ROC203 Operator Instructions PDF
ROC203 Operator Instructions PDF
ROC203 Operator Instructions PDF
code
AIB
ROC 203PC
2000-05
Operator’s Instructions
for
Pneumatic Crawler Drills
ROC 203PC
1250 0071 04
The owner of the equipment is granted permission to take copies of this publication solely for internal
use, however, it is recommended to order further copies from the Atlas Copco representative in order to
benefit from the latest revision.
Atlas Copco Rock Drills reserves the right to make changes in its product without notice in order to
improve design or performance characteristics.
The information in this publication is assumed to be accurate at the time of publication, but is subject to
change in order to remedy detected deficiencies or to follow changes in the product.
Any user of this publication is requested to inform Atlas Copco Rock Drills AB of deficiencies detected in
this publication, particularly in product safety matters.
2
Foreword
This instruction book is part of the complete delivery of the pneumatic crawler drills ROC 203PC .
It gives information on features and handling of the rig and contains advice and measures necessary to
keep the rig operational.
This instruction book does not replace a thorough training on the rig.
The documentation is made up from the following:
Section 1
Operating safety
Section 2
Equipment description
Section 3
Operation
Section 4
Settings and maintenance by the operator
Section 5
Technical Data
This instruction book shall be read in advance by everyone who is tasked to operate the rig or carry
out maintenance or repairs to it.
3
Table of contents
Page
Operating safety 5
! General safety advice
Special safety advice
5
8
Danger zone 9
Equipment description 10
Features & Controls overview ROC 203PC-00 11
Operating controls ROC 203PC-00 12
Hydraulic control panel 12
Pneumatic control panel 13
Controls 14
General air and oil flow controls 14
Track oscillation shut-off valve 15
Level indicator 15
Principal system functions 16
Pneumatic system 16
Hydraulic system 16
Operation 17
Daily checks 17
Extra safety check 18
Topping-up liquids 20
Connecting air supply 21
Functional checks 22
Manoeuvring 25
Tramming 25
Towing 27
Hoisting 31
Drilling 32
Set-up for drilling 32
Collaring & drilling down the first rod 34
Adding rods 36
Withdrawing the drill string 38
When the drillstring gets stuck during withdrawing 42
Reconnection of the boom swing cylinder 43
Technical data 48
Masses 48
Performance 48
Hydraulic system 48
Component specifications 49
Recommended hydraulic oils and lubricants 51
Volumes 51
Tightening torques 51
Transport dimensions 52
Coverage areas 53
Annex: Documentation Feedback form 56
4
Operating safety
Dear Operator,
like driving a car, drilling bears hazards to you and your
environment. Good training, discipline and well maintained
equipment are the keys to safe operation. This instruction book
is no replacement for a thorough training on the rig, but as a
training aid and a reference book it shall help you to maintain a
safe working environment and the operability of your rig.
Yours faithfully
Atlas Copco Rock Drills AB
Intended use:
The pneumatic drill rig ROC 203PC is solely designed for drilling holes in surface
working,
i.e. usually quarries, opencast mines and construction engineering.
Any use going beyond this shall be considered not to be intended use.
Not-intended use is e.g.:
- Lifting and transport of loads
- Lifting and transport of personnel
- Stabilization of other equipment
The manufacturer is not liable for damage incurred as a result; this shall be at the
owner’s risk. Proper use also includes observation of operating, servicing and
maintenance instructions stipulated by the manufacturer.
The ROC 203PC may only be operated, serviced and repaired by personnel familiar with
it and informed of the dangers.
Relevant accident prevention regulations as well as other generally recognized safety,
occupational medicine and traffic regulations must be observed.
The manufacturer is not liable for any damage caused by unauthorized alterations made
to the crawler drill.
Organizational measures:
1. The pneumatic drill rig ROC 203PC shall be operated only by personnel, which has
been given a practical training on the rig. Particular emphasis shall be laid on safety
precautions.
2. Keep this instruction book as well as the other instructions books listed in the chapter,
"Separate Instruction Books“ on the rig at any time.
5
3. As far as necessary or required by regulations use personal protective equipment.
4. In case of possibly safety relevant changes of the rig or its operational behavior
immediately shut down the rig and investigate the problem (seek advice from your
Atlas Copco representative if necessary).
5. Keep the warning plates attached to the rig complete and legible.
6. Have the daily safety check carried out as described in this instruction and follow the
maintenance measures as described in the service schedule.
