Atlas Copco

Rocket Boomer L1 C/L2 C Mark4

Maintenance instructions

Roc ket Boomer L2 C

PM No. 9852 1458 01

2003-11
 SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.

Special attention must be paid

to information alongside
this symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

© Copyright 2003, Atlas Copco Rock Drills AB, Sweden

Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
Table of Content

Safety ............................................................................................................. 5

Maintenance instructions ............................................................................ 9

3
4
Safety
Reference................................................................................................................. 7

5
6
Reference

Note
Always read the safety information before operating the rig or
beginning maintenance work.

1250 0099 89

7
8
Maintenance instructions
1. General ................................................................................................................... 25
Environment .......................................................................................................... 25
Contact details ....................................................................................................... 27
Target group and objective .................................................................................... 29
Hydraulic systems ................................................................................................. 30
General.............................................................................................................. 30
Repairing hydraulic components ...................................................................... 30
Hydraulic workshops ........................................................................................ 31
Replacement of hydraulic hoses ....................................................................... 31
Welding.................................................................................................................. 31
Electrode recommendations.............................................................................. 32
Tightening torque in bolted joints. ........................................................................ 33
Markings and plates............................................................................................... 33
Dismantling and assembly..................................................................................... 34
Fault finding .......................................................................................................... 34
Starting with an auxiliary battery .......................................................................... 35

2. Lubricants, coolants and propellants...................................................................... 37

Introduction ........................................................................................................... 37
Hydraulic oil.......................................................................................................... 37
Hydraulic systems............................................................................................. 37
Lubrication oil ....................................................................................................... 38
Rock drilling machine (ECL lubrication system) ............................................. 38
Diesel engine .................................................................................................... 38
Hydraulic transmission ..................................................................................... 39
Wheel axle centre and hub reduction gears ...................................................... 39
Compressor ....................................................................................................... 39
Reeling units ..................................................................................................... 40
Gears ............................................................................................................ 40
Lubrication grease ................................................................................................. 40
Rock drilling machine....................................................................................... 40
Feeder ............................................................................................................... 40
Boom................................................................................................................. 40
Drill steel support ............................................................................................. 41
Carrier ............................................................................................................... 41
RCS and electrical systems............................................................................... 41
Service platform................................................................................................ 41
Rod handling equipment................................................................................... 42
Propellants ............................................................................................................. 42
Diesel engine .................................................................................................... 42
Coolants................................................................................................................. 42
Diesel engine cooling system ........................................................................... 42
Air conditioning................................................................................................ 43

3. Feeder ..................................................................................................................... 44
Safety..................................................................................................................... 44
6000-series............................................................................................................. 44
Technical data ........................................................................................................ 45

9
 6000-series ........................................................................................................ 45
Fitting the rock drill/rotation unit .......................................................................... 46
Preparation ........................................................................................................ 46
Assembly .......................................................................................................... 46
Check after four hours ........................................................................................... 46
Drilling machine hoses .......................................................................................... 47
Location of hoses .............................................................................................. 47
Adjusting the hoses ........................................................................................... 49
Haul and return ropes ............................................................................................ 49
Locations........................................................................................................... 49
Replacing the haul rope .................................................................................... 49
Adjusting haul and return ropes........................................................................ 50
Tension of return rope....................................................................................... 50
Adjusting the cradle on the feed beam .................................................................. 51
Adjusting the feed beam on the telescope feeder .................................................. 52
Replacing the slide pieces in the holder ................................................................ 53
Replacing slide rails............................................................................................... 54
Adjusting different drill steel lengths for the telescope feeder.............................. 54
Feed cylinder ......................................................................................................... 55
Dismantling the feed cylinder........................................................................... 55
Tension bushing for spacer ............................................................................... 57
Description ................................................................................................... 57
Dismantling .................................................................................................. 57
Assembly...................................................................................................... 57
Long-term storage.................................................................................................. 57

