Atlas Copco SmartROC T4511 - Walter S. Pratt & Sons, Inc...Atlas Copco is not liable for any damage,...

Atlas Copco

SmartROC T4511Maintenance

Original instructions© 2015 Atlas Copco AB20150317 | No: 871696139.2.9007200127358475 enUS

SmartROC T45-11 Table of Contents

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Table of Contents1 Introduction ........................................................................................................... 9

1.1 Safety First.................................................................................................................................. 9

1.2 The Purpose of This Publication .............................................................................................. 9

1.3 Target Group .............................................................................................................................. 9

1.4 Product Warranty ....................................................................................................................... 9

2 About Maintenance Management ...................................................................... 112.1 Maintenance Planning and Counters ..................................................................................... 11

2.2 Maintenance Records .............................................................................................................. 11

3 General Machine Condition................................................................................ 133.1 Wash Machine Externally ........................................................................................................ 13

3.2 Check Condition of Signs ....................................................................................................... 13

4 Boom Unit ............................................................................................................ 154.1 Lubricate Boom and Feeder.................................................................................................... 15

4.2 Check Boom Condition ........................................................................................................... 16

5 Feeder Unit .......................................................................................................... 175.1 Checking Chain Feed Tension................................................................................................ 17

5.2 Check Jack Chain Cover ......................................................................................................... 18

5.3 Check Feed Beam .................................................................................................................... 19

5.4 Check Chain Guide .................................................................................................................. 20

5.5 Check Sprocket Wheel ............................................................................................................ 20

5.6 Check DrillSteel Support........................................................................................................ 21

5.7 Check DrillSteel Support........................................................................................................ 22

5.8 Check Chain Feed .................................................................................................................... 23

5.9 Check Rod Handling ................................................................................................................ 24

5.10 Clean Behind Sealing Disc...................................................................................................... 25

5.11 Lubricate Rod Handling........................................................................................................... 26

5.12 Lubricate Chain Feed............................................................................................................... 26

5.13 Replace Bearing Unit ............................................................................................................... 27

5.14 Replace Slide Rails .................................................................................................................. 27

5.15 Replace Slide Pieces in the Holder ........................................................................................ 28

5.16 Adjusting Chain Feed Tension ............................................................................................... 29

5.17 General Checking Guidelines for Steel Cables ..................................................................... 295.17.1 Checking Cable for Wire Breaks ............................................................................................ 305.17.2 Checking Cable for Strand Breaks ......................................................................................... 305.17.3 Checking Cable for Surface Wear .......................................................................................... 305.17.4 Checking Cable for Corrosion ................................................................................................ 305.17.5 Checking Cable for Decreased Diameter ............................................................................... 315.17.6 Checking Cable for Reduced Elasticity .................................................................................. 315.17.7 Checking Cable for Heat Exposure ........................................................................................ 31

6 Drilling Machine .................................................................................................. 336.1 Check Lubrication Oil Level Tank .......................................................................................... 33

6.2 Drill Lubrication Pumps........................................................................................................... 33


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7 Hydraulic System................................................................................................ 357.1 About Working on Hydraulic Components............................................................................ 35

7.2 About Hydraulic Workshops................................................................................................... 35

7.3 About Replacing Hydraulic Hoses ......................................................................................... 35

7.4 Check Hoses and Couplings................................................................................................... 35

7.5 Hydraulic Filters ....................................................................................................................... 367.5.1 Return Oil Filter ...................................................................................................................... 367.5.2 Check Breather Filter.............................................................................................................. 367.5.3 Replace Return Oil Filter ........................................................................................................ 377.5.4 Replace Breather Filter........................................................................................................... 38

7.6 Tanks......................................................................................................................................... 387.6.1 Drain Condensate from Hydraulic Oil Tank ............................................................................ 387.6.2 Drain Condensate in Pressure Tank ...................................................................................... 397.6.3 Clean Hydraulic Tank ............................................................................................................. 397.6.4 Drain Hydraulic Oil Tank......................................................................................................... 407.6.5 Fill Hydraulic Oil...................................................................................................................... 40

7.7 Check Mounting Hydraulic Jack............................................................................................. 42

8 Electrical System ................................................................................................ 438.1 Charging the Battery................................................................................................................ 43

8.2 Charging Battery Using 24V Charger..................................................................................... 44

8.3 Charging Battery Using 12V Charger..................................................................................... 45

8.4 Starting with Auxiliary Battery................................................................................................ 46

9 Fire Fighting Equipment..................................................................................... 479.1 Check Fire Extinguishers ........................................................................................................ 47

9.2 Check Emergency Stops and Work Lights............................................................................ 48

9.3 Check Fire Extinguishers ........................................................................................................ 49

10Control System and Sensors ............................................................................. 5110.1 General Maintenance Control System and Sensors............................................................. 5110.1.1 Remote Control Battery .......................................................................................................... 5110.1.2 Cleaning Remote Control ....................................................................................................... 51

11Cooling System................................................................................................... 5311.1 Cooling System Overview ....................................................................................................... 5311.1.1 Clean Radiators...................................................................................................................... 5411.1.2 Check Coolant Level .............................................................................................................. 5511.1.3 Add Coolant............................................................................................................................ 56

12Operator's Environment ..................................................................................... 5712.1 Check Cabin ............................................................................................................................. 57

12.2 Replacing Air Condition Main Air Filter ................................................................................. 58

12.3 Replacing Air Condition Prefilter .......................................................................................... 58

12.4 Replacing Air Condition Circulation Filters........................................................................... 59

12.5 Troubleshooting AC................................................................................................................. 59

13 Track Frames....................................................................................................... 6113.1 Tensioning the Crawler Tracks............................................................................................... 61

13.2 Checking Track Frames Torques ........................................................................................... 62

13.3 Procedures for Checking Wear............................................................................................... 6313.3.1 Checking for Front Wheel Wear ............................................................................................. 63


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13.3.2 Checking for Track Roller Wear ............................................................................................. 6413.3.3 Checking for Carrier Roller Wear ........................................................................................... 6413.3.4 Checking for Track Shoe Wear .............................................................................................. 6513.3.5 Checking for Wear on Track Shoe ......................................................................................... 6513.3.6 Checking for Track Link Depth Wear...................................................................................... 6613.3.7 Checking for Bushing Wear.................................................................................................... 6613.3.8 Checking for Track Chain Elongation Wear ........................................................................... 67

13.4 Check Track Frames ................................................................................................................ 68



13.7 Change Oil on Track Frames .................................................................................................. 70

14Dust Collector...................................................................................................... 7114.1 Checking Function of Dust Collector..................................................................................... 71

14.2 Check Dust Collector Filters .................................................................................................. 72

14.3 Replace Dust Collector Filters ................................................................................................ 72

15Diesel Engine....................................................................................................... 7515.1 Check Motor Oil Level ............................................................................................................. 75

15.2 Drain PreFilter ......................................................................................................................... 76

15.3 Fuel Quality............................................................................................................................... 76

15.4 Draining Fuel Tank................................................................................................................... 76

15.5 Filling with Fuel ........................................................................................................................ 77

15.6 DEF Fluid .................................................................................................................................. 77

15.7 Location of DEF Tank .............................................................................................................. 78

15.8 Draining DEF Tank ................................................................................................................... 78

15.9 Filling with DEF Fluid............................................................................................................... 79

15.10Replace PreFilter..................................................................................................................... 79

15.11Replace Secondary Fuel Filter................................................................................................ 80

15.12Replacing DEF Tank Filter....................................................................................................... 80

15.13Belts .......................................................................................................................................... 8115.13.1 Replace Multibelt ................................................................................................................... 81

15.14Replace Longterm Effective Coolant .................................................................................... 82

15.15Air System ................................................................................................................................ 8315.15.1 Air Filter Indicator Function..................................................................................................... 8415.15.2 Replace the Filter Cartridge.................................................................................................... 84

16Compressed Air System..................................................................................... 8716.1 Overview Air Compressor System ......................................................................................... 87

16.2 Check Compressor Oil Level .................................................................................................. 89

16.3 Oil Change and Oil Filter Replacement.................................................................................. 89

16.4 Replacing Air Compressor Oil and Oil Filter ......................................................................... 89

16.5 Change Oil on Compressor..................................................................................................... 91

16.6 Replace Separator Filter.......................................................................................................... 92

16.7 Changing to New Type of Compressor Oil ............................................................................ 92

16.8 Flushing Air Compressor ........................................................................................................ 94

16.9 Check Compressor Components ........................................................................................... 96

16.10Drain Compressor.................................................................................................................... 96


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16.11Clean Compressor Oil Cooler ................................................................................................. 97

17Automatic Central Lubrication System CLS..................................................... 9917.1 Central Lubrication System Pump ......................................................................................... 99

17.2 Setting Lubrication and Interval Time.................................................................................. 100

17.3 Check Condition of CLS pump ............................................................................................. 101

17.4 Setting Lubrication Pump ..................................................................................................... 102

17.5 Filling Lubricant ..................................................................................................................... 103

17.6 Bleeding Lubrication Pump .................................................................................................. 103

17.7 Lubrication Pump Program Display Alarm List .................................................................. 104

17.8 Troubleshooting CLS............................................................................................................. 104

18Water Mist System ............................................................................................ 10718.1 Check Seals on Water Mist Pump ........................................................................................ 108

18.2 Filling Water Mist Tank .......................................................................................................... 109

18.3 Draining Water Mist System.................................................................................................. 110

18.4 Starting Up Water Mist System from Dry............................................................................. 111

18.5 Clean Filter in Water Mist Tank............................................................................................. 112

19Welding .............................................................................................................. 11319.1 About Welding........................................................................................................................ 113

19.2 CAN Bus System Disconnection Before Welding............................................................... 113

20Downtime........................................................................................................... 11520.1 Preparations Before Long Period of Downtime .................................................................. 115

20.2 Restoring After Long Period of Downtime .......................................................................... 115

20.3 Inspection and Maintenance During Period of Downtime.................................................. 116

21StartUp.............................................................................................................. 11721.1 About Special StartUp .......................................................................................................... 117

21.2 Performing Special StartUp ................................................................................................. 117

21.3 Flushing of Hoses and Pipes ................................................................................................ 117

21.4 About Testing Pressure Release Valves.............................................................................. 118

22Options............................................................................................................... 11922.1 Winch ...................................................................................................................................... 11922.1.1 Check Attachment of Winch Cable....................................................................................... 11922.1.2 Check Winch Unit Attachment.............................................................................................. 12022.1.3 Lubricate Winch.................................................................................................................... 12122.1.4 Check Winch ........................................................................................................................ 12222.1.5 Check Small Remote Control ............................................................................................... 122

22.2 Service Tool Bag RCS ........................................................................................................... 123

22.3 Checking CAN Network ......................................................................................................... 124

22.4 Checking CAN Power Supply ............................................................................................... 124

22.5 Checking CAN Cable ............................................................................................................. 124

22.6 Checking Digital Inputs on I/O Module ................................................................................ 125

22.7 Checking Digital Outputs Voltage on I/O Module ............................................................... 126

22.8 Checking Digital Outputs Current on I/O Module ............................................................... 127

22.9 Checking PWM Outputs Current on I/O Module.................................................................. 128


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22.10Checking Analog Inputs on I/O Module ............................................................................... 129

22.11Encoder Inputs ....................................................................................................................... 129

22.12Checking Resolver Module Resolver Inputs ....................................................................... 130

22.13Checking Resolver Module Encoder Inputs ........................................................................ 131

22.14Checking Resolver Module Analog Inputs .......................................................................... 131

22.15Replacing a RCS Module....................................................................................................... 133

23Specifications.................................................................................................... 13523.1 Standard Tightening Torques Bolted Joints ....................................................................... 135

23.2 Signs for Ordering Spare Parts ............................................................................................ 136

Maintenance table ............................................................................................. 137


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SmartROC T45-11 1 Introduction

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1 Introduction

1.1 Safety FirstAlways read the information in the Safety document before starting to use the product orstarting maintenance work.