7. Works to the hydraulic system shall be carried out only by personnel with particular
skills and experience.
8. Any welding shall be carried out only by an authorised welder qualified acc. to
EN 287 part 1 or equivalent.
9. Following repair, the rig shall be inspected and approved by the proper authorities
before being put back into normal service.
10. Never carry out alterations or modifications to the rig, which might affect the
operating safety, without full approval of the manufacturer.
11. The sound power level at the operator’s place are 126 dB(A).
6
Frequently encountered safety risks
1. During transportation and particularly during hoisting there is an increased hazard
of overturning. During hoisting the Track oscillation shut-off valve must be in
position BOTH CYLINDERS CLOSED.
2. The rig could tip over during tramming in extreme terrain. In order to avoid
overturning during tramming:
- Keep Track oscillation shut-off valve in position BOTH CYLINDERS OPEN
- Lay down feed resp. to provide an optimum center of gravity
- Max. inclination in tramming direction: ± 20° solo machine (feed laid down)
- Max. lateral inclination: ± 20° solo machine (feed laid down)
- Operate the rig from the uphill side
3. The rig could tip during drilling in extreme positions. In order to avoid tipping during
drilling:
- Keep Track oscillation shut-off valve in position BOTH CYLINDERS CLOSED
- Max. inclination in tramming direction: ± 20°
- Max. lateral inclination : ± 20°
- Operate the rig from the uphill side
4. When the drill string gets stuck never grip the drill steel nor apply a spanner or
similar tool while the rotation motor is under pressure. The drill steel could suddenly
break free and squeeze the arm resp. toss about or fling the tool all of which could
lead to severe injury or death.
5. Before maintenance depressurize the rig.
7
Special Safety advice:
On the rig or in this instruction book you may find the following signs:
NOTE This sign indicates advice for the efficient, economic and
environmentally compliant use of the rig.
8
Danger Zone
Any zone within and / or around the drill rig in which a person is exposed to risk of injury
or damage to health.
7m
7m
7m
Bench drilling
2m
7m 7m
2m
Tramming
Working area
The area near the drill rig in which its tools are moved in order to carry out work.
9
Equipment description
10
ATLAS COPCO
12 14
8
7
17
11 Max.
a x.
M
9106 1073 21
9106 1073 06
9106 1071 00
16
15
4 13
5
10
Features & Control overview
ROC 203PC
* optional
11
Operating controls
ROC 203PC
* optional
12
9 De-clutching left 11 1 2 3 4 5 6
12
a) ON
b) OFF
10 De-clutching right
a
a) ON
b) OFF b
c
11 Signal Horn
12 Button Emergency stop
closes the valve 'air supply'
(disengage before restart)
10
a
20 DCT (Dust collector) * b
a) CLEANING
a 8
b) OFF 7
c) ON b
9
c
21 Set screw Feed pressure
- REDUCE (anti-clockwise)
20
+ INCREASE (clockwise)
22 Gauge Feed pressure a
21
-+ b
c
23 Feed speed a
a) RAPID FEED ON b 22
23
b) RAPID FEED OFF 28
24 Feed (speed and direction)
a) REVERSE FEED 24
/ RAPID REVERSE FEED**
b) NEUTRAL
c) DRILL FEED / RAPID FEED** a
a) REVERSE c
b) NEUTRAL
c) DRILL ROTATION
26 Impact / Flushing (DTH) 27 a
a) NEUTRAL
b
b) MAX. IMPACT / FLUSHING
27 Flushing air (TH)
a) NEUTRAL 26 b
b) MAX. FLUSHING AIR a
28 Button emergency stop
Closes the valve 'air supply'
(disengage before restart)
* optional
** this function is possible when lever 23 is ON
13
Controls
1 Air inlet 2
2 Main air valve
Pneumatically operated 3
3 Lubrication valve (rock drill) 1
See chapter
"Settings and maintenance by the operator"
4 Tramming valve
a) CLOSED
b) OPEN
5 Pressure regulating valve
(pump motor, rock drill, flushing air T.H.)