4. Boom ...................................................................................................................... 58
BUT 35 G .............................................................................................................. 58
Technical data ........................................................................................................ 59
BUT 35 G.......................................................................................................... 59
Bolted joints........................................................................................................... 60
Tightening torques ............................................................................................ 60
Bulkhead lead-through .......................................................................................... 63
Hose location .................................................................................................... 63
Starting to use a new boom.................................................................................... 63
Slinging and hoisting ............................................................................................. 64
Safety ................................................................................................................ 64
Hoisting............................................................................................................. 64
Slinging ............................................................................................................. 65
Dismantling the boom ........................................................................................... 65
Safety ................................................................................................................ 65
Dismantling the feeder...................................................................................... 66
Dismantling the boom....................................................................................... 66
Expander shafts...................................................................................................... 67
Dismantling....................................................................................................... 67
Assembly .......................................................................................................... 67
Boom telescope...................................................................................................... 68
Dismantling the boom telescope....................................................................... 68
Safety............................................................................................................ 68
Dismantling the boom .................................................................................. 68
Dismantling of telescope and bearing housing ............................................ 69

10
 Checking the bushings in the bearing housing ................................................. 70
Checking the keys............................................................................................. 71
Checking the slide rails..................................................................................... 71
Rotation unit .......................................................................................................... 72
Safety ................................................................................................................ 72
General.............................................................................................................. 72
Function of the rotation unit ............................................................................. 73
Reconditioning rotary actuators........................................................................ 75
Dismantling of rotary actuator from boom .................................................. 75
Constituent parts of the rotary actuator........................................................ 77
Removing the rotary actuator....................................................................... 78
Assembly of rotation unit............................................................................. 82
Action after rotary actuator assembly .......................................................... 84
Mounting of rotary actuator on boom .......................................................... 85
Adjusting the feed lookout cylinder ...................................................................... 89
Directional control - angle sensor.......................................................................... 91

5. Engine .................................................................................................................... 92
Engine unit Deutz 1013 C ..................................................................................... 92
Technical data ........................................................................................................ 93
Tightening torques................................................................................................. 93
Safety..................................................................................................................... 94
Fuel system............................................................................................................ 95
Changing fuel filter........................................................................................... 95
Bleeding the fuel system................................................................................... 96
Draining the fuel tank ....................................................................................... 97
Air system.............................................................................................................. 98
General.............................................................................................................. 98
Changing filter insert ........................................................................................ 98
Cleaning the filter insert ................................................................................... 99
Cleaning the dust valve..................................................................................... 99
Cooling system ...................................................................................................... 99
Coolant level ..................................................................................................... 99
Cleaning the cooling system ........................................................................... 100
Draining the cooling system ........................................................................... 101
Topping up/bleeding the cooling system ........................................................ 102
Oil system............................................................................................................ 103
Topping up with engine oil ............................................................................. 103
Changing oil.................................................................................................... 103
Checking oil level ........................................................................................... 104
Changing oil filter........................................................................................... 104
Belts..................................................................................................................... 105
Tension gauge ................................................................................................. 105
Tensioning belts .............................................................................................. 106
Fan belt....................................................................................................... 106
Generator.................................................................................................... 107
Coolant and fuel pump............................................................................... 108
Changing belt on coolant / fuel pump............................................................. 108
Changing generator belt.................................................................................. 109
Valve clearance.................................................................................................... 109
Alternating current generator ...............................................................................111

11
 Safety .............................................................................................................. 111
Instructions...................................................................................................... 111
Lifting device....................................................................................................... 111
Fault finding ........................................................................................................ 112
........................................................................................................................ 112
Deutz instruction manual..................................................................................... 113

6. Transmission......................................................................................................... 114
Locations ............................................................................................................. 114
Technical data ...................................................................................................... 114
Wheels ............................................................................................................ 114
Steering ........................................................................................................... 115
Drive shafts ..................................................................................................... 115
Hydraulic transmission ................................................................................... 115
Fitting tyres and rims........................................................................................... 115
Drive shafts.......................................................................................................... 115
Checking oil level in central gear ................................................................... 115
Changing oil in the final drive ........................................................................ 116
Checking oil level in hub gear ........................................................................ 117
Changing oil in hub gear................................................................................. 118
Hydraulic transmission ........................................................................................ 119
Safety .............................................................................................................. 119
Checking oil level ........................................................................................... 119
Changing filter and oil .................................................................................... 120
Lubricating the chassis ........................................................................................ 121
Propeller shafts ............................................................................................... 121
Central lubrication of chassis.......................................................................... 121
Towing ................................................................................................................. 122
Safety .............................................................................................................. 122
Before towing ................................................................................................. 122
Release the brakes........................................................................................... 123
Removing propeller shafts .............................................................................. 123
Disconnecting the steering cylinder................................................................ 124
After towing.................................................................................................... 124
Steps to take ............................................................................................... 124