1.2 The Purpose of This PublicationThe objective of these maintenance instructions is to detect and rectify faults at an earlystage so that breakdowns, costly secondary damage and accidents can be prevented.Regular maintenance is a precondition for planning necessary interruptions in operationsuch as reconditioning and repairs. This allows maintenance to be carried out when mostsuitable with regard to production instead of causing complete breakdown.

1.3 Target GroupThe information in this publication is intended for everyone involved in the application, operation, and maintenance of the machine and related equipment. All readers are expectedto possess basic competence regarding mining methods, construction methods, and themachines used for that kind of operation.

Atlas Copco is not liable for any damage, injuries, or deaths caused by users who misunderstand the published information and/or use it incorrectly.

1.4 Product WarrantyThe product warranty relies on correct use, maintenance and repair of the machine and itscomponents at all times.n Use only Atlas Copco original parts. Any damage or operational interruptions caused

by using spare parts of other manufacture than Atlas Copco will not be covered bywarranty.

n Atlas Copco is not liable for any damage caused by unauthorised modification to themachine and its equipment.

n Atlas Copco is not liable for damage caused by inappropriate use.n Overloading the machine can result in damage to the structure which is not noticed

during normal usage. Such damage is not covered by the warranty.n Damage that occurs as a result of inadequate maintenance, substandard repairs, or

damage to equipment that is attributable to older unrepaired damage, is not coveredby the warranty.

SmartROC T45-11 1 Introduction

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SmartROC T45-11 2 About Maintenance Management

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2 About Maintenance Management

2.1 Maintenance Planning and CountersMaintenance is organised at scheduled intervals.

Scheduled intervals supplement each other. Longer interval contains maintenance taskssupplementary to tasks from shorter interval. Maintenance scheduling should be appliedperiodically to unit/ function's shortest interval (whichever comes first during operation).

Operational maintenance is planned based on the following counters:n Hour meters for the rock operation systemn Hour meter for the engine or motorn Calendar based maintenance applies to all rubber details, lubricants that risks break

ing up during standstills, pressure vessels. Corrosion and such where age, substanceregression and environmental exposure are vital to maintenance factors.

2.2 Maintenance RecordsCorrect records enable maintenance personnel to identify and evaluate problems and/orhigh cost areas. All maintenance procedures should be checked off as the inspection orprocedure is completed. Quantities of refilled lubricants and fluids, and pressure and flowreadings, should be recorded. Any faults or deviations should be recorded irrespective ofwhether they have been rectified or are waiting for rectification.

SmartROC T45-11 2 About Maintenance Management

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SmartROC T45-11 3 General Machine Condition

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3 General Machine Condition

3.1 Wash Machine Externallyn Rinse the machine with water at least once a day to remove drill cuttings, mud and

dirt.

The feeder, front part of the boom and track frames are particularly important to keepclean.

3.2 Check Condition of Signsn Make sure all signs are intact, clean and fully readable.n Make sure all signs are in place. Compare with the drawing.n Always replace defect or missing signs.

SmartROC T45-11 3 General Machine Condition

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SmartROC T45-11 4 Boom Unit

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4 Boom Unit

4.1 Lubricate Boom and Feeder

n Pump grease into 21 grease nipples (A).

SmartROC T45-11 4 Boom Unit

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4.2 Check Boom Condition

n Check mounting on boom head (A). Tightening torque 73 Nm (54 lbf.ft).

n Check clearance between feed and feed bracket (B). Clearance 24 mm.

n Check mounting on the feed bracket (C). Tightening torque 185 Nm (136 Ibf.ft).

n Check clearance between bushes, shaft and holder (D). If necessary change bushesand perhaps also the shaft.

n Check clearance on the bearings in cylinder lugs (E). Maximum clearance 1 mm.

n Check mounting, damage. 9 plates on locking plates (F). Tightening torque 73 Nm (54lbf.ft).

SmartROC T45-11 5 Feeder Unit

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5 Feeder Unit

5.1 Checking Chain Feed Tension

C Feed beam

D Chain

Condition p A poorly tensioned chain causes increased wear on the chain and associated parts.

n Check that the chain feed is correctly tensioned.

Result è When the chain feed is correctly tensioned, it should come into contact with the inneredge on the lower prism on the feed beam at point (B) when the feed is placed in ahorizontal position (transport position).


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5.2 Check Jack Chain Cover

n Check if the chain links chafe against the jack chain cover (A).

Result è Replace the jack chain cover if worn.


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5.3 Check Feed Beam

The feed beam is fitted with black protective plastic covers (A). The covers is designed toprevent the chain and beam from damaging each other

1. Check covers for wear.

Result è If covers are worn, they must be replaced.


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5.4 Check Chain Guide

n Check the chain guide (B) for wear. If chain guide is damaged or overly worn, replaceit.

5.5 Check Sprocket WheelAs a general rule, replace the drive on every third chain change.

A Worn Sprocket Wheel

n Check whether there are uneven patches.

n Check that the chain runs smoothly when the chain is coupled in and out of thesprocket wheel.

n Inspect the teeth for reduced areas and sharp points.


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Result è If the teeth are too worn, the sprocket wheel should be replaced.

! NOTE: Do not run a new chain on a worn sprocket wheel.

NOTE: Do not run a worn chain on a new drive.

5.6 Check DrillSteel Support

n Check the torque of the cylinder mounting, upper drillsteel support (A).

n Check the torque of the lock nut for adjusting screw, lower drillsteel support (B).

n Check the torque of the cylinder mounting, lower drillsteel support (C).


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n Check adjustment and check for wear and cracks on the upper drillsteel supporthalves (A).

n Check adjustment and check for wear and cracks on the lower drillsteel supporthalves (B).

n Check mounting, play and centering of the lower drillsteel support (C) and check fordamage.

n Check that bolted joints are properly tightened.


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5.8 Check Chain Feed

1. Check slide pieces (A) regarding to play, damage and tightening torque. Play shouldbe 24 mm.

2. Check slide rails (B) for wear.

3. Check mounting and function of the sensors (C). Check distance, approximately 5mm.

4. Check bushing halves (D) for wear and cracks.

5. Check mounting of hydraulic cylinders (E).

6. Check clearance for ball bearings in cylinder lugs (F). Maximum 5 mm clearance.

7. Check drillsteel support halves (G) for adjustment, wear and cracks.

8. Clean cutting behind the sealing disc (H).

9. Check the attachment of the feed cylinders and check for damage.

10. Check chain feed tension.


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5.9 Check Rod Handling

n Check the mounting of the hydraulic motor (A). Applies only to machines equippedwith RHS.

n Check for wear and cracks on the bushing halves (B).

n Check the mounting of the hydraulic cylinders (C).

n Check the mounting and functionality of the sensors (D). Applies only to machinesequipped with RHS.

n Check the bracket (E) for cracks and proper attachment. Applies only to machinesequipped with RHS.


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5.10 Clean Behind Sealing DiscOver time cuttings collect behind the sealing disc (B). Cuttings can damage the chain anddrive.

n Bend the sealing disc down to clean out dust which has collected behind it.


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5.11 Lubricate Rod Handling

n Pump grease into the 14 grease nipples (A).

5.12 Lubricate Chain Feed

n Grease the nipples (A) on drive.


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n Lubricate the jack chain drive (B) with 23 pump strokes of grease in the grease nipple on the drive shaft.

n Grease the nipples (C) of the jack chain drive.

5.13 Replace Bearing Unit

n Replace the bearing unit (B) every 5000 engine hours.

5.14 Replace Slide Rails


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Condition p Slide rails should be replaced if they are worn or severely scratched.p Before replacing the front slide rails, run the rock drill/rotation unit to its rear end position.p Before replacing the rear slide rails, run the rock drill/rotation unit to its front end position.

1. Remove the cradle for the rock drill, intermediate drillsteel support and the hosedrum from the beam.

2. Remove the slide rails (A) by prising the lower edges of the bars outwards.

3. Clean the beam surfaces thoroughly.

4. Fit the new slide rails. The larger edge on the slide rail must be facing upwards. Therails should be pressed in place by hand.

5. Refit the rock drill cradles, intermediate drillsteel support and waterhose drum.

5.15 Replace Slide Pieces in the Holder

The slide pieces must be replaced at regular intervals so the steel in the holder does notwear against the beam.

Condition p Replace if there is less than 1 mm of wear allowance on any the slide pieces. Replaceall slide pieces at the same time.

1. Remove the bolts (B) to dismantle the holder (A) from the cradle (E).

2. Remove the keys (D). Each slide piece is kept in place by three keys.

3. Remove the slide pieces (C) from the holder.

4. Slide a new slide piece into the holder track and fit it to the holder.

5. Fit new keys.

6. Refit the holders to the cradle correctly and adjust so the total lateral play is 23 mm.


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5.16 Adjusting Chain Feed Tension

The distance (C) must be at least 280 mm.

1. Lubricate the bolts (A) using the grease nipples (B). A little grease should be placeddirectly on the boltthreads (A).

2. Tighten or loosen the chain feed tension by screwing the bolts (A) clockwise or anticlockwise.

5.17 General Checking Guidelines for Steel CablesSteel cables should be scrapped when they display any of the following:n Wire break at attachmentn Certain number and type of wire breaksn Concentrations of wire breaksn Occurrence of wire breaks due to operating timen Occurrence of strand breaksn Surface wearn Effects of heatn Reduced elasticityn Decreased cable diametern Permanent extension of the cablen Deformation of the cable


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5.17.1 Checking Cable for Wire BreaksWire breaks occur after a certain operating time depending on operating conditions andsubsequently occur more frequently. The number of wire breaks in relation to the operatingtime should be determined and documented. This can then be used to estimate the futureincrease in wire breaks and the foreseeable time point for scrapping. On 6 and 8strand cables, wire breaks are primarily superficial.n Broken wires at cable ends indicate that they have been heavily loaded and can be

caused by faulty end mountings. Shorten the cable and reattach it. Check that thelength of the remaining cable sufficient.

n If there are concentrations of cable breaks, the cable must be scrapped. If such concentrations occur within a length less than 60 cm or on an individual strand, the cablemust be scrapped. even if the number of wire breaks is less than the maximum specified in the table.

Number of loadbearing wires inthe outer strand.

Filler wire is notconsidered loadbearing.

Number of visible wire breaks that require scrapping

Machine groups M1 and M2

Cross Lay Equal Lay

Over a length of cable diameter (d)

30d 6d 30d 6d

21220 9 18 4 9

221240 10 19 5 10

In cables with several layers of strands, only the outer, visible layer is considered. In cableswith steel cores, the core is regarded as an inner strand and is not included. In the event ofa wire break, two ends can be visible.

5.17.2 Checking Cable for Strand BreaksIf there are strand breaks, the cable must be scrapped.

5.17.3 Checking Cable for Surface WearInner surface wear is caused by friction between the wires and the strands.

Outer surface wear is caused by friction between the cable drums (rolls) and the cable under pressure (acceleration and braking). Outer surface wear is visible through the formation of reflected images on the outer wires.

Surface wear is increased through faulty or no lubrication, thereby increasing the effect ofdirt and dust. Surface wear reduces static tensile strength through reduction in the cable'smetallic cross section and dynamic strength through surface wear nicks. If the cable's diameter decreases more than 7% in relation to the nominal diameter of the cable, it must bescrapped. It should be scrapped even if no wire breaks have been detected.