INCREASE (clockwise)
DECREASE (anti-clockwise)
6 Lubrication valve
(rock drill, tramming motor, extra air outlet) 6
See chapter
"Settings and maintenance by the operator"
5
7 Extra air outlet
a) CLOSED
b) OPEN
7b
4a
4b 7a
14
Track oscillation shut-off valve
1 LEFT CYLINDER
2 RIGHT CYLINDER
a) OPEN
both cylinders OPEN
(to be used for tramming)
b) CLOSED
both cylinders CLOSED (to be used when rig is set up
for drilling or lifting and transport condition
b b
1 2
a a
Gradient meter
Indicates angles for safe operation of the 5 5 4
4 3 2
2 3 1
1 01 01
2 3
3 2 0 4
0
0
30 300
200
5
02
specified. 30 2 0
15
Principal system functions
Pneumatic system
extra lubricating
oil Emergency
air outlet stop
tank
lubrication lubrication
valve valve
dust
DCT* trap inlet
main
valve
*optional
Hydraulic system
Positioning
cylinders:
- feed extension
- feed swing track
- feed dump track oscillation oscillation
shut-off valve cylinders
- boom lift
- boom swing
positioning control
return air
oil hydraulic motor
filter pump
16
Operation
Daily checks
Carry out
! "Daily checks"
Prior to each shift !
For inspection/maintenance every 40, 125, 500 and 1500 hours of operation
follow separate instruction:
Service Schedule for
Pneumatic Crawler Drills
ROC 203PC
Printed matter no. ASB 181 00 10
17
! Extra safety check
12*
ATLAS COPCO
10*
11*
9
14
2
8
3 6
13
1
15
18
Before each shift commences,
an extra and thorough safety check
shall be carried out, intended to
detect:
l cracks or fractures in materials or
at welded points.
l damage, which could cause
structural weakness or fracture,
l loose junctions,
loose threaded unions.
1. Tow hook
2. Chain tensioner
3. Track frame attachment
4. Boom support
5. Boom
6. Boom head
7. Drill steel support
8. Feed gear (*)
9. Feed holder with attachment
10. Feed beam *
11. Rock drill and cradle *
12. Feed chain with attachments *
For readjustment of chain slack see
"Service schedule for Pneumatic Crawler Drills
ROC 203PC
Printed matter no. ASB 182 00 10
13. Cylinder brackets
14. ‘S’ link
15. Bellow housing
19
Topping-up liquids
WARNING
Hazardous air pressure
Can cause severe injury
l Release pressure in tank
before removing any plug
3a
3b
AIR
R E
Type CE IVER
9
Seria 090 0492
lN 00
Volum o.
e
Max. I. 12
3217
5431
20
Connecting air supply
1 Wire mesh hose, chain, attachment:
Check for attachment and damage
CAUTION
Always secure air hose with wire mesh hose
1
2 Air hose:
Route air hose through wire mesh hose and
connect it to the air inlet
2
3
3 Compressor:
Switch on compressor
45
21
Functional checks
22
Functional ckecks
NOTE
The emergency stops (all) have to be checked
WARNING
before each shift and after each tramming Never operate a defective drill rig
Can cause severe injury and property
Emergency stops (all)
l Close the air main valve if the drill rig
Check that each emergency stop individually
closes the inlet valve. All the rig function will has failed one or more checkpoints
then stop. Before checking the next emergency
stop the previous emergency stop must be in
released mode before restart.
1 Operating controls
Check function and for leakages
3 Traction units
Check for leakage
23
7 DCT hose and skirts 7
Check for attachment and leakage
8 Lubricating valve(s):
Check that the exhaust air from the rock drill
contains oil (both rotation and impact)
47
WARNING
Never operate a defective drill rig
24
Manoeuvring
Tramming
WARNING WARNING
Tip over hazard Tip over hazard
Can cause severe injury and property damage Can cause severe injury and property
damage
l Keep feed in tramming
position and boom inside l Keep unauthorized
the track limits persons out of
working area
l Keep oscillation cylinders
open
NOTE
The emergency stops (all) have to be checked
after each tramming (see 21)
25
2 Air valve to position OPEN
CAUTION
Fully lay down the feed beam beneath
the hydraulic tank resp. if
3 Lift feed
26
WARNING
Electrical hazard
Can cause severe injury and property damage
l Keep distance from
power lines
Max.
Max.