7. Brake system ........................................................................................................ 125

Safety ................................................................................................................... 125
General................................................................................................................. 125
Technical data ...................................................................................................... 126
Brake system................................................................................................... 126
Checking brake pressure...................................................................................... 126
Service brake pressure .................................................................................... 126
Parking brake pressure.................................................................................... 127
Bleeding the brakes ............................................................................................. 128
Checking brake discs ........................................................................................... 128
Adjusting the brakes ............................................................................................ 129
Function check, parking brake............................................................................. 130
Function check, service brakes............................................................................ 130
Checking accumulator charge pressure ............................................................... 131
Checking brake pressure control valve................................................................ 132

12
 Checking the accumulators.................................................................................. 133
Scrapping an accumulator ................................................................................... 134

8. Control system ..................................................................................................... 136

RCS...................................................................................................................... 136
Logging in ........................................................................................................... 137
Menu overview.................................................................................................... 138
Menu structure ................................................................................................ 138
Menus, basic system and options.................................................................... 139
Settings ................................................................................................................ 140
General............................................................................................................ 140
Numerical values ............................................................................................ 141
On / Off........................................................................................................... 142
Administration..................................................................................................... 143
Administration menu ...................................................................................... 143
Save and retrieve parameters .......................................................................... 143
Allocation time ............................................................................................... 144
Date and time .................................................................................................. 144
Sensors................................................................................................................. 145
Sensors menu (Drilling).................................................................................. 145
Lubrication oil menu....................................................................................... 145
Sensors menu (Rig)......................................................................................... 146
Calibration of pressure sensor ........................................................................ 146
Calibrating flow sensor B250 ......................................................................... 147
Calibrating flow sensor B252 ......................................................................... 147
Actuations............................................................................................................ 148
Actuation menus ............................................................................................. 148
Actuations menu (Boom)................................................................................ 148
Actuations menu (Drilling)............................................................................. 149
Actuations menu (Rig).................................................................................... 149
Actuations menu (Service platform)............................................................... 150
Actuation of desired value .............................................................................. 150
Parameters ........................................................................................................... 151
Lubricating oil ................................................................................................ 151
Lubrication oil menu.................................................................................. 151
Min air pressure ......................................................................................... 151
Min oil pressure ......................................................................................... 151
Max oil pressure......................................................................................... 151
Time before measurement.......................................................................... 151
Time before alarm / Time before drill stop ................................................ 152
Boom............................................................................................................... 152
Parameters menu (Boom)........................................................................... 152
Rigs with hydraulic parallel holding.......................................................... 152
Rigs with electronic parallel holding ......................................................... 153
Feed, flow ....................................................................................................... 154
Feed, flow menu......................................................................................... 154
Feed speed, manual collaring..................................................................... 154
Feed speed, automatic collaring................................................................. 154
Feed speed collaring locked....................................................................... 154
Feed speed, drilling .................................................................................... 154
Lowest feed speed...................................................................................... 155

13
 Highest feed speed ..................................................................................... 155
Feed speed, return ...................................................................................... 155
Feed pressure .................................................................................................. 155
Feed, pressure menu................................................................................... 155
Feed pressure, collaring ............................................................................. 155
Feed pressure, drilling................................................................................ 156
Pressure for rock contact sensor................................................................. 156
Highest feed pressure ................................................................................. 156
Feed pressure, return .................................................................................. 156
Valve current for collaring feed pressure ................................................... 157
Min valve current ....................................................................................... 157
Max valve current ...................................................................................... 157
Percussion ....................................................................................................... 157
Percussion menu......................................................................................... 157
Percussion pressure, collaring.................................................................... 158
Percussion pressure, drilling ...................................................................... 158
Limit, percussion pressure (FPCI) ............................................................. 158
Percussion pressure button......................................................................... 158
Rotation........................................................................................................... 159
Rotation menu ............................................................................................ 159
Rotation speed LEFT ................................................................................. 159
Rotation speed RIGHT............................................................................... 160
Rotation pressure, drilling (RPCF) and Activation pressure, anti-jamming160
Max rotation pressure, anti-jamming ......................................................... 161
Resume pressure, after anti-jamming......................................................... 161
Times............................................................................................................... 162
Times menu ................................................................................................ 162
Collaring time............................................................................................. 162
Percussion time, bit cleaning...................................................................... 162
Other ............................................................................................................... 163
Other menu................................................................................................. 163
Pressure gauge filter constant..................................................................... 163
Lowest water pressure................................................................................ 163
Frequency, lubrication................................................................................ 163
Auto return ................................................................................................. 163
Flush distance from hole bottom................................................................ 164
Extended collaring time ............................................................................. 164
Increase of damper press. for rock contact................................................. 164
Telescope feeder.............................................................................................. 164
BMHT Menu.............................................................................................. 164
Feed pressure.............................................................................................. 165
Counter pressure, COP 1432 .......................................................................... 165
Counter pressure menu (drilling machine COP 1432)............................... 165
Regulation of counterpressure.................................................................... 165
Counter pressure......................................................................................... 165
Min valve current counter pressure............................................................ 166
Rig................................................................................................................... 166
Parameters menu (Rig)............................................................................... 166
Min air pressure load.................................................................................. 166
Max air pressure load ................................................................................. 166
Oil temperature, cooler............................................................................... 167

