 51 - (0)1 - 224 86 80
Fax: + 51 - (0)1 - 224 01 53
Philippines P.O. Box 1373 MCPO 1200
Makati City
Phone: + 63 - (0)2 - 843 05 35
Fax: + 63 - (0)2 - 843 02 42
Poland Aleja Krakowska 61A Sekocin
Nowy
PL-05-090 Raszyn
Phone: + 48 - (0) 22 - 572 68 00
Fax: + 48 - (0) 22 - 572 68 09
Portugal Apartado 14 PT-2796-953
Linda-a-Velha
Phone: + 351 - 21- 416 85 00
Fax: + 351 - 21 - 416 01 66
Russia 15, Vashutinskoe Road, Khimki
Moscow Region, 141402
Phone: + 7 - 495 - 933 55 52
Fax: + 7 - 495 - 933 55 58
Saudi Arabia P O Box 7330 Jeddah 21462 Phone: + 966 - (0)2 - 693 33 57
Fax: + 966 - (0)2 - 693 28 92
Singapore Jurong Point P O Box 438
Singapore 916415
Phone: + 65 - (66) 68 62 28 11
Fax: + 65 - (66) 68 63 60 98

SmartROC D65 Tier 4 Final 2 General
15
Country Address Phone and fax number
South Africa P O Box 14110 Witfield 1467 Phone: + 27 - (0)11 - 821 90 00
Fax: + 27 - (0)11 - 821 92 02
Spain Apartado 43 E-28820 Coslada
Madrid
Phone: + 34 - (9)1 - 627 91 00
Fax: + 34 - (9)1 - 627 92 39
Sweden SE-195 82 Märsta Phone: + 46 - (0)8 - 58 77 85 00
Fax: + 46 - (0)8 - 59 11 87 82
Switzerland Büetigenstrasse 80 CH-2557
Studen/Biel
Phone: + 41 - (0)32 - 374 15 00
Fax: + 41 - (0)32 - 374 15 15
Taiwan P O Box 14-45, Chungli Tao
Yuen Hsien
Phone: + 886 - (0)3 - 479 68 38
Fax: + 886 - (0)3 - 479 68 20
Thailand 125 Moo 9 Wellgrow Industrial
Estate Bagna
Trad Km 36 Bnagwua Bang-
pakong
Chachoengsao 24180
Phone: + 66 - (0)38 - 56 29 00
Fax: + 66 - (0)38 - 56 29 01
Turkey Istasyon Mah. Ibisaga Cad. No
6
34940 Tuzla - Istanbul
Phone: + 90 - (0)216 - 581 05
81
Fax: + 90 - (0)216 - 581 05 82
Ukraine 9, Moskovskiy Avenue Building
3 04073 Kiev
Phone: + 380 - (0)44 499 18 70
Fax: + 380 - (0)44 499 18 77
USA PO Box 1159 Commerce City
CO 80022
Phone: + 1 - 303 - 287 88 22
Fax: + 1 - 303 - 217 28 39
Venezuela Apartado 76111 Caracas 1071 Phone: + 58 - (0)212 - 300 83
00
Fax: + 58 -(0)212 - 300 83 49
Vietnam Lot F, Street No 12, Song Than
II -
Industrial Zone, Di An District,
Binh Duong
Phone: + 84 - (0) - 127 27 56
699
Fax: + 84 - (0) 650 - 373 84 85
Zambia P O Box 11291 Chingola Phone: + 260 - (0)2 - 12 31 12
81
Fax: + 260 - (0)2 - 12 31 38 77
Zimbabwe P.O. Box CY 935 Causeway Phone: + 263 - (0)4 - 62 17
63/64/65
Fax: + 263 - (0)4 - 62 17 94
Table1: Addresses, telephone numbers and fax numbers to Atlas Copco companies