9106 1071 00
27
Towing
WARNING
Hazardous rolling motions
Can cause severe injury
and property damage
l Place wedge blocks
underneath both tracks,
before de-clutching
28
6 Right track control to position
FORWARD
(hold till de-clutching lever operation) 9106 1073 21
6
9106 1073 06
7
7 Right de-clutching lever to position
OFF
10 Remove Wedges
29
13 Disconnect Tow bar
14
14
30
Hoisting
1 Position the boom system so that the crawler
is as compact as possible. This will obtain the
best possible point of balance and centre of ROC 203 PC
gravity
WARNING
Suspended load
Can cause severe injury and property
damage
l Keep away from a
suspended load
l Use only lifting device
and cargo sling with
sufficient hoisting
capacity
WARNING
Tip over hazard
Can cause severe injury
and property damage
l Lock oscillation
cylinders when the
drill rig is being
hoisted
WARNING
Always make sure that nobody is
anywhere near a suspended load
31
Drilling
WARNING
Hazardous moving and rotating parts
Can cause severe injury
l Keep unauthorized
persons out of
working area
l Stay away from the rotating drill string
4 Insert a drillrod
5 Mount a drillbit
32
CAUTION
Use Boom lift to lift the tracks
Using Feed extension puts excessive load
onto the boom head
8
33
Collaring & drilling down
the first rod
* optional
34
5 Adjust Feed pressure in order to obtain the
optimum rotation torque:
* optional
35
Adding rods
1 Lever Rotation to REVERSE
Shank adapter / adapter rotates out of coupling
36
7 In order to couple shank adapter to new rod
and new rod to old rod:
Lever Rotation to SLOW DRILL ROTATION
Lever Feed to DRILLFEED
* optional
37
Withdrawing the drill string
... 3 - 6 sec:
* optional
38
6 Lever Feed to NEUTRAL
... 20 sec:
* optional
39
11 Lever Rotation to NEUTRAL
40
16 Lever Feed to RAPID FEED
until the shank adapter
reaches the coupling
41
When the drill string gets stuck
during withdrawing ...
NOTE
42
Reconnection of the
feed swing cylinder
2
To simplify certain types of drilling work, it is
possible to reconnect the feed swing cylinder so
that the boom system can operate outside the 1
confines of the track frames
CAUTION
Operating the feed within sector 2 causes
reduced stability of the crawler. Strictly follow
the procedures given below in order to
prevent accidents
43
4 Track oscillation shut-off valve to
BOTH CYLINDERS CLOSED
a
5 Remove
c b
a) Screws 6
b) Lock Plate
c) Pin
CAUTION 7b
8b
8a
44
Settings and
maintenance
by the operator
Replacing the oilfilter cartridge
When the needle of return oil pressure gauge is in
the red field, the filter cartridge needs to be
replaced
4a
4b
45
Cleaning the strainer
1 Emergency stop switch
(on both control panel) to position
PUSH MODE
SYSTEM DEPRESSURIZATION
5 Remove strainer
5
6 Clean up the strainer
2
7 Assemble strainer, return line filter assly.,
drain plug
A = 25 - 50 mm !
A > 50 mm ?
46
Setting the lubricating valves
47
Technical data *
Masses
ROC 203 PC-00 2500 kg 5520 lbs
Optional Equipment
Dust collector DCT 60-E 85 kg 187 lbs
Assembly kit DCT 110 kg 242 lbs
Performance
Max. travel speeds (w/o compressor on level ground) 2.5 km/h 1.55 miles/h
Max. towing speed 5 km/h 3.1 miles/h
Tractive force 18.8 kN 4225 lbf
Tramming (w/o compressor) 20° 20°
Tramming with compressor (max. 3500kg.) 15° 15°
Max. longitudinal inclination for drilling 20° 20°
Max. lateral inclination
Tramming 20° 20°
Drilling 15° 15°
Drilling with reconnected feed swing cylinder 10° 10°
Average ground pressure 0.04 N/mm2 5.8 psi
Ground clearance 295 mm 11.63"
Track oscillation ± 12° ± 12°
Max. ambient temperature 45°C 113°F
Max. operating air pressure 12 bar 171.5 psi
Sound level 126 dB(A) 126dB(A)
Hydraulic system
Max. operating pressure 210 bar 3045 psi
Air motor
Type Piston motor
Performance max. 7.5 kW (at 6 bar) 10 hp
Torque max. 69 Nm 51 lbf.ft.