14
 Oil temperature, alarm ............................................................................... 167
Oil temperature, pump stop........................................................................ 167
Service platform.............................................................................................. 167
Parameters menu (Service platform).......................................................... 167
Cylinder speed............................................................................................ 167
Fault finding ........................................................................................................ 168
Modules .......................................................................................................... 168
Modules menu............................................................................................ 168
Module status ............................................................................................. 168
Levers ............................................................................................................. 169
Lever menu (Fault finding) ........................................................................ 169
Lever function ............................................................................................ 169
Lever calibration menu (Fault finding)...................................................... 170
Lever menu (Service platform) .................................................................. 170
Calibration.................................................................................................. 170
Calibration test ........................................................................................... 171
XY dead zone............................................................................................. 171
Z dead zone ................................................................................................ 171
Guards............................................................................................................. 172
Guards menu .............................................................................................. 172
Other guards menu ..................................................................................... 172
Guards' status ............................................................................................. 173
Configuration .................................................................................................. 173
Configuration menu ................................................................................... 173
Software information ................................................................................. 173
Event log ......................................................................................................... 174
Event log menu .......................................................................................... 174
Save event log ............................................................................................ 174
Loading new software ......................................................................................... 174

9. Hydraulic systems ................................................................................................ 177

Safety................................................................................................................... 177
Technical data ...................................................................................................... 177
Hydraulic systems M2 C and L2 C................................................................. 177
Filter .................................................................................................................... 178
Return oil filter ............................................................................................... 178
General ....................................................................................................... 178
Changing the return oil filter...................................................................... 179
Breather filter.................................................................................................. 180
General ....................................................................................................... 180
Changing the breather filter ....................................................................... 181
Oil sampling ........................................................................................................ 181
Changing oil ........................................................................................................ 182
Draining .......................................................................................................... 182
General............................................................................................................ 182
Filling up......................................................................................................... 183
General ....................................................................................................... 183
Filling manually ......................................................................................... 183
Electric filling, option ................................................................................ 184
Draining condensation from the hydraulic oil tank............................................. 184
Pumps .................................................................................................................. 186

15
 Power unit pumps ........................................................................................... 186
Checking pump rotation direction .................................................................. 186
Starting a new or reconditioned pump ............................................................ 187
Bleeding the pumps ........................................................................................ 187
Hydraulic motors ................................................................................................. 188
Starting a new or reconditioned hydraulic motor ........................................... 188
Settings ................................................................................................................ 189
Safety .............................................................................................................. 189
General............................................................................................................ 189
Percussion pump ............................................................................................. 190
Stand-by pressure ....................................................................................... 190
Max. pressure ............................................................................................. 191
Positioning pump ............................................................................................ 192
Stand-by pressure ....................................................................................... 192
Max. pressure ............................................................................................. 193
Rotation pump................................................................................................. 194
Max. pressure ............................................................................................. 194
Drilling machine damper pressure....................................................................... 196
Setting rotation pump flow .................................................................................. 196
Pressure reducing function for positioning pump................................................ 197
Positioning pressure with diesel power ............................................................... 198
Maximum pressure and speed of reeling units .................................................... 199
Setting water pump speed.................................................................................... 199
Speed control for air flow.................................................................................... 201
1-boom and 2-boom rigs................................................................................. 201
Standard rig ................................................................................................ 201
Rig equipped with air flushing, option....................................................... 202
3-boom rigs ..................................................................................................... 204
Sensors................................................................................................................. 206
Setting pressure monitor B121 ....................................................................... 206
Checking pressure sensors B100, B101, B132, B133 .................................... 206