5.17.4 Checking Cable for CorrosionCorrosion is especially problematic in marine environments and in areas where the air ispolluted by industrial emissions. Corrosion can reduce operational strength through rustspots and static tensile strength through a reduction in the cross section of the metallic cable. Severe corrosion can reduce elasticity.

Outer corrosion can be easily detected through visual examination.


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Inner corrosion is more difficult to detect. Inner corrosion is characterised by the following:n Absence of gap between the strands in the outer layer of the cable, often in combina

tion with wire breaks in the strands.n The cable diameter varies.

The parts of the cable that are bent over discs usually have a decreased diameter. At anysign of corrosion, the cable should be checked by an authorised person. If inner corrosionis detected, the cable must be scrapped.

5.17.5 Checking Cable for Decreased DiameterDecrease in cable (steel wire) diameter through material fatigue in the cable can have thecauses:n Inner surface wear and surface wear nicksn Inner surface wear through friction between the strands and wires in the cablen Fatigue of plastic coren Break in steel coren Break in inner layer in multistrand cable

If the cable's diameter decreases more than 10% in relation to the nominal diameter of thecable, it must be scrapped. It should be scrapped even if no wire breaks have been detected.

5.17.6 Checking Cable for Reduced ElasticityUnder certain conditions, the cable loses its elasticity. Reduced elasticity is difficult to detect. If in doubt, consult a specialist. If the cable has lost elasticity, the following characteristics usually appear:n Decrease in cable diametern Extension of the cablen No gap between individual wires and between the strands. This is caused by its com

ponents being pressed together.n Fine, brown dust inside the strands.n Even if there are no visible wire breaks, the cable is noticeably stiffer.n The cable's diameter decreases more quickly than during normal wear of the individual

cable strands.

Reduced elasticity can lead to sudden cable breaks during heavy loads. The cable shouldbe scrapped.

5.17.7 Checking Cable for Heat ExposureThe effects of heat can be established through annealing colour. Cables exposed to extreme heat must be scrapped.


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SmartROC T45-11 6 Drilling Machine

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6 Drilling Machine

6.1 Check Lubrication Oil Level Tank

The lubricating oil tank is mounted on the left side of the machine frame.

n Check the tank and connections for signs of leakage.

n Make sure the lubrication oil level is above the top sight glass (B).

n Refill with lubrication oil (A) if necessary. Always use a funnel with strainer.

! NOTE: The lubrication oil level should not be below 40 mm (1.6"). If the lubricating system is completely drained the system will have to be bled.

6.2 Drill Lubrication PumpsThe lubrication pumps are placed behind the lubricant tank.

A Pump for thread lubrication (ECG)

B Pump for lubricating rock drill (ECL)

SmartROC T45-11 6 Drilling Machine

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SmartROC T45-11 7 Hydraulic System

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7 Hydraulic System

7.1 About Working on Hydraulic ComponentsThe hydraulic system is sensitive to contamination. The environment where the machine isnormally used is generally an unsuitable place for repairing hydraulic components. Avoidrepairing hydraulic systems outside workshops.

Observe the following points to minimize interruptions in operation due to contaminated hydraulic oil:n Keep the machine clean. Use a degreasing additive for washing.n Before opening any hydraulic connection, clean the area round it.n Use clean tools and work with clean hands.n Always plug hydraulic connections immediately after they have been detached.n Use clean protective plugs.n Hydraulic components, for example like hoses, valves, engines, must always be stored

with suitable protective plugs fitted.n Spare parts for hydraulic components must always be kept in sealed plastic bags.n Change filter cartridges when filters indicate clogging.

7.2 About Hydraulic WorkshopsWorkshops used for the repair of hydraulic components must include:n A clean environment to avoid dust and particlesn Suitable washing equipment which is required for repairing the componentsn Suitable tools for work on hydraulic systemsn Adequate ventilation system

7.3 About Replacing Hydraulic HosesLoad, vibration and other mechanical stresses put high demands on hydraulic hoses.When replacing, check that replacement hoses are made:n With correct crimped couplingsn With correct quality classn With correct dimensions

All pressurised components should be purchased from Atlas Copco. Grades and dimensions of hoses are specified in the spare parts catalogue. Also make sure that hose couplings are clean, not damaged and properly tightened.

7.4 Check Hoses and Couplingsn Inspect all hydraulic hoses and connections thoroughly with respect to cracking and

swelling that indicates an external or internal leak. Inspect hose location and clips.

n Inspect hose casing with respect to any swelling that indicates inner hose or cordbreakage.


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n Inspect hydraulic couplings with respect to leaks, indentations and adapters. Couplings should be fastened securely if they have screw flanges. If there are any signsof connection leaks, change sealings or the complete coupling.

n Inspect that all hose attachments and clamps are intact.

n Inspect all pressed couplings for signs of cracks or damage to compression sleeves.Replace defective hoses with new ones.

7.5 Hydraulic Filters

7.5.1 Return Oil FilterThe return oil filter cleans the oil before it returns to the tank. The filter cartridges should bereplaced according to the maintenance schedule. If the return filter pressure gauge on theoperator display indicates a clogged filter, all return oil filters must be replaced immediately.

Symbol for Clogged Filter

7.5.2 Check Breather FilterThe purpose of the breather filter is to equalise the pressure differences in the tank thatwould otherwise arise when the level in the tank changes. The breather filter is fitted on thehydraulic oil reservoir.

n Check breather filter (A).


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! NOTE: If the breather filter becomes covered in oil it will be ruined.

7.5.3 Replace Return Oil FilterThe filter inserts are located in the hydraulic tank.

1. Clean on and around the filter cap. Loosen and remove the nuts (A).

2. Lift off the cap (B) and replace the Oring (C) if damaged.

3. Lift out the filter cannister (D).

4. Remove the nut (E). Lift out and clean the magnetic rod (F).

5. Take out filter cartridge (G) from the cover (H) and replace with a new filter cartridge.

Only the filter cartridge is replaced. The filter cover is reused.

6. Refit all parts.


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7.5.4 Replace Breather Filter

1. Clean thoroughly on and around the filter housing (A).

2. Detach the cover plate by turning it anticlockwise.

3. Replace with a new filter. Apply a little hydraulic oil to the ceiling surface/threads.

4. Replace the cover.

! NOTE: If the breather filter is covered in oil it is ruined and must be replaced.

7.6 Tanks

7.6.1 Drain Condensate from Hydraulic Oil Tank

Water in the hydraulic oil can seriously damage components in the hydraulic system andcause corrosion.


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Condition p The hydraulic system has not been in operation for twelve hours before draining the hydraulic oil tank.

1. Remove the plug on the ball valve (A) underneath the hydraulic oil tank.

2. Place a vessel under the ball valve.

3. Open the ball valve to drain the water.

4. Close the ball valve when oil starts to drain.

5. Refit the plug.

6. Check oil level and top up if necessary.

7.6.2 Drain Condensate in Pressure Tank

A Compressor Tank

B Compressor Cooler

C Compressor Element

Condition p The machine must have been switched off for at least 1 hour.

n Drain the condensate from plug 1 at the draining point on the righthand side of themachine.

7.6.3 Clean Hydraulic TankHydraulic tank is cleaned manually through the access hatch at the top.

Condition p The hydraulic tank is drained from oil.

1. Remove the access hatch.

2. Clean the inside of the tank completely.

3. Use only lintfree rags. Wipe all sides, top and bottom of the tank. Be especially thorough in corners, hedges, and around connecting holes. Make sure no pieces of ragget stuck or get left in the tank.

4. Refit the access hatch as fast as possible after cleaning to prevent any particles fromentering. Make sure the access hatch closes tightly.


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7.6.4 Drain Hydraulic Oil Tank

1. Remove the plug from the ball valve (A) underneath the hydraulic tank.

2. Fit a hose to the ball valve and place the other end of the hose into a vessel.

3. Open the ball valve and empty the tank.

4. Close the ball valve and remove the hose.

5. Refit the plug on the ball valve.

7.6.5 Fill Hydraulic Oil

WARNING

Risk of Eye Injuries

Hydraulic oil can cause eye injuries

u Use protective goggles

1. Check the return oil filter.

2. Check that all the couplings and hoses normally filled with hydraulic oil are clean.

3. Activate the Enable hydraulic oil filler pump function in the Settings 2 menu in thecontrol system.

4. Connect the attached hose to the oil source.


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5. Press button (A) to start filling.

6. Check that the lower sight glass is fully covered and the upper sight glass is half covered.

Result è The electric filler pump stops automatically when the hydraulic tank is full. It alsostops if the source of oil runs out.


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7.7 Check Mounting Hydraulic Jack

n Check mounting and torque on hydraulic jack (A).

n Check mounting and torque on footplate (B).

SmartROC T45-11 8 Electrical System

43

8 Electrical System

8.1 Charging the Battery

WARNING

Risk of Fire and Explosion

May cause serious personal injury and damage to property.

u Explosive gas is formed in the battery during charging.

u Avoid naked flames and sparks.

u Ensure good ventilation.

u Always disconnect the negative terminal first, and connect it last.

The battery is normally charged by the alternator. If the battery is fully discharged for somereason, it must be recharged using a battery charger. Cell plugs should be unscrewed andleft in the holes during charging. Batteries contains corrosive fluid. Always turn off thecharge current before disconnecting the clips. If the density has not risen noticeably despite a number of hours of charging, the battery is probable expended. Rapid charging,when carried out correctly, will not damage the battery. Rapid charging should not be undertaken too often and is not recommended for old batteries. Repeated discharging forlong periods will impair the service life of the battery. Avoid, for example, leaving the lightson while the engine is stationary. Discharging with high current is not normally harmful.

Since the 24V electrical system is powered by two 12V batteries connected in series, observe:n The batteries must have the same capacity (Ah).n The batteries must be the same age. This is because the charging current required to

bring a battery up to a certain voltage changes with age.n The batteries must not be loaded unevenly.n Series coupling maintains the same capacity but increases the voltage. For example,

when 2 x 12V 60Ah batteries are connected in series, the voltage will be 24V but thecapacity remains at 60Ah.

n Use a 24V charger when charging both batteries connected. Use a 12V charger whencharging each battery individually. Observe the voltage before connecting a batterycharger.


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8.2 Charging Battery Using 24V Charger

WARNING







1. Turn off battery isolation switch.

2. Disconnect the cable between chassis ground and the negative terminal on battery(A).

3. Connect the battery charger's positive cable to the batteries positive terminal (B).Connect the battery chargers negative cable to the batteries negative terminal (A).

4. Start the battery charger.

5. Turn off the battery charger when batteries are fully charged.

6. Disconnect the battery charger's negative cable from the batteries negative terminal(A). Disconnect the battery charger's positive cable from the batteries positive terminal (B).

7. Connect the cable between chassis ground and the negative terminal on battery (A).

8. Turn on battery isolation switch.


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8.3 Charging Battery Using 12V Charger

WARNING







Serial Connected 12V Batteries

1. Turn off the battery isolation switch.

2. Disconnect the cable between chassis ground and the negative terminal on battery(A).

3. Disconnect the jumper lead between the negative terminal on battery (B) and the positive terminal on battery (A).

4. Connect the battery charger's positive cable to the positive terminal on battery (A).Connect the battery charger's negative cable to the negative terminal on battery (A).


6. Turn off the battery charger when battery (A) is fully charged.

7. Disconnect the battery charger's negative cable from the negative terminal on battery(A). Disconnect the battery charger's positive cable from the positive terminal on battery (A).

8. Connect the battery charger's positive cable to the positive terminal on battery (B).Connect the battery charger's negative cable to the negative terminal on battery (B).