Rotation speed max. 1100 rpm 1100 rpm
Pump
Type Gear pump
Pressure max. max. 210 bar 3000 psi
Traction motor
Type Gerotor motor
Displacement per revolution 160cc
Filter (Filtration degree) 25 µm nominal 25 µm nominal
48
Component specifications
Pneumatic chain feed Top Hammer
1) BMM 35K 157-00 (Single start)
Mass excl. rock drill 300 kg 661 lbs
Total length 5430 mm 17" 9.8"
Travel length 3940 mm 12’ 11"
Travel speed max. 0.3 m/s 11.8"/s
Feed force max. 8 kN 1800lbf
Air consumption during drilling max. 9 l/s 19 cfm
49
Pneumatic rock drill BBC 120 (TH)
Hole Dia 48-76 mm 2"-3"
Weight 69 kg. 152 lbs
Length 780 mm 2' 6.7"
Piston Dia 120 mm 4.72"
Stroke 65 mm 2.56"
Impact rate at 6 bar 2100 blows / min 2100 blows / min
Rotation speed 180 rpm 180 rpm
Air Consumption at 6 bar 212 l/s 448 cfm
Flushing:
Water 58 l/min. 263.6 lmp.gal/min
15.3 US gal/min
Air 45 l/min. 204.5 lmp.gal/min
11.9 US gal/min
Hose connections:
Impact mechanism 38 mm 1 1/2"
Rotation 10 mm 3/8"
Flushing water 19 mm 3/4"
50
Recommended hydraulic oils and lubricants
Hydraulic oil tank l Use mineral-based hydraulic oils with good anti-wear, anti-rust, anti-oxidation and foam inhibiting
properties and with good air and water separation characteristics. Choose an oil with viscosity
grade (VG) and viscosity index (VI) in accordance with the table below. An oil with a high viscosity
index is less sensitive to the effects of temperature:
Hydraulic oil temperature in tank °C (°F) Viscosity Viscosity
Normal operating temp. Min. starting temp. Max. temp grade VG index VI
(viscosity 25-50 mm2/s (cST)) (viscosity min. (ISO 3448)
1000 mm2 /s (cST))
+ 45 to + 60 (113 to 140) -5 (23) 75 (167) ISO VG 68 min. 100
+ 35 to + 50 (95 to 122) -10 (14) 65 (149) ISO VG 46 min. 100
+ 25 to + 40 (77 to 104) -15 (5) 55 (131) ISO VG 32 min. 100
+ 10 to + 25 (50 to 77) -25 (13) 45 (113) ISO VG 15 min. 100
NB: When operating in extremely low temperature, installation of additional heating equipment is
recommended. If the oil temperature exceeds +60 °C (140 °F) during long periods, a tropical
oil cooler should be installed.
Traction gears l Use mineral-based transmission oils (for cars) that conform to quality SAE HD 80W/90 and to the
Feed gear norm MIL-L-2105C
Air motro l Use mineral-based engine oils that conform to quality SAE20 W / 40
(Power pack)
Volumes
Tightening torques
Size Wrench size Tightening torque in Nm (lbf.ft.)
8.8 12.9
M 10 17 mm 49 (36) 69 (51)
M 12 19 mm 86 (63) 120 (89)
M 16 24 mm 210 (156) 295 (218)
M 20 30 mm 410 (303) 580 (428)
51
Transport dimensions
Height
Without DCT ........ 1595 mm 5’ 2.8"
With DCT 60-E ............................. 3265 mm 10’ 8.5"
Width
Across tracks.................................. 1950 mm 6’ 4.7"
Incl. DCT 60-E in transport pos.... 2150 mm 7’ 1"
Incl. DCT 60-E in working pos...... 2635 mm 8’ 8"
Length 5500mm 18'1"
ATLAS COPCO
-203
ROC
ROC
Track oscillation
52
Coverage area
(Boom swing)
72°
35°
37°
Manoeuvring possibilities
Max. and Min. height position as well as feed extension
800
ATLAS COPCO
03
C-2
RO
2672
ROC
1484
425
53
Feed swing after reconnection of feed swing cylinder
°
68
13°
54
Documentations Feedback
Dear Operator,
if you find any deficiency in this manual (a procedure insufficiently or not described,
a safety risk not referred to etc.), please take a copy of this page, fill it in and send it to:
S-701 91 Örebro
Sweden
Feedback E-mail: rde.techdoc@atlascopco.com
Description of deficiency:
TUESDAY
31
DECEMBER
Signature
55