10. Air system .......................................................................................................... 208

Safety ................................................................................................................... 208
Compressor instructions ...................................................................................... 208
Compressor GAR 5......................................................................................... 208
Checking oil level ........................................................................................... 209
Oil and oil filter............................................................................................... 210
Safety.......................................................................................................... 210
Changing oil and oil filter .......................................................................... 210
Air reservoir .................................................................................................... 211
Safety.......................................................................................................... 211
Changing the separator element ................................................................. 211
Changing air filter ........................................................................................... 212
Adjusting drive belts ....................................................................................... 212
Safety valve..................................................................................................... 213
Pressure switch B188...................................................................................... 213
Freeze prevention measures................................................................................. 214
Draining the air tank ....................................................................................... 214
Fault finding ........................................................................................................ 214
Fault finding, compressor ............................................................................... 214

16
 Compressor will not start................................................................................ 215
Compressor starts but does not load ............................................................... 215
Compressor will not unload, safety valve blowing ........................................ 215
Compressor air delivery or pressure lower than normal................................. 216
Abnormal oil consumption or oil in outlet line .............................................. 216
Safety valve blowing after loading ................................................................. 216
Air outlet temperature higher than normal ..................................................... 216

11. Water system ...................................................................................................... 217

Technical data ...................................................................................................... 217
Hose dimensions ............................................................................................. 217
Safety................................................................................................................... 217
Water pump.......................................................................................................... 217
General............................................................................................................ 217
Direction of rotation ....................................................................................... 218
Setting flow switches. ..................................................................................... 218
Pressure sensor B136 ...................................................................................... 219
Cleaning the water strainer.................................................................................. 220
Freeze prevention measures ................................................................................ 220
Draining the water system .............................................................................. 220

12. Electrical system, IEC and Australia ................................................................. 222

Safety................................................................................................................... 222
General ................................................................................................................ 222
Safety standard................................................................................................ 222
Low-voltage circuit......................................................................................... 222
Extra low-voltage circuit ................................................................................ 223
Before starting ................................................................................................ 223
Cable marking................................................................................................. 223
Replacement of components........................................................................... 223
Electric cubicle, high-current .............................................................................. 223
Indicator lamps ............................................................................................... 223
IEC standard ................................................................................................... 224
Inside.......................................................................................................... 224
Australian standard ......................................................................................... 225
Inside.......................................................................................................... 225
Voltmeter and ammeter................................................................................... 225
Electrical system protection ................................................................................ 226
Main switch .................................................................................................... 226
General ....................................................................................................... 226
Main circuit breaker dip switches .............................................................. 227
Overload protection.................................................................................... 227
Short circuit protection............................................................................... 228
Phase sequence switch .................................................................................... 228
Earth fault equipment ..................................................................................... 228
IEC standard............................................................................................... 228
Australian standard .................................................................................... 229
Motor protection ............................................................................................. 230
Electronic motor protection relay .............................................................. 230
If the motor protection has been triggered ................................................. 230
Setting rated current ................................................................................... 231

17
 Setting triggering time................................................................................ 233
Power supply cubicle........................................................................................... 233
General............................................................................................................ 233
Setting charge voltage..................................................................................... 234
Cable recommendations ...................................................................................... 235
Fault finding ........................................................................................................ 236

13. Electrical system, North America ...................................................................... 237

Safety ................................................................................................................... 237
General................................................................................................................. 237
Safety standard................................................................................................ 237
Low-voltage circuit......................................................................................... 237
Extra low-voltage circuit ................................................................................ 238
Before starting................................................................................................. 238
Cable marking................................................................................................. 238
Replacement of components ........................................................................... 238
Electric cubicle, high-current .............................................................................. 239
Front................................................................................................................ 239
Inside............................................................................................................... 240
Electrical system protection................................................................................. 240
Main switch..................................................................................................... 240
General ....................................................................................................... 240
Main switch short-circuit protection .......................................................... 240
Main switch short-circuit protection .............................................................-2
Phase sequence switch .................................................................................... 241
Earth fault breaker .......................................................................................... 241
Motor protection ............................................................................................. 241
Electronic overload protection ................................................................... 241
Circuit breaker............................................................................................ 242
Power supply cubicle........................................................................................... 243
General............................................................................................................ 243
Setting charge voltage..................................................................................... 244
Fault finding ........................................................................................................ 244