10. Turn off the battery charger when battery (B) is fully charged.

11. Disconnect the battery charger's negative cable from the negative terminal on battery(B). Disconnect the battery charger's positive cable from the positive terminal on battery (B).


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12. Connect the jumper lead between the negative terminal on battery (B) and the positive terminal on battery (A).

13. Connect the cable between chassis ground and the negative terminal on battery (A).

14. Turn on battery isolation switch.

8.4 Starting with Auxiliary Battery

WARNING

Explosion Risk

The batteries could explode if a fullycharged battery is connected to a completely discharged battery.

Condition p Switch off the RCS system on the control system panel, if present.

1. Check that the auxiliary batteries (A) have the same voltage as the chassis batteries(B).

2. Connect the positive terminal of the auxiliary batteries (A) to the positive terminal ofthe chassis batteries (B).

3. Connect the negative terminal of the auxiliary batteries (A) to ground on the chassis.

! NOTE: Do not connect the negative terminal of the auxiliary batteries (A) to the chassis batteries (B) negative terminal.

4. Disconnect the cable from the chassis ground as soon as the engine starts.

5. Disconnect the cable from the negative terminal on the auxiliary batteries (A).

6. Disconnect the cable between the positive terminal of the chassis batteries (B) andthe auxiliary batteries (A).

SmartROC T45-11 9 Fire Fighting Equipment

47

9 Fire Fighting Equipment

9.1 Check Fire Extinguishers

1. Check that the indicator is in the green zone.è Replace the fire extinguisher if the indicator is within, or close to, any of the red

zones.

2. Check that none of the seals are broken and that service has been performed withinthe prescribed time.

3. Inspect the complete fire extinguisher and holder for loose parts, defects or damages.


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9.2 Check Emergency Stops and Work Lights

n Check each emergency stop (A) individually. The engine must be off. Before the nextemergency stop is checked, the previous one must be reset before restarting.

n Check the functionality of the work lights, front and rear (B).


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1. Check that the instructions are legible.

2. Check the condition of the fire extinguisher (A).


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SmartROC T45-11 10 Control System and Sensors

51

10 Control System and Sensors

10.1 General Maintenance Control System and Sensors

10.1.1 Remote Control Batteryn The remote control batteries should be regularly fully discharged and then fully

recharged.n Charging can only take place in the temperature range +10 °C and +40 °C.n NiCd batteries can be partially charged or discharged before arrival. Batteries must al

ways be fully charged before use.

! NOTE: Protect the batteries against short circuiting. Do not store them in a tool box orloose in a pocket together with metal objects as these can short circuit the battery.

10.1.2 Cleaning Remote ControlThe remote control may require cleaning. It is important that the remote control is not damaged.n Make sure the active stop on the remote control is not blocked by dirt or similar.n The battery contacts should be cleaned and lubricated at regular intervals.n To clean the remote control use a damp rag or a fine brush to remove dirt and dust.

! NOTE: Never clean the remote control using highpressure or steam washing. Strongchemicals can destroy the remote control rubber bellows.

SmartROC T45-11 10 Control System and Sensors

52

SmartROC T45-11 11 Cooling System

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11 Cooling System

11.1 Cooling System Overview

DANGER

Scalding and Pressure

High pressure in the radiator can cause serious personal injury.

u Undo the radiator cap slowly to gradually release the pressure.

The machine has two radiators. The lefthand radiator (A) is for the compressor oil and hydraulic oil. The righthand radiator (B) is for the engine coolant. When delivered from thefactory, the coolant is protected from freezing down to 30° C ( 22° F).

See the separate instructions for the diesel engine.


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See reference documentation

Diesel engine instruction manual

11.1.1 Clean Radiators

! NOTE: High pressure water jets must be directed parallel to the radiator flanges(straight ahead or from behind).

Clean radiators frequently to maintain the systems cooling capacity.

1. Blow compressed air to clean the radiator flanges. Use degreaser and high pressurewater jet if dirt remains.

2. Blow compressed air on the fan blades until the blades are clean.

3. Remove the fan grille and wipe the fan blades clean from dirt.

4. Clean the inside of the fan grille.


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11.1.2 Check Coolant Level

Condition p The coolant level must be checked when the diesel engine is cold.

n Check the coolant level (B).è The level should be between the upper and lower mark.


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11.1.3 Add Coolant

1. Loosen the radiator cap (A) to the stop position, release the pressure in the coolingsystem and only then remove the cap.

2. Add coolant until the level is between the upper and the lower mark (B). Only CATELC coolant may be used.

SmartROC T45-11 12 Operator's Environment

57

12 Operator's Environment

12.1 Check Cabin

n Clean or change the filter element in the circulation filter (A, B).

n Clean or change the primary filter (C).

n Clean or change the prefilter (D).

n Run the air conditioning system for five minutes (winter and summer).

n Clean the condenser element with compressed air.

n Check that the instructions on the fire extinguisher (E) are legible.

n Check the mounting on steps (F) for cracks and other damage.

n Check the mounting on the handle for cracks and other damage.

n Check the protective roof mountings for damage.

n Check that the horn is in working.

n Check function of the backup warning signal and beacon.

n Check that all warning and safety labels are properly attached and legible.

n Replace the circulation filter

n Replace primary filter

n Replace prefilter

n Lubricate door hinges.

n Check the cabin mounting tightening torque and for damage.


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12.2 Replacing Air Condition Main Air Filter

1. Remove screws from the cover (A).

2. Open cover and lift out the filter.

3. Replace with new filter.

4. Close cover and refit screws.

12.3 Replacing Air Condition Prefilter

1. Remove screws on the louvre cover (A).

2. Open louvre cover and lift out the filter.


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3. Replace with new filter.

4. Close cover and refit screws.

12.4 Replacing Air Condition Circulation Filters

1. Remove screws on the covers (A and B).

2. Open covers and lift out the filters.

3. Replace with new filters.

4. Close covers and refit screws.

12.5 Troubleshooting AC

Fault Symptom Action

No cooling at all Check fuses, electric connections, compressorground, electromagnets, switches and pressureswitches

Check Vbelt and compressor

Check expansion valve and temperature controlvalve

Check coolant hoses

Poor cooling Check freshair fan and Vbelt tension

Check if the air is passing the evaporator in theunit

Check the expansion valve capillary tube is firmlytightened against the evaporator outlet pipe


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Fault Symptom Action

Check the thermostat does not cut out too early

Uneven cooling Check connections to switches, magnetic couplingor pressure switch are not loose

Check the expansion valve is not clogged

Check that the system is filled and that the thermostat is working

n Abnormal system noise is often related to incorrectly assembled components. If the compressor isnoisy at a certain speed, and the noise disappears when the speed increases or decreases, thereis probably nothing wrong with the compressor itself. The difference between the pressure on thesuction side and the pressure side also affects the level of noise. A compressor with low suctionmakes more noise than a compressor with high suction. Likewise, a compressor with highpressure makes more noise because it puts more load on bearings and other components.

Abnormal noise Check the multiVbelt to the compressor is thoroughly tightened and that the compressor retaining bolts are tightened

Check the system is filled sufficiently and not overfilled

Check the expansion valve is in working order

Check the airflow across the evaporator is sufficient

Check the condenser is clean and the airflow issufficient

SmartROC T45-11 13 Track Frames

61

13 Track Frames

13.1 Tensioning the Crawler Tracks

Track tension is checked between the front wheel (C) and support roller (A).Condition p Machine is on a levelled ground.

p Tracks are under normal load

1. Place a levelling board (B) on top of each track and maintain a clearance (E) of 25mm to 50 mm (0.98" to 1,97") between them.

! NOTE: If the tracks do not have any support roller (A) position thelevelling board between the end wheels with a maximum of 50 mmslack in the centre.

2. Fill grease via the nipple (D) to tension the track.

! NOTE: The grease nipple is not to be used during lubrication, butonly during this procedure.

3. If the track tension becomes too tight, grease can also be drained from the tensioncylinder by unscrewing the nipple (D).


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13.2 Checking Track Frames Torques

Size Torque in Nm(lbft)

Quantity/trackframes

Comments

A M16 295 20

B1 M12 86 4 T50LF, D60, D65,C65LF

B2 M16 210 1 T45, C50, D50,D55, T50SF,C65SF

C M16 210 32

D M12 90 3

E M16 295 18

F1 9/16” UNF 260 ± 10 176 T45, C50, D50,D55, T50SF,C65SF


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Size Torque in Nm(lbft)

Quantity/trackframes

Comments

F2 M16 370 ± 20 176 T50LF, D60, D65,C65LF

G M16 210 28

G M16 210 10

Table 1: Tightening Torques for Track Frames

13.3 Procedures for Checking Wearn When components on the track frames are worn down to the minimum recommended

levels, they must be replaced with new components.n Regular and accurate measuring is required in order to establish the extent of the wear

and when replacement is necessary.n The components must be thoroughly cleaned for measuring.n Measurements must be taken at several points. The degree of wear is determined by

the maximum value, not the average value.

13.3.1 Checking for Front Wheel Wear

n Check the wear by measuring the distance (A) between the top and bottom of thefront wheel.

Specification Metric Data Imperial U.S Data

New Front Wheel 16.5 mm 0.65 in

Wear 25% 17.6 mm 0.70 in

Wear 50% 19.4 mm 0.77 in

Wear 75% 21.7 mm 0.86 in

Wear 100% 24.4 mm 0.96 in

Also see about this

2 Procedures for Checking Wear [} 63]


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13.3.2 Checking for Track Roller Wear

n Check the wear by measuring the diameter (A) of the track rollers.


New Track Roller 160.0 mm 6.30 in

Wear 25% 156.8 mm 6.18 in

Wear 50% 153.0 mm 6.03 in

Wear 75% 148.9 mm 5.86 in

Wear 100% 143.7 mm 5.66 in

Also see about this


13.3.3 Checking for Carrier Roller Wear

n Check the wear by measuring the diameter (A) of the carrier roller.


New Carrier Roller 100.0 mm 3.93 in

Wear 25% 97.0 mm 3.82 in

Wear 50% 93.7 mm 3.68 in

Wear 75% 89.6 mm 3.53 in

Wear 100% 84.7 mm 3.33 in

Also see about this



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13.3.4 Checking for Track Shoe Wear

CAUTION

Increased Risk of Sliding

Worn track shoes reduce the friction with the ground considerably and increase the riskof sliding

u Always follow the maintenance recommendation for wear of track shoes.

n Check the track shoe wear by measuring the distance (A) between the top and bottom of the track shoe.


New Track Shoe 22.0 mm 0.87 in

Wear 25% 19.2 mm 0.76 in

Wear 50% 16.0 mm 0.63 in

Wear 75% 12.9 mm 0.51 in

Wear 100% 9.7 mm 0.38 in

Also see about this


13.3.5 Checking for Wear on Track Shoe

Condition n Check the track shoe wear by measuring the distance (A) between the top and bottom of the track shoe.


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New Track Shoe 47.0 mm 1.85 in

Wear 25% 40.9 mm 1.61 in

Wear 50% 34.2 mm 1.35 in

Wear 75% 27.5 mm 1.08 in

Wear 100% 20.8 mm 0.82 in

Also see about this


13.3.6 Checking for Track Link Depth Wear

n Check the wear by measuring the dimension (A) for the chain.


New Chain 83.0 mm 3.27 in

Wear 25% 81.6 mm 3.22 in

Wear 50% 79.8 mm 3.15 in

Wear 75% 77.9 mm 3.07 in

Wear 100% 75.7 mm 2.98 in

Also see about this


13.3.7 Checking for Bushing Wear

n Check the wear by measuring the dimension (A) for the bushing.