SmartROC D65 Tier 4 Final 2 General
16
2.1.4 Signs for outsourced components
Signs are placed on the larger components of the drill rig. When ordering spare parts or
making enquiries in regard to the drill rig, the type designation and serial number must al-
ways be stated. Type designations and serial numbers are specified in a separate docu-
ment, MI (Machine Identification). Spare parts can always be ordered through Atlas Copco.
2.1.5 Dismantling and assembly
CAUTION
Risk of injury
Exercise extreme caution when slinging and hoisting heavy objects
uCan cause personal injury
uHoisting must take place at the centre of gravity
uOnly use slings which are intact and designed for the load they shall carry
uFasten the straps to lifting eyes, when available
Before transporting in shafts or the like it may be necessary to fully or partially dismantle
the drill rig. Observe the following when dismantling, hoisting and assembling:
nBefore dismantling, hose the entire rig clean with water and/or detergent containing a
grease solvent.
nObserve the strictest cleanliness when dismantling hydraulic, compressed air and wa-
ter flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes, or seal
and protect them from dirt in some other suitable way.
nMark hoses, pipes and other connections, where this has not already been done, to
make reassembly easier and prevent mix-ups.
nUse properly secured lifting tackle of generous dimensions.
!NOTE: When the drill rig is scrapped, all materials that are harmful to the environment
must be disposed of in a manner prescribed by the authorities.
2.1.6 Long-term storage
The following points must be observed for long-term storage of the drill rig. In the event of
special conditions e.g. a dusty or corrosive environment, additional measures may be ne-
cessary.
nThe rig must have protection from rain, snow and strong sunshine.
nUntreated steel surfaces must be rustproofed.
nThe water mist system must be drained and rinsed with antifreeze.
nThe battery must be disconnected. If the temperature falls below freezing point then
the battery must be stored indoors.
nThe rock drill's shank adapter must be greased.
nThe rock drill's gas accumulator must be drained.
nIf the rig is to be shutdown for a long time then the rock should drill should be removed
and stored protected.
nFuel and oil tanks must be filled.

SmartROC D65 Tier 4 Final 2 General
17
Inspection and maintenance during the shutdown period
The following action must be carried out every month.
nCheck oil and coolant levels.
nStart the diesel engine and let it run until normal operating temperature has been
reached.
nOperate the rig a few metres back and forth so that the tramming gears are lubricated.
nOperate the tilt cylinders, boom, feeder, drill support and rod handling so that all cylin-
ders reach their end positions.
nDrain condensed water from the hydraulic oil tank and compressor oil tank.
2.1.7 Scaling
When the entire drill rig or part of the rig is to be scrapped, local regulations in force re-
garding handling, waste management, recycling and destruction must be followed. Collect
and dispose of:
nRest oil and oil spill
nOil waste such as filters
nRest fuel and fuel spill
nRest grease and grease spill
nBatteries
nDiscarded refrigerant, air conditioning
nChemicals such as flushing additives, other additives and coolants
nMetals, e.g. steel and aluminium (metals that are recyclable)
nPlastics and rubber (often marked in various classifications for recycling)
nElectrical components such as cables, electronics
nEmissions cleaning unit
2.1.8 Tightening torque in bolted joints.
All joints are tightened to the torque required by Atlas Copco Standard K 4369 unless oth-
erwise specifically stated. In such cases, this will be specified in the maintenance instruc-
tions of the module in question.
Size Strength class Torque in Nm. Tolerance ±
M6 8.8 8 2
M8 8.8 20 5
M10 8.8 41 10
M12 8.8 73 18
M14 8.8 115 25
M16 8.8 185 45
M20 8.8 355 85
M24 8.8 600 150
M12 x 1.25 10.9 135 6
M16 x 1.25 10.9 315 15
M18 x 1.25 10.9 460 20

SmartROC D65 Tier 4 Final 2 General
18
Size Strength class Torque in Nm. Tolerance ±
M6 12.9 14 3
M8 12.9 34 8
M10 12.9 70 17
M12 12.9 120 30
M14 12.9 195 45
M16 12.9 315 75
M20 12.9 600 150
M24 12.9 1020 250
Table2: Atlas Copco Standard torques.
2.1.9 Work on painted surfaces
WARNING
Serious injury
This rig has been painted with oxyran ester paint and polyester powder.
uSubstances are formed when the paint is heated which are hazardous to health and
amongst other things could cause eczema, eye irritation, respiratory system difficulties
and in severe cases asthma or other illnesses.
uWelding, grinding and other hot work involving paint being heated must only be carried
out where sufficient ventilation can be used. In addition, use personal safety equip-
ment: compressed air powered breathing protection, eye protection and gloves.
2.1.10 Welding
nApplies to drill rigs equipped with one of the following engines:
lCAT C13, Tier 4
lCAT C15, Tier 4
!NOTE: It is important to consult Atlas Copco for approval of welding and choice of
electrodes.
Connections that must be disconnected prior to welding
nAlternator
nBattery
nAll sensors on boom and feeder
nAll cables in the cabin
nAll connections to electric cabinet, A1
nEngine electronic unit - ECM. See the instructions for diesel engine.
nAll contacts to GPS and ProCom units.