14. Reeling units, option .......................................................................................... 245

Cable reeling unit................................................................................................. 245
Hose reeling unit.................................................................................................. 245
General................................................................................................................. 245
Reeling unit gear.................................................................................................. 246
Adjusting reeling unit drive chain ....................................................................... 246
Adjusting the reeling unit slip clutch................................................................... 247
Collector, cable reeling unit................................................................................. 248
Collector F460/1 and K4122/1 ....................................................................... 248
Checking the collector .................................................................................... 248
Settings ................................................................................................................ 249
Limit switch, option............................................................................................. 249
Description...................................................................................................... 249
Adjusting......................................................................................................... 249

15. Exhaust filtering, option ..................................................................................... 252

Safety ................................................................................................................... 252

18
 Scrubber............................................................................................................... 252
General............................................................................................................ 252
Filling up with water....................................................................................... 253
Freeze prevention measures............................................................................ 254
Draining ..................................................................................................... 254
Particle filter ........................................................................................................ 255
General............................................................................................................ 255
Technical data ................................................................................................. 256
Flashing the filter ............................................................................................ 256
Safety ......................................................................................................... 256
Introduction................................................................................................ 256
Flashing the filter, model K ....................................................................... 256
Flashing filter, model S .............................................................................. 257
Extra filter cleaning ........................................................................................ 258
Checking the indicator lamp ........................................................................... 259
Catalytic converter............................................................................................... 259
General............................................................................................................ 259
Changing the catalytic converter .................................................................... 259

16. Fire fighting equipment, option.......................................................................... 260

Fire fighting systems ........................................................................................... 260
Description...................................................................................................... 260
Ansul............................................................................................................... 260
Forrex.............................................................................................................. 260
Locations ............................................................................................................. 261
Manual triggering ................................................................................................ 261
Maintenance of fire fighting system.................................................................... 262
Safety measures .............................................................................................. 262
Modification of the machine........................................................................... 262
Service ............................................................................................................ 263
Steps to take after a fire or activation of the fire-fighting system .................. 263

17. Service platform ................................................................................................. 264

HL 210-300 MB, HL 210-300 MBC................................................................... 264
Technical data ...................................................................................................... 264
HL 210 MB/MBC........................................................................................... 264
HL 230 MB/MBC........................................................................................... 265
HL 300 MB/MBC........................................................................................... 265
Safety................................................................................................................... 266
Slinging................................................................................................................ 266
Distance to centre of gravity when slinging ................................................... 266
Supporting the service platform .......................................................................... 267
Tools .................................................................................................................... 267
Adjusting play in telescope tube guide................................................................ 268
Bleeding the hydraulic system............................................................................. 268
Rear boom link .................................................................................................... 269
Checking clearances ....................................................................................... 269
Lubricating before start ....................................................................................... 269
Function check..................................................................................................... 269
Long-term storage ............................................................................................... 270
Transport.............................................................................................................. 270

19
 18. Swellex pump ..................................................................................................... 272
HSP A51 Mk IB, option ...................................................................................... 272
Swellex arm ......................................................................................................... 273
Safety ................................................................................................................... 274
Technical data ...................................................................................................... 274
HSP A51 Mk IB.............................................................................................. 274
Connecting the Swellex pump............................................................................. 276
Component parts.................................................................................................. 277
Pressure switch ............................................................................................... 277
General ....................................................................................................... 277
Basic setting ............................................................................................... 277
Check pressure switch settings................................................................... 278
Change pressure switch settings................................................................. 279
Error messages ........................................................................................... 279
Pressure control valve ..................................................................................... 280
General ....................................................................................................... 280
Setting the pressure control valve .............................................................. 280
Pressure reducing valve .................................................................................. 281
Adjusting the pressure reducing valve ....................................................... 281
Water filter ...................................................................................................... 283
General ....................................................................................................... 283
Changing water filter and bleeding the system .......................................... 283
Swellex arm .................................................................................................... 284
Changing chuck seals................................................................................. 284
Water pump..................................................................................................... 284
Checking the seals...................................................................................... 284
Checking the valves ................................................................................... 285
Repairing the water pump .......................................................................... 287
Swelling bolts to other pressures ......................................................................... 288
Change of pressure.......................................................................................... 288
Checking a change of pressure ....................................................................... 288
Changing oil ........................................................................................................ 289
Recommended oils.......................................................................................... 289
Changing oil.................................................................................................... 289
Test running ......................................................................................................... 290
Long-term storage................................................................................................ 296
Freeze prevention measures................................................................................. 296
Draining the Swellex pump ............................................................................ 296
Extra freeze prevention measures ................................................................... 298
Electrical system.................................................................................................. 298
Fault finding ........................................................................................................ 299
General............................................................................................................ 299
Fault finding help............................................................................................ 300