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New Bushing 45.0 mm 1.77 in

Wear 25% 44.6 mm 1.76 in

Wear 50% 44.2 mm 1.74 in

Wear 75% 43.7 mm 1.72 in

Wear 100% 43.0 mm 1.69 in

Also see about this


13.3.8 Checking for Track Chain Elongation Wear

n Check chain wear by measuring the distance (A) between the center point in the firstpin to the center point of the fifth pin.


New Track Roller 160.0 mm 6.29 in

Wear 25% 162.0 mm 6.37 in

Wear 50% 164.0 mm 6.45 in

Wear 75% 166.0 mm 6.53 in

Wear 100% 168.0 mm 6.60 in

Also see about this



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13.4 Check Track Frames

1. Check for signs of leakage on the traction motor (A).

2. Check for signs of leakage on the traction gears (B).

3. Check for signs of leakage on the carrier roller (C).

4. Check for signs of leakage on the track rollers (D).

5. Check the tension on the crawler tracks (E), visual inspection.

6. Check that the springs and dampeners move freely on the front wheel (F). Clean ifnecessary.

7. Check for loose screws and nuts.


! NOTE: First oil change after 150 engine hours, then every 1500 engine hours. Flushthe gears with oil before new oil is added. Volume approximately 2 liters. The level plug(E) must be positioned just above the center of the traction gear.


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n Check for signs of leakage on the traction gears (A).

n Pump grease into the two grease nipples (B).

n Check for signs of leakage on the front wheel (C) and dampener.

n Check the position of the dampener (D). If the slide block sticks out more than 50 mmoutside the frame, the chain must be replaced.

n Tighten all mountings after 50 engine hours and then every 250 engine hours.



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1. Check oil level on the traction gear (A). The level plug must be positioned above thecentre of the traction gear.

2. Check for signs of leakage and wear on the track rollers (B).

3. Check the crawler track tension (C).

4. Check the wear on the track shoe and link chain on the crawler tracks (C).

5. Check for signs of leakage and wear on the carrier roller (D).

6. Check for drive wheel wear (E).

7. Check for front wheel wear (F).

8. Check for any damage to the frame.

9. Check the mountings.

13.7 Change Oil on Track Frames

n Change the oil on the traction gear. Flush the gears with oil before adding new oil.Volume approximately 2 liters. The level plug must be positioned above the center ofthe traction gear.

SmartROC T45-11 14 Dust Collector

71

14 Dust Collector

14.1 Checking Function of Dust Collector

Factory setting is 46 pulses during cleaning time.Condition p The air pressure must be less than 8 bar (manual valve).

1. Turn the ignition key to ignition position. Set the switch mode (A) in the position fordrilling on the operator's panel.

2. Activate the dust collector by turning button (C). Make sure flushing air (B) is in position “Reduced flushing air”.

3. Activate the flushing air with the right drill lever by moving it maximal to the left. Terminate the function by pressing button (D, E) on the right drill lever.

4. Check that air blows through the filters and check pulse interval.

Adjust the number of pulses if necessary.


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14.2 Check Dust Collector Filters

1. Remove the plugs (A) and apply a differential pressure gauge to the 2 holes.

2. Measure the pressure drop while air flushing is activated.è If the pressure drop is greater than an 800 mm (wg) column of water, all filters

must be replaced.

14.3 Replace Dust Collector Filters


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1. Open the door (A).

2. Remove the old filters (B).

3. Replace with new filters. The recommended tightening torque when installing the newfilters is 13 Nm.


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SmartROC T45-11 15 Diesel Engine

75

15 Diesel Engine

15.1 Check Motor Oil Level

WARNING

Burning Hazard

Hot components and surfaces can cause serious injury.

u Use working gloves and cover your arms with long sleeves.

Condition p The diesel engine is off.

1. Check that the oil level is between the upper and lower mark on the dipstick (A).

2. Top up through the fill cap (B) if necessary.




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15.2 Drain PreFilter

n Drain water from the prefilter by opening the drain outlet (A).

15.3 Fuel Qualityn The engine must be off before refueling starts. Do not handle fuel in the vicinity of hot

surfaces, sparks or open flames.n Cleanliness is important when filling fuel. Ensure that the tank and tank cover are

clean. Fuel must not be added if there is a risk that it is contaminated, for example inwindy or wet weather or when there is dust in the air.

n Fuel that is stored must not have contact with the air, but must be stored in a closedvessel. The vessel must be clean and approved for its purpose.

n Use Ultra Low Sulfur Diesel (ULSD). Its sulfur level must not exceed 15 ppm.

15.4 Draining Fuel Tank

! NOTE: Always fill the fuel tank with clean diesel oil and fuel of the correct grade for thetemperature.

1. Undo the front protective plate on the underside of the machine.

2. Undo the bottom plug by holding the nut with a 22 mm box end wrench and unscrewing with an 8 mm Allen key. Allow the water to drain.

3. Use track oscillation to tilt the drill rig in order to drain the tank completely.

4. Tighten the plug so the diesel oil cannot leak out.


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15.5 Filling with Fuel

n Unscrew the filler cap (A) to fill with fuel.

15.6 DEF Fluidn DEF fluid is topped up with each refueling. The DEF tank must not be overfilled. In a

cold climate DEF fluid freezes and needs space to expand.n Cleanliness is important during the filling of DEF fluid. Make sure that the container

and funnel are clean.n The DEF fluid must fulfil the requirements specified in ISO 222411. See the operator's

instructions for the diesel engine.n See the operator's instructions for the diesel engine regarding the storage of DEF fluid.n When the DEF tank is almost empty, a series of warnings will be shown on the ma

chine's display. When the tank is empty, the engine will switch off.


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15.7 Location of DEF Tank

DEF Tank

A DEF tank

15.8 Draining DEF Tank

n Drain the DEF tank by loosening the plug (A).


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15.9 Filling with DEF Fluid

n Unscrew the filler cap (A) to fill with DEF fluid.

15.10 Replace PreFilter

1. Unscrew the prefilter (B) using a suitable tool.

2. Collect any residual fuel.

3. Clean the surface of the filter holder.

4. Oil the rubber seal of the new fuel filter sparingly.

5. Screw on the filter all the way by hand.

6. Tighten the filter an additional half turn using a suitable tool.

7. Check that the fuel filter does not leak.





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15.11 Replace Secondary Fuel Filter

1. Unscrew the secondary filter/filters (A) using a suitable tool.

2. Collect any residual fuel.

3. Clean the surface of the filter holder.

4. Lubricate the rubber seal of the new fuel filter sparingly with a little oil.

5. Screw on the filter by hand until the gasket makes contact with the surface of the filterholder.

6. Tighten the filter an additional half turn.

7. Check that the fuel filter does not leak.




15.12 Replacing DEF Tank Filtern See the separate instructions for the diesel engine regarding DEF tank filter replace

ment.




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15.13 Belts

15.13.1 Replace Multibelt

Condition p The engine must be off.

1. Remove the belt cover.

2. Turn the tensioning wheel (A) to loosen the belt tension.

3. Use a pin to lock the tensioning wheel in position at the point where the belt is slack.


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4. Remove the bolts (4) in the axle coupling to create a gap between the coupling rubberand the shaft flange.

5. Remove the old belt.

6. Insert a new belt through the gap.

7. Insert and tighten the bolts (185 Nm).è The belt is tensioned automatically when the pin is removed from the tensioning

wheel.

8. Reinstall the belt cover.

15.14 Replace Longterm Effective Coolantn Replace the longterm effective coolant (ECL).





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15.15 Air System

The air filters consist of a filter housing with cover, filter cartridge, safety cartridge, indicatorand evacuation valve. Air filtration is performed in two stages. The first stage comprises acyclone and the second stage a normal filter. Both filtration stages take place in the filterhousing. A filter's performance will improve right up until it becomes clogged. For this reason, the filter cartridge should not be replaced at regular intervals, but only when it starts tobecome clogged. The filter cartridges must never be cleaned as this impairs filtration andalso risks damaging the filter element. There is an indicator situated on the filter housing toadvise when the filter cartridge is clogged. It is connected to the display in the cabin. A yellow warning symbol appears on the status bar at the bottom of the display if a filter is starting to clog.

Warning Symbol for Engine Air Filter

Warning Symbol for Compressor Air Filter


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15.15.1 Air Filter Indicator Function

To ensure filter clogging is detected, the function of the air filter indicator (A) must bechecked regularly. This is done by gradually covering the air intake with a piece of wood orsimilar. The air filter indicator should then send a signal and the warning symbol or thewarning light should come on. If a warning is not indicated, start by checking the cable connections. If there are no problems with the connections, then the air filter indicator is faultyand must be replaced. The air filter indicator is not included in the filter housing, but is ordered separately.

! NOTE: Be sure to use an intact and clean piece of wood so that dirt or other particlesdo not enter the filter housing.

15.15.2 Replace the Filter Cartridge


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! NOTE: Never clean the filter cartridges. When an evacuation valve is damaged, replace it. If the warning symbol for clogged air filter continues to be shown, the safetycartridge must be replaced.

Condition p The diesel engine is off.

1. Undo the clamps (A) and remove the cover (B).

2. Remove the main cartridge (C).

3. Clean inside the filter housing and lid with a clean, dry cloth.

! NOTE: If the safety cartridge (E) has also been removed for changing, the filter housing air outlet must be completely covered with adhesive tape before cleaning the filter housing.

4. Check that the evacuation valve (D) is not damaged. Change it if necessary.

5. Remove any adhesive tape on filter housing air outlet.

6. Install a new main cartridge and a new safety cartridge if required.

7. Refit the cover and fasten the clamps.


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SmartROC T45-11 16 Compressed Air System

87

16 Compressed Air System

16.1 Overview Air Compressor SystemThe machine is equipped with a singlestage screw compressor which is driven by thediesel engine. The compressed air from the compressor flows to an air receiver which alsofunctions as an oil separator. The majority of the oil is removed in the air tank by centrifugalforce. The remaining oil is separated in an oil separator element in the air receiver. Theseparated oil is collected in the lower section of the air receiver, which functions as an oiltank.

Compressor System Parts

A Safety Valve

B Thermostat

C Oil Filter

D Inlet Valve

E Compressor

F Exhaust valve

G Air Filter

H Air valve

I Ball Valve


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J Pressure Gauge

K Pressure Reducing Valve

L Air Filter

M Air Filter Switch

N Oil Stop Valve

O Temperature Sensor

P Check Valve

Q Restrictor

R Pressure Tank

S Minimum Pressure Valve

T Pressure Sensor

Diagram Air Compressor System

Pos See Compressor System Parts


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16.2 Check Compressor Oil Level

1. Make sure the machine is on flat ground.

2. Switch off the machine and allow the oil level to settle for at least 5 minutes.

3. Check the compressor oil level. The indicator on the gauge (A) must be in the greenzone.

Fill with oil at (B), if required. Use the correct amount and oil grade.

16.3 Oil Change and Oil Filter ReplacementThe intervals for oil change are determined by oil grade and operating temperature. Theprescribed interval is based on an oil temperature of up to 120 °C and normal operatingconditions. Oil should be changed more frequently when working in high ambient temperatures or very dusty or damp conditions.

The system must be flushed clean before new oil is filled if the oil has beenn contaminated by incorrect oiln broken down due to excessive temperaturen used beyond the operating interval

16.4 Replacing Air Compressor Oil and Oil Filter

WARNING

Fire and Explosion Risk

Using incorrect or old oil may lead to risk of fire or explosion in the compressor system

u Use correct, new oil according to the Fluids and Lubricating Greases manual.


90

1. Run the compressor to operating temperature. Confirm that the pressure is zero.

2. Put vessels under the drain plugs. Remove drain plugs for compressor tank, compressor cooler and compressor element. Drain the oil. Tighten the plugs after draining.