SmartROC D65 Tier 4 Final 2 General
19
Points to be observed when welding
nGrind off rust and paint from the area that is to be welded and carefully prepare the
joint.
nWeld in a dry area.
nConnect the welding ground cable to a clean surface as close as possible to the weld-
ing area. Avoid welding close to bearings and bushes. If these cannot be removed,
connect ground cables on both sides of the weld.
nAlterations and reinforcements must not be made without previous consultation with
Atlas Copco.
nDO NOT weld the hydraulic oil tank, valve block, compressed air tank, pressure lines
or the engine exhaust cleaning unit (CEM).
nSee separate instructions for diesel engines for work on the exhaust cleaners soot
sensors.
nWelding on the exhaust cleaning unit frame and bracket is prohibited.
nAlways keep a fire extinguisher for oil fires near at hand during all types of welding,
cutting and grinding. Screen off the work area from flammable materials.
nAlways protect hoses, cables and electric components.
nGrind off spatter after welding. If possible, also grind the surface of the weld smooth
and treat it with anti-corrosion paint.
Electrode recommendations
Use only intact and clean electrodes that have been stored in a dry place. The generally
recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the equivalent in
accordance with the standard below:
ISO: 2560 E51 5B 120 20 H
SS: 14 3211 H10
DIN 1913: E51 55 B10
AWS: A/SFA 5.1 E 7018
Table3: Electrode recommendations
The use of MIG welding equipment is perfectly acceptable. The generally recommended
type of electrode is ESAB-OK Autrod 12.51 or the equivalent in accordance with the stand-
ard below:
SS: 14 3403 3423
DIN 8559: SG 2
AWS: A/SFA 5.18: ER 70 S-6
Table4: MIG electrodes
If in any doubt, contact Atlas Copco for advice.
2.1.11 Welding CAN BUS
Preparations before welding
Disconnect the supply voltage to all modules, both + and -, as follows:
nCable KC50A is removed from the right-hand rear pillar outside the cabin.
nCable KC50B is removed from the right-hand rear pillar outside the cabin.

SmartROC D65 Tier 4 Final 2 General
20
nCable D530X1 is removed from D530/X1
nCable D511X25 is removed from D511/X25
nCable D102X25 is removed from D102/X25
nCable D510X25 is removed from D510/X25
nCable D101X25 is removed from D101/X25
nCable D103X25 is removed from D103/X25
nCable D512X25 is removed from D512/X25
nContact P61 is removed from J61 "Customer connection" to the ECM.
nThe battery ground cable is removed.
2.1.12 Diagnostics
Fault finding is a logical sequence of activities to locate a fault, thereby making it possible
to rectify the fault as soon as possible.
Always try to investigate the location of the fault in order to limit fault finding to a certain
system or function.
2.2 Battery
2.2.1 Environmental considerations regarding batteries
NOTICE
Environmental effect
Think of the environment!
uBatteries contain acids and heavy metals. For this reason, expended batteries can be
hazardous to the environment and to health.
uExpended batteries must be sent for destruction in accordance with local regulations.
2.2.2 Charging the battery
WARNING
Serious injury
Risk of fire and explosion
uMay cause serious personal injury and damage to property
uFlammable hydrogen gas
uCorrosive fluid
uAvoid naked flames and sparks
uAlways detach the negative terminal first, and connect it last
The battery is normally charged by the drill rig's alternator. If the battery is fully discharged
for some reason, it must be recharged using a battery charger. Follow the instructions
carefully. Cell plugs should be unscrewed but left in the holes during charging.