19. Rod handling equipment, option ........................................................................ 301

RAS ..................................................................................................................... 301
Settings ................................................................................................................ 302
Sensors ............................................................................................................ 302
Position sensors menu ................................................................................ 302
Other sensors menu .................................................................................... 303
Adjusting the RAS arm position sensors ................................................... 303

20
 Adjusting the gripper claw sensors ............................................................ 304
Actuations ....................................................................................................... 304
Actuations menu ........................................................................................ 304
Parameters....................................................................................................... 305
Parameters menu ........................................................................................ 305
Time before thread cutting ......................................................................... 305
In-feed pressure.......................................................................................... 305
In-feed speed .............................................................................................. 306
In-rotation speed ........................................................................................ 306
Out-feed pressure ....................................................................................... 306
Out-feed speed ........................................................................................... 306
Out-rotation speed...................................................................................... 306
Percussion time .......................................................................................... 306
Slow feed speed ......................................................................................... 307
Auto-RAS menu......................................................................................... 307
Time for open/close drill support............................................................... 307
Time for open/close gripper claws............................................................. 307
Max times................................................................................................... 307
Pressure for detection of tightened thread.................................................. 308
No. of unthreading retries.... ...................................................................... 308
Percussion pressure and time for unthreading ........................................... 308
Cradle positions .............................................................................................. 308
Introduction................................................................................................ 308
Cradle positions menu................................................................................ 310
Setting the cradle position.......................................................................... 310
Setting the pressure regulators........................................................................ 311
Valve block................................................................................................. 311
Operator panel............................................................................................ 311
Pressure regulator for drill steel support BSH 110 .................................... 312
Pressure regulator for RAS arms ............................................................... 312
Pressure regulator for gripper claws .......................................................... 312
Mechanical adjustments.................................................................................. 312
Drill centre for RAS arms .......................................................................... 312
Parked position for RAS arms ................................................................... 313
After adjustment......................................................................................... 313

20. Directional control, option ................................................................................. 314

ABC R (Advanced Boom Control Regular)........................................................ 314
Sensor calibration ................................................................................................ 315
Introduction..................................................................................................... 315
Conditions....................................................................................................... 315
Inclination sensor............................................................................................ 317
Console lift, type "Wide Eagle"...................................................................... 318
Console lift, type "Standard Eagle" ................................................................ 318
Boom telescope............................................................................................... 320
Feed telescope................................................................................................. 321
Drilling machine position ............................................................................... 321
Feed rotation ................................................................................................... 324
Feed lookout ................................................................................................... 325
Boom extender................................................................................................ 326
Feed holder ..................................................................................................... 327

21
 Setting coefficient for swing and lift angles. .................................................. 328
Setting rig laser ............................................................................................... 329
Calibrating Boom swing, boom lift, feed swing and feed lift......................... 330
Replacement of components................................................................................ 331
Replacement of angle sensors......................................................................... 331
Replacement of length sensor ......................................................................... 333
Boom telescope/Feed extension................................................................. 333
Feeder......................................................................................................... 335
Fault finding ........................................................................................................ 336
Angle sensors .................................................................................................. 336
Inclination sensor ............................................................................................ 336
Length sensor .................................................................................................. 337
Length sensor, drilling machine...................................................................... 338

21. Automatic, option............................................................................................... 340

Settings ................................................................................................................ 340
Service menus ................................................................................................. 340
Anchoring ....................................................................................................... 340
Positioning ...................................................................................................... 341
Sensors ............................................................................................................ 342
Actuations ....................................................................................................... 343
Calibrating boom speed ....................................................................................... 343
Parameters....................................................................................................... 343
Lowest valve current .................................................................................. 344
Highest valve current ................................................................................. 344
Checking boom movement ........................................................................ 345