3. Remove the oil filters (C). Collect the oil in vessels.

4. Clean the filter seat on the manifold using new oil, and make sure that no dirt fallsdown into the system. Lubricate the gasket on the new filters with new oil. Replacethe filters.

5. Remove the filler plug and fill oil into the air receiver (B) until the oil level reaches thefiller pipe. The indicator on the gauge (A) must be in the upper section of the greenzone. Fit and tighten the filler plug.

6. Operate the unit without any load for several minutes in order to circulate the oil andforce out any air in the oil system.

7. Stop the compressor. Allow the oil to settle for several minutes. Confirm that the pressure is zero. Remove the filler plug and fill with oil until the indicator on the oil levelgauge (A) is in the green zone. Fit and tighten the filler plug.

! NOTE: If the oil has been destroyed the system must be flushed clean before new oil isfilled.


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16.5 Change Oil on Compressor

1. Change the compressor oil (A).

2. Replace the old cartridge on the oil filter (B) with a new one.

3. Perform a 15 bar pressure test on the safety valve (C).


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16.6 Replace Separator Filter

n Replace separator filter (A) in the pressure tank.

! NOTE: Check that the washer (1) under the filter remains in place.Do not throw it away with the old filter during replacement.

16.7 Changing to New Type of Compressor OilTo avoid problems when changing to a new type of oil, a special procedure for compressoroil flushing must be followed. The table is only applicable if the replaced oil has not passedits expiration date. Old oil is best detected by using an analysis program for oil samples,SOS (Scheduled Oil Sampling). Indications that the oil is old are that it smells strongly, thatthere are contaminants such as sediments inside the oil reservoir and the stop valve, orthat the oil has a brownish colour.

Paroil M Paroil S Paroil Sxtreme

Paroil M Drainage * Flushing Flushing

Paroil S Drainage ** Drainage * Drainage

Paroil Sxtreme Drainage ** Drainage Drainage *


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* When changing to the same oil within the interval between changes, drainage is sufficient

** Changing not recommended


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16.8 Flushing Air Compressor

WARNING

Fire and Explosion Risk

Using incorrect or old oil may lead to risk of fire or explosion in the compressor system

u Use correct, new oil according to the Fluids and Lubricating Greases manual.


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Condition p Run the compressor to operating temperature and confirm that the pressure is zero.

1. Place vessels under the drain plugs.

2. Remove drain plugs for compressor tank, compressor cooler and compressor element and drain the oil.

3. Refit and tighten the plugs.

4. Remove the oil filters (E).

5. Open the cover plate (A) on the air reservoir and remove the oil separator element.

6. Check the inside of the oil reservoir (B).è If sediments are detected, the parts (AD) must be thoroughly cleaned before

the procedure is completed.

7. Insert a new oil separator element and refit the cover plate (A).

8. Clean the filter seat on the manifold using new oil, and make sure that no dirt fallsdown into the system.

9. Lubricate the gasket on the new filters with new oil.

10. Replace the filters (E) and close the valve (C).

11. Fill the oil reservoir with the minimum amount of oil permissible thru the oil inlet (F).

12. Run the compressor unloaded in light mode for 30 minutes.

13. Drain the oil.

14. Fill the system with new oil.

The indicator on the gauge (G) must be in the upper section of the green zone.

15. Run the compressor without load in light mode for 15 minutes and check for leaks.

16. Check that the oil level on gauge is in green zone and top up if necessary.


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16.9 Check Compressor Components

n Check for signs of oil or water leakage on the compressor (A).

n Check connections and couplings on intake manifold on the air filters (B) for compressor and diesel engine.

16.10 Drain Compressor

Condition p The drill rig must have been standing still for eight hours before draining off the water.

n Open the drain plug (A) and drain off the water.


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16.11 Clean Compressor Oil Coolern Use compressed air to keep the compressor oil cooler clean in order to maintain effi

cient cooling.


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SmartROC T45-11 17 Automatic Central Lubrication System CLS

99

17 Automatic Central LubricationSystem CLS

17.1 Central Lubrication System PumpThe central lubricating pump is a piston pump. An electric motor powers the pump element,which pumps grease into the lubricating system. There is room for six pump elements. Therequired pump time intervals can be set on the Program Display of the pump. The pump isdesigned for maximum two hours continuous operation. The system can be damaged bycontinuous operation under maximum pressure.

A Spring

B Grease outlet

C Safety valve

D Outlet

E Suction port

F Piston


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17.2 Setting Lubrication and Interval Time

Adjustment Unit

Condition p A time limit of 20 seconds must not be exceeded without touching any symbol. If so, theprogram returns to the last time interval stored.p If the power is cut off, the last program set is used.p The pump is designed for maximum two hours continuous operation.

1. Start the adjustment of lubrication time by quickly moving the adjustment unit (A) overthe SERVICE symbol twice. A green light comes on and the second digit starts toflash.

2. Change the second digit by moving the magnetic coupling over the ADDITIONALCYCLE symbol until the correct value is obtained.

3. Confirm by touching the SERVICE symbol.

4. The first digit starts to flash. Change the first digit by moving the magnetic couplingover the ADDITIONAL CYCLE symbol until the correct value is obtained.



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6. The minutes or seconds start to flash in the program display. Select the correct timeunit by moving the adjustment unit over the ADDITIONAL CYCLE symbol.


8. A yellow light comes on and the second digit starts to flash, indicating setting of interval time.

9. Change the second digit by moving the magnetic coupling over the ADDITIONALCYCLE symbol until the correct time is obtained.


11. The first digit starts to flash. Change the first digit by moving the magnetic couplingover the ADDITIONAL CYCLE symbol until the correct time is obtained.

12. Finish by touching the SERVICE symbol for two seconds with the adjustment unit.

Result è The time will be counted down to the next cycle in the display. If the pump runs forone lubrication cycle, the time is counted down to the next interval. If the pump is stationary, it counts down to the next lubrication cycle.

17.3 Check Condition of CLS pump

n Check that there is no leakage on the safety valve (A) on the CLS pump.


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17.4 Setting Lubrication PumpThe adjustments are made by moving an adjustment unit (A) over the SERVICE andADDITIONAL CYCLE symbols on the Program display. The adjustment unit (A) is mountedbelow the pump (B). If there is no adjustment unit, a strong magnet can be used. If a faultsignal caused by the engine or control equipment appears, contact Atlas Copco. Do notopen the protective engine cover.

Display Function

WAIT. Yellow LED Interval

LUB. Green LED Lubrication

WARN. Red LED warning, error

HOUR Time Unit

MINUTE Time Unit

SECOND Time Unit

SERVICE Used When Setting


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Display Function

ADDITIONAL CYCLE Extra Lubrication Cycle and Used When Setting

17.5 Filling Lubricant

! NOTE: When lubricant is added to the container, maximum cleanliness is required.Use a filler pump when filling with lubricant.

n Fill with lubricant via the nipple (A) or fast coupling (B).

17.6 Bleeding Lubrication Pump

! NOTE: It is important to bleed the pump after filling with lubricant when replacing thepump or pump element.

Condition p The lubrication pump must be switched off.

1. Remove the pump element from the pump housing.

2. Remove the piston and spring.

3. Add grease to the housing.

4. Compress with the piston.


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5. Repeat until the grease is free from air and emerges at the outlet.

6. Install the pump element in the pump housing.

17.7 Lubrication Pump Program Display Alarm ListAlarms shown in the program display:

Alarm Type Function

A1 Low Level Alarm Fill the container. Not all containers are equippedwith a low level sensor.

A2 Pressure Alarm Set pressure is achieved. Not all pump elementsare equipped with a pressure monitor.

A3 Motor Alarm There is an open circuit in a cable or a motor malfunction.

A4 Fuse Alarm A fuse has blown.

17.8 Troubleshooting CLS

! NOTE: Flushing with high pressure water can damage the pump and control system.

Fault Symptom Indication Action

Pump does not work. The system has paused. Wait until the next lubrication cycle or move the adjustment unitover the ADDITIONAL CYCLEsymbol (EC type) to start a lubrication cycle.

The electrical contact has comeloose or been damaged.

Check all cables and electricalconnections.

The pump works but does notdeliver lubricant.

The container is empty. Add lubricant.

There is air in the pump element. Bleed the pump.

If lubricant leaks from the safety valve, this is because some of the distributors have been blocked.Carry out a fault search, replace or clean the blocked distributor. A blocked distributor means that thepressure in the system is the same as the pressure set at the safety valve.

All lubrication points are dry. Container is empty Add grease in container

Break in feed line Repair feed line

Control unit incorrectly set Reset control unit


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Dirt in check valve in pump element.

Check the pump element by detaching the line. Run manual lubrication and check that thepump is supplying grease without it being drawn back in.

Overpressure valve trips. One of the metering pistons isstuck due to contamination

With the pump switched on, startby releasing outgoing lines fromthe main block one at a time tosee if there is overpressure inone of the lines.

If there is no overpressure, thefault lies in the lower block towhich the lines are connected.Do the same there, release oneline at a time.

If there is overpressure in the lubrication point line, the fault liesbetween the metering block andthe lubrication point.

If there is no overpressure, oneof the metering pistons in themetering block has stuck. Replace or clean the meteringblock.

Lubricant line or lubrication pointblocked

Pump does not run Cable break Check that there is power to thepump unit. If there is power, thefault lies in the pump.

If there is no power, check thatthere is power to the fuse forsupplying the pump.

Check if electrical contact detached.

Fuse blown Replace the fuse.

Not enough lubrication Lubrication time too short Increase lubrication

Pause time too long Shorten the pause time

Dirt in pump element checkvalve

Check the pump element by detaching the line. Run manual lubrication and check that thepump is supplying grease without it being drawn back in.

Overpressure valve trips One of the metering pistons hasstuck due to contamination

With the pump switched on, startby releasing outgoing lines fromthe main block one at a time tosee if there is overpressure inone of the lines.

Lubricant line or lubrication pointblocked


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If there is no overpressure, thefault lies in the lower block towhich the lines are connected.Do the same there, release oneline at a time.

If there is overpressure in the lubrication point line, the fault liesbetween the metering block andthe lubrication point.

If there is no overpressure, oneof the metering pistons in themetering block has stuck.

Replace or clean the meteringblock.

SmartROC T45-11 18 Water Mist System

107

18 Water Mist System

NOTICE

Damage to Water Mist Pump

Risk of damage to water mist pump if it is run without water in the system.

u Do not run the pump without water in the system.

NOTICE

Risk of Damage to Water Mist System

During cold weather, the water present in the water mist system can freeze and damage the system when the machine is turned off for a prolonged period.

u Drain the water mist tank.

u Flush antifreeze through the system.

NOTICE

Risk of Damage to DCT

If the dust collecting in the DCT is damp or if water starts flushing out of the drill hole,hoses and filters in the DCT can start to clog.

u Switch off the dust collector if the dust is damp or if water starts flushing out of the drillhole.

Water is pumped from a tank on the machine into the air circuit by a hydraulicdrivenpump. The pump is located in a compartment on top of the water tank. The water mist system is not pressurized.


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18.1 Check Seals on Water Mist Pump

1. Run the water mist pump (A) for 1 minute.

2. Count the number of water drops that run out from the drain holes (B).


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è Replace the all old seals with new ones if more than 10 drops leak out of thedrain holes during one minute.

Seals on Water Mist Pump

A Seals

B Piston seals

18.2 Filling Water Mist Tank

NOTICE


Filling the water mist tank with dirty water can cause damage to the system.

u Always fill the water mist tank with clean water.


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1. Remove the filler cap (B).

2. Add water to the tank via hole (A).

3. Refit the filler cap (B).

18.3 Draining Water Mist System

1. Unscrew bolt from the drain hole (B).

2. Drain water from water mist tank.

3. Screw the bolt back into the drain hole (B).

4. Put the machine in drilling mode.


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5. Turn off flushing air.

6. Run the water mist pump for 20 seconds at full power to purge the water from thehoses.

7. Turn on flushing air for a few seconds to blow out the remaining water from the system.

18.4 Starting Up Water Mist System from Dry

NOTICE


Filling the water mist tank with dirty water can cause damage to the system.

u Always fill the water mist tank with clean water.

NOTICE

Damage to Water Mist Pump

Risk of damage to water mist pump if it is run without water in the system.

u Do not run the pump without water in the system.

1. Fill up the water mist tank.

2. Turn off flushing air.

3. Run the water mist pump at full speed for a few seconds so that the system fills upwith water.


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18.5 Clean Filter in Water Mist Tank

Condition p The water mist tank must be empty.

1. Unscrew and remove the 6 bolts holding the cover (A) in place.

2. Reach into the hole and slide the filter (B) off the water intake pipe and remove it frominside the tank.

3. Inspect and clean the filter. If the wire mesh is damaged, replace it with a new filter.

4. Reach into the tank and push the filter back onto the water intake pipe.

5. Refit the cover using the 6 bolts. Ensure that all washers and seals are correctlyplaced.

6. Fill up the water mist tank with clean water and check that the cover does not leak.

SmartROC T45-11 19 Welding

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19 Welding

19.1 About Welding

WARNING

Risk of Poisoning

Substances are formed when the paint is heated which are hazardous to health andcould cause eczema, eye irritation, respiratory system difficulties and in severe casesasthma or other health problems.

u Always use personal protection such as appropriate breathing apparatus, eye protection and gloves.

u Always ensure there is good ventilation when welding, grinding and other hot work thatinvolves heating the paint.

! NOTE: Any modification to the machine, associated equipment and accessories is notallowed in any form.

Contact Atlas Copco before welding on components or frames. Consult Atlas Copco for approval of welding and choice of electrodes.n All welding must be performed by authorized personnel.n If repair welding is necessary, damaged units should preferably be removed and re

paired separately.n Disconnect the cables from the alternator, the battery and the electronic modules.n Welding equipment must be grounded correctly.n Framework, brackets and loadcarrying structures are made of special materials. Any

repair welding carried out using incorrect materials or additives can weaken the structure.

n Avoid welding close to bearings and bushes.n Do not weld hydraulic tanks, valve blocks, compressed air tanks or pressure lines.n Protect hoses, cables and electric components.n If possible, grind the surface of the weld smooth and treat it with anticorrosion paint.

! NOTE: Always keep a fire extinguisher for oil fires near during all types of welding, cutting and grinding. Screen off the work area from flammable materials.

19.2 CAN Bus System Disconnection Before Welding

! NOTE: The CAN bus and RCS can be severely damaged when welding.

NOTE: Consult Atlas Copco for approval of welding and choice of electrodes.

n Locate all modules present on the machine. Disconnect supply voltage to all modules,both + (positive) and (ground).

l Example of modules which can be present: application module, I/O module,resolver module and CSmodule.

SmartROC T45-11 19 Welding

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n Locate all sensors on the machine and disconnect them.n Locate the safety controller and disconnect supply voltage, both + (positive) and

(ground).n Locate all panels included in RCS and disconnect supply voltage, both + (positive) and

(ground).n Remove the battery's ground cable.

SmartROC T45-11 20 Downtime

115

20 Downtime

20.1 Preparations Before Long Period of DowntimeProtect the equipment from corrosion and storage damage if downtime is expected to lastthree months or longer. If environment is, for example corrosive or dusty, additional protection may be necessary.n Wash the equipment thoroughly and wipe it dry. Use compressed air to blow any col

lections of water out of cavities and pockets.n Protect from rain, snow and strong sunshine. Keep regulated temperature and ventila

tion. Recommended storage environments should maintain a temperature of 1020 ºCand maximum 2050% humidity. Storage site must be free from severe vibration in order to avoid spot damage to the equipment.

n Apply corrosive protection compound (Tectyl 506 for example) to machined surfaces.n Apply touchup paint to any scratches and damage on painted areas.n Cover all equipment with plastic sheet.n Clean old grease from lubrication points to prevent coke formation. Pump new grease

into lubrication nipples. Apply grease with a brush to sliding surfaces and splineswhere these occur. Use the correct grease for each point.

n Observe the strictest cleanliness when dismantling hydraulic, compressed air and water flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes, or sealand protect them from dirt in some other suitable way.

n Mark hoses, pipes and other connections to make reassembly easier and prevent mixups.

n Hoses and rubber parts should be packed in airtight plastic to reduce ageing and drying out. Ensure that components are dry before packing.

n The water mist system must be drained and rinsed with antifreeze.n The battery must be disconnected. If the temperature falls below freezing point then

the battery must be stored indoors.n The gas accumulator must be drained.n The shank adapter must be greased.n Fuel and oil tanks must be filled.n If shutdown is planned for a long time, the rock drill must be removed and protected

before storage.

20.2 Restoring After Long Period of Downtimen Change lubricant and hydraulic oil where appropriate.n Change filter and drain water separators where appropriate.n Inspect joints, bushings and splines for corrosion. Remedy any corrosion by cleaning

or replacing components.n In order to remove any moisture binding from lubrication points: Pump new grease into

the grease nipples and apply grease with a brush to sliding surfaces and splines wherethese occur. Use the correct grease for each point.

n Carry out special startup as instructed.

SmartROC T45-11 20 Downtime

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20.3 Inspection and Maintenance During Period ofDowntimen Check levels for oils and coolants.n Start the diesel engine and let it run until normal operating temperature has been

reached.n Operate the rig a few metres back and forth so that the tramming gears are lubricated.n Operate the tilt cylinders, boom, feeder, drill support and rod handling so that all cylin

ders reach their end positions.n Drain condensed water from the hydraulic oil tank and compressor oil tank.n Rotate the electric motors a few turns at least every three months to avoid spot dam

age on motor bearings.

SmartROC T45-11 21 Start-Up

117

21 StartUp

21.1 About Special StartUpSpecial startup is performed when commissioning the machine for the first time. An AtlasCopco representative will perform a special startup procedure.

Special startup of drilling machine and associated equipment is also performed in the following cases:n After a long standstill (one month or more).n After major change of components or repairs.

Maintenance personnel or an Atlas Copco representative shall take part when starting upor during a test startup after maintenance.

21.2 Performing Special StartUp

WARNING

Risk of Serious Personal Injury

u Stay out of the machine's operating zone.

1. Followup on any installation or maintenance work that has been carried out and components that have been changed. These will require special attention during specialstartup.

2. The pumps must be primed before start if the circuits have been drained.

3. At the startup moment, the operator and any personnel present should stay out of themachine's operating zone (4 m allround). Maintenance technicians can later enterthis zone. Operators should remain with the operating console or remote panel in theimmediate vicinity of the emergency stop.

4. Check that the fire extinguisher and fire fighting system are fully functional.

5. Pay extra attention to any electrical work that has been carried out.

6. Listen for any noise that indicates defects. Stop the machine immediately if thisshould occur.

7. Look for any signs of overheating or fire.

8. After a special startup, the operator and maintenance technician must carry out remaining checks as instructed.

21.3 Flushing of Hoses and PipesAfter first startup and after long standstill, flushing of the external hoses and pipes are recommended.

SmartROC T45-11 21 Start-Up

118

1. Disconnect the hoses from the hydraulic cylinders and join together the hose pistonand piston rod end.

2. Flush each circuit for approximately 10 minutes. Use a high flow at low pressure.

3. Check the hydraulic oil level on the level gauge before flushing the next circuit.

4. After flushing all the circuits, switch off and connect the hoses to the cylinders.

5. Place a vessel by the hydraulic tank with a hose from the filling/draining system in thevessel. Remove the protective hose plug.

6. Top up the oil level in the hydraulic tank after bleeding air from the system.

21.4 About Testing Pressure Release ValvesThe test procedure involves removing each valve and loading it with pressure in a testbench to ensure its setting and function. This requires special test equipment and a soundknowledge of the hydraulic system. Contact Atlas Copco for pressure testing relief valvesused in critical safety functions.

SmartROC T45-11 22 Options

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22 Options

22.1 Winch

22.1.1 Check Attachment of Winch Cable

WARNING

Risk of Tipping and Cable Failure


u The anchorage point must be firm and secure.

u The safety hook must not slide or detach from the attachment point.

u Do not use a damaged cable or hook.

! NOTE: It is important that the cable is correctly fitted in the winch eye.

A Cable

B Rope lock

C Connector sleeve with wedge plug

D Hook

Correct assembly:n The cable must run in line with the eye on the connector sleeve.n The rope lock must only lock the end cable.n The free end must be at least 69 times the diameter of the cable in order to ensure

that the whole section of the cable, that is either lashedin or annealed and tapered, isoutside the connector sleeve.


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The cable and winch eye must be checked:n before each use.n when replacing the cable.n when attaching the cable after shortening.

Check that the winch locking mechanism is fully engaged in the drum before use, followingthe attachment of the cable eye on the anchorage point.

22.1.2 Check Winch Unit Attachment

n Check tightening torque (A).


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22.1.3 Lubricate Winch

1. Remove the plug (A) in the bottom of the gear housing for draining. The gearing ispermanently lubricated.

2. Lubricate with oil if the drum brake (B) does not rotate freely.


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22.1.4 Check Winch

n Check for damage, unwinding, wear and corrosion on the winch wire rope (A).

n Check for damage, cracks and wear on the hook (B) and check that it is properlymounted.

22.1.5 Check Small Remote Control


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n Make sure none of the rubber bellows (A) on switches/levers on the winch box isdamaged

22.2 Service Tool Bag RCSThe service tool bag is used for troubleshooting machines equipped with Atlas CopcoRCS.

A CAN Tester

B Resolver Tester

C Multimeter

D Encoder Tester

E CAN Open Cable

F I/O Tester

G Signal Cable

H Test Cables

I Test Box

J Connectors

K Torque tools


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L Torque tools

M Contact

22.3 Checking CAN Network1. Set the multimeter range to DC Volt.

2. Connect the tester's 5pin connectors to the CAN network requiring measurement:

a. Decoder: contact X3 or X4

b. Display, application and master modules: connector X2, X3 or X4

c. I/O modules: contact X1 or X19

d. Resolver modules: contact X3 or X4

Result è MAIN POWER (Supply voltage) 2428 V (shines green)

CAN POWER (CAN power supply) 2024V (shines green)

CAN HI (CAN communication), about 2.5V (flashes green)

CAN LO (CAN communication), about 2.3 V (flashes green)

Table 2: Normal State

CAN HI glows red constantly for short circuit to ground

CAN HI glows green constantly for voltage above 3.5 V

CAN LO glows green constantly for short circuit to ground

CAN LO glows red constantly for voltage above 3.5 V

If neither CAN HI nor CAN LO is lit, there is no communication even though poweris being supplied to CAN

If any light is flashing red, then CAN communication is at the wrong level or is inverted

Table 3: Fault Indication

22.4 Checking CAN Power Supply1. Set the multimeter range to DC Volt .

2. Connect the tester's 5pin connector to the module's power supply.

3. I/O modules: contact X25. 7pin contact. Use enclosed Tcross.

4. Other modules: connector X1. 4pin connectors.

Result è MAIN POWER (The power supply) must be 2428V (lights green).

22.5 Checking CAN CableCondition p Make sure the RCS system is shut down.

1. Set the multimeter measuring range to ohms.


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2. Connect the tester's 5pin connectors to the CAN network requiring measurement:

a. Decoder: contact X3 or X4

b. Display, application and master modules: connector X2, X3 or X4

c. I/O modules: contact X1 or X19

d. Resolver modules: contact X3 or X4

3. Select CABLE TEST on the CAN tester.è The multimeter should read about 6065 Ohms if the cable is intact.

Because of the internal resistance in the tester the multimeter reads about 100 kOhm if thecables are not connected or if there is an open circuit.

22.6 Checking Digital Inputs on I/O ModuleIn each designated contact there are two digital inputs, A and B.

1. Connect the 5position connector on the I/O tester between the input of interest on theI/O model and the guard.

2. Connect the multimeter between Ground and the Signal A (+A) or Signal B (+B) output of interest.

3. Measure the voltage according to the table.


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è The signal is 0V for an open contact and +24V for a closed contact.

Pin Function

1 +24V DC

2 Signal B

3 Ground

4 Signal A

5 Ground

Table 4: Pin Configuration

22.7 Checking Digital Outputs Voltage on I/O ModuleIn each designated contact there are two digital outputs, A and B.

1. Connect the 5position connector on the I/O tester between the output of interest onthe I/O module and the valve.

2. Connect the multimeter between Ground and the Signal A (+A) or Signal B (+B) output of interest.

3. Activate the function. The multimeter should read 24V.


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Result è If the valve is not activated, there can be an open circuit in the cable running to thevalve or in the coil in the valve.

Pin Function

1 +24V DC

2 Signal B

3 Ground

4 Signal A

5 Ground


22.8 Checking Digital Outputs Current on I/O ModuleIn each designated contact there are two digital outputs, A and B.


2. Connect the multimeter in series with the +A or +B output.

3. Activate the function. The multimeter should read 1A.

Result è If the multimeter reads 0.00A and the solenoid coil diode comes on, there could bean open circuit in the valve's coil.


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22.9 Checking PWM Outputs Current on I/O ModuleIn each designated contact there are two PWM outputs, A and B.


2. Connect the multimeter in series with the +A or +B output that is of interest.

3. Activate the function. Check that the current corresponds with the actuated value onthe display.

Pin Function

1 Not Used

2 Out +B

3 Out B

4 Out +A

5 Out A



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22.10 Checking Analog Inputs on I/O ModuleIn each designated contact there are one analog input.

1. Connect the 5position connector on the I/O tester between the input of interest on theI/O model and the sensor.

2. Measure the values according to the table.

Pin Function

1 +24V DC

2 05V

3 Ground

4 420mA

5 +5V DV


22.11 Encoder InputsEach encoder connector has two signals, A and B.

There are two designated contacts, X12 and X18, for the pulse sensor.

Pin Function

1 +24V DC

2 B

3 Ground


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Pin Function

4 A

5 Ground

22.12 Checking Resolver Module Resolver InputsThere are designated contacts, X6 X9, for the inputs.

1. Connect the resolver tester to the relevant cable. Turn the test sensor slowly andcheck that the angle shown on the sensor menu changes.

a. If the angle changes, the sensor on the boom is faulty.

b. If the angle does NOT change, the cable on the boom must be checked.

2. Connect the test sensor and test cable directly to the resolver module input. Turn thetest sensor slowly and check that the angle on the sensor menu changes.

a. If the angle changes, the cable on the boom is faulty

b. If the angle does NOT change, the resolver module is faulty.

Pin Function

1 Ref +

2 Ref

3 Sine Signal

4 Sine Ground

5 Cosine Signal

6 Cosine Ground



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22.13 Checking Resolver Module Encoder InputsThere are a designated contact, X10, for the pulse sensor.

1. Connect the encoder tester to the relevant cable. Turn the test sensor slowly andcheck that the length measurement shown on the sensor menu changes.

a. If the measured value changes, the sensor on the boom is faulty.

b. If the measured value does NOT change, the cable on the boom must bechecked.

2. Connect the test sensor with test cable directly to the resolver module input. Turn thetest sensor slowly and check that the length measurement shown on the sensor menuchanges.

a. If the measured value changes, the cable on the boom is faulty.

b. If the measured value does NOT change, the resolver module is faulty.

Pin Function

1 + 15V

2 + 15V

3 Signal A

4 Ground

5 Signal B

6 Ground


22.14 Checking Resolver Module Analog InputsThere are two designated connectors, X11 and X12, for analog input.


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1. Connect the resolver module connector X11 or X12 to test box connector (B).

2. Connect the multimeter to test box pins 2 and 3.

3. Set the multimeter to DC voltage. It should read 4.5V on connector X11 and 15V onconnector X12.

If the multimeter reading is 0V there may be a fault in the signal cable or resolvermodule. Continue as follows:

a. Connect the cable (C) on the test box to resolver module input X11 or X12 andmeasure between 1 and 2.

b. Recheck the multimeter reading. If it is 0V, there is a fault on the resolver moduleinput , X11 or X12.

Pin Function

1 Ground

2 + 4.5V DC Power Supply Out

3 Signal In

4 Not Used

5 Not Used

Table 10: Pin configuration for input X11

Pin Function

1 Ground

2 + 15V DC Power Supply Out

3 Signal In

4 Not Used

5 Not Used

Table 11: Pin configuration for input X12


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22.15 Replacing a RCS ModuleCondition p Make certain that electric power is present at the machine or that the diesel engine is

running before loading the program. Avoid starting the diesel engine while the program isbeing loaded. Never turn off the system while the program is being loaded.

1. Make certain the module has the correct address plug and that the end plug (if any) ismounted in place.

2. When any of the application module, I/O or resolver module is replaced, the programmust be read into the system again.

3. Insert the USB memory stick with the program into the USB port and start the RCSsystem.

4. When the program has been fully loaded, the following will appear on the display: Remove card and restart the system!.

5. Switch off the system remove the USB memory stick and start the RCS system.


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SmartROC T45-11 23 Specifications

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23 Specifications

23.1 Standard Tightening Torques Bolted JointsAll bolted joints are tightened to the torque required by Atlas Copco Standard K 4369:01 K(metric) and 4368K/01K (imperial) unless otherwise specifically stated. In such cases, thiswill be specified in the maintenance instructions of the module in question.

All bolted joints must be lubricated with Molycote 1000 or corresponding thread lubricantwith a coefficient of friction 0.11 μ.

Size Grade 8.8 Nm(lbft)

Grade 10.9 Nm(lbft)

Grade 12.9 Nm(lbft)

Tolerance

M6 8.6 (6.4) 12.4 (9.2) 14.5 (10.7) ±5%

M8 21 (16) 30 (22) 35 (26) ±5%

M10 42 (31) 60 (44) 70 (51) ±5%

M12 73 (54) 104 (77) 122 (90) ±5%

M14 116 (85) 166 (122) 194 (143) ±5%

M16 181 (133) 258 (190) 302 (222) ±5%

M18 257 (189) 355 (262) 415 (306) ±5%

M20 365 (269) 503 (371) 590 (435) ±5%

M24 631 (465) 872 (643) 1018 (751) ±5%

M30 1254 (925) 1734 (1279) 2024 (1493) ±5%

M36 2187 (1613) 3027 (2232) 3535 (2608) ±5%

M39 2834 (2090) 3917 (2889) 4580 (3378) ±5%

Table 12: Tightening Torques Metric

Size SAE Grade 5 Nm(lbft)

SAE Grade 8 Nm(lbft)

Tolerance

.2520 10 (7) 13 (10) ±5%

.3816 35 (26) 50 (36) ±5%

.5013 85 (62) 120 (88) ±5%

.6311 170 (124) 240 (175) ±5%

.7510 300 (220) 420 (310) ±5%

.889 480 (355) 680 (500) ±5%

1.008 720 (530) 1020 (750) ±5%

1.137 890 (655) 1445 (1065) ±5%

1.257 1260 (930) 2040 (1500) ±5%

SmartROC T45-11 23 Specifications

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Size SAE Grade 5 Nm(lbft)

SAE Grade 8 Nm(lbft)

Tolerance

1.386 2120 (1560) 3442 (2540) ±5%

1.506 2190 (1610) 3540 (2610) ±5%

Table 13: Tightening Torques Imperial U.S

23.2 Signs for Ordering Spare PartsSigns are placed on the larger components. When ordering spare parts or making inquiriesregarding the machine, the type designation and serial number must always be stated.Type designations and serial numbers are specified in a separate document, MI (MachineIdentification). Spare parts can be ordered from Atlas Copco.

SmartROC T45-11 Maintenance table

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Maintenance table

Maintenance cycle Personnel Additional information

50 Percussion Hours Operating Personnel 7.6.1 Drain Condensate from Hydraulic OilTank

Maintenance Personnel 7.6.1 Drain Condensate from Hydraulic OilTank

100 Percussion Hours Maintenance Personnel 5.7 Check DrillSteel Support

5.9 Check Rod Handling

250 Percussion Hours Maintenance Personnel 5.10 Clean Behind Sealing Disc

500 Percussion Hours Maintenance Personnel 14.2 Check Dust Collector Filters

50 Diesel Engine Hours Maintenance Personnel 5.5 Check Sprocket Wheel

5.12 Lubricate Chain Feed

7.5.2 Check Breather Filter

12.1 Check Cabin


16.9 Check Compressor Components

16.10 Drain Compressor

16.11 Clean Compressor Oil Cooler

22.1.2 Check Winch Unit Attachment

250 Diesel EngineHours

Maintenance Personnel 4.2 Check Boom Condition


5.8 Check Chain Feed

5.14 Replace Slide Rails

5.15 Replace Slide Pieces in the Holder

7.5.4 Replace Breather Filter

11.1.1 Clean Radiators


18.1 Check Seals on Water Mist Pump


Maintenance Personnel 5.2 Check Jack Chain Cover

5.3 Check Feed Beam

5.4 Check Chain Guide


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7.7 Check Mounting Hydraulic Jack


15.15.2 Replace the Filter Cartridge


Maintenance Personnel 3.2 Check Condition of Signs

7.6.4 Drain Hydraulic Oil Tank

15.11 Replace Secondary Fuel Filter

15.15.1 Air Filter Indicator Function

16.5 Change Oil on Compressor

18.5 Clean Filter in Water Mist Tank


Maintenance Personnel 13.7 Change Oil on Track Frames

22.1.3 Lubricate Winch


Maintenance Personnel 7.4 Check Hoses and Couplings

14.3 Replace Dust Collector Filters

16.6 Replace Separator Filter


Maintenance Personnel 5.13 Replace Bearing Unit

15.10 Replace PreFilter


Maintenance Personnel 15.14 Replace Longterm Effective Coolant

Daily Operating Personnel 3.1 Wash Machine Externally

6.1 Check Lubrication Oil Level Tank

7.6.2 Drain Condensate in Pressure Tank


9.2 Check Emergency Stops and WorkLights

11.1.2 Check Coolant Level


15.1 Check Motor Oil Level

15.2 Drain PreFilter

16.2 Check Compressor Oil Level

17.3 Check Condition of CLS pump

22.1.1 Check Attachment of Winch Cable

22.1.4 Check Winch


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22.1.5 Check Small Remote Control

Weekly Maintenance Personnel 5.11 Lubricate Rod Handling

Quarterly Maintenance Personnel 3.2 Check Condition of Signs

Annually Maintenance Personnel 7.4 Check Hoses and Couplings

7.6.3 Clean Hydraulic Tank

Atlas Copco SmartROC T4511 - Walter S. Pratt & Sons, Inc...Atlas Copco is not liable for any damage,...

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Transcript of Atlas Copco SmartROC T4511 - Walter S. Pratt & Sons, Inc...Atlas Copco is not liable for any damage,...