22. Air conditioning, option ..................................................................................... 346

Safety ................................................................................................................... 346
Technical data ...................................................................................................... 346
Adjusting compressor V-belts.............................................................................. 347
Fresh air filter and recirculation filter.................................................................. 347
Electric heater ...................................................................................................... 348
Fault finding ........................................................................................................ 349
No heating....................................................................................................... 349
No cooling....................................................................................................... 349
Poor cooling.................................................................................................... 349
Uneven cooling ............................................................................................... 349
Abnormal noise............................................................................................... 350

23. Service equipment, option.................................................................................. 351

Service tool bag RCS........................................................................................... 351
Overview of RCS system .................................................................................... 352
Checking the power supply and the CAN network ............................................. 352
Measuring voltage/power ............................................................................... 354
CAN cable test ................................................................................................ 354
Lever panel .......................................................................................................... 355
Connections .................................................................................................... 355
Decoder ........................................................................................................... 356
Lever casing, service platform........................................................................ 357
Replacement of decoder or lever .................................................................... 357

22
Display, application and master modules ............................................................ 358
Connections .................................................................................................... 358
I/O module........................................................................................................... 359
Connections .................................................................................................... 359
Check digital inputs X11, X15, X24............................................................... 359
Interrupted signal (open circuit)................................................................. 360
Short circuit or open circuit in the power supply....................................... 361
Checking digital outputs X2, X20, X22 ......................................................... 361
Output with open circuit ............................................................................ 362
Output with open circuit in valve coil........................................................ 363
Output with short circuit of (+) to the chassis or (-) in the cable............... 364
Checking analogue inputs X6, X8, X10, X14, X16, X17. ............................. 364
Input with short or open signal circuit ....................................................... 365
Input with short circuit in the power supply .............................................. 366
Checking PWM outputs X1, X3, X4, X5, X19, X21, X23. ........................... 366
Output with short circuit of (-) or (+) to the chassis. ................................. 367
Measuring voltage/power...................................................................... 367
Measuring current ................................................................................. 368
Output with short circuit between (+) and (-) in the cable......................... 369
Measuring voltage/power...................................................................... 369
Measuring current ................................................................................. 370
Output with open circuit ............................................................................ 371
Measuring voltage/power...................................................................... 371
Measuring current ................................................................................. 372
Resolver module.................................................................................................. 373
Connections .................................................................................................... 373
Checking resolver inputs X6 - X9 .................................................................. 373
Checking the encoder input (Pulse sensor input) X10.................................... 374
Checking analogue input channels X11 and X12 ........................................... 375
Replacing the module .......................................................................................... 376

23
24
1. General

Environment

25
26
Contact details
Table 1.1. Addresses, telephone numbers and fax numbers to Atlas
Copco companies
Country Address Phone and fax number
Argentina P O Box 192 Suc. 37 Phone: +54 - (0)11 - 47 17 22 00
1437 - Buenos Aires Fax: +54 - (0)11 - 47 17 02 27
Australia P O Box 6134 Phone: +61 - (0)2 - 96 21 97 00
Delivery Centre Fax: +61 - (0)2 - 96 21 98 13
Blacktown NSW 2148
Austria Postfach 108 Phone: + 43- (0)1 -76 01 20
A-1111 Vienna Fax: + 43 - (0)1 - 769 56 72
Bolivia Casilla 8742 Phone: + 591 - (0)2-22 98 62
La Paz Fax: + 591 - (0)2-22 10 36
Brazil P O Box 12737 Phone: + 55 - (0)11 - 247 88 00
Sao Paulo, SP Fax: + 55 - (0)11 - 541 76 71
04744-970
Canada P.O. Box 745 Phone: + 1 - 514 631 55 71
Pointe-Claire Dorval Fax: + 1 - 514 631 92 17
Quebec, H9R 4S8
Chile Casilla 10239 Phone: + 56 - (0)2-442 3600
Santiago Fax: +56 - (0)2 - 623 5131
China / Hong 41-1 Huang Jia Wei Phone: + 86 - (0)25 - 562 01 18
Kong Zhong yang Men Wai Fax: + 86 - (0)25 - 551 52 25
210037 Nanjing
CMT International S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00
Fax: + 46 - (0)8 - 702 21 29
Colombia A.A. 95310 Phone: +57 - (0)1 - 291 54 90
Santafé de Bogotá, D.C. Fax: +57 - (0)1 - 430 65 14
Czech Republic Belohorska 159/187 Phone: + 420 - (0)2 -205 14 604
169 00 PRAHA 6 Fax: + 420 - (0)2- 205 14 614
Brenov
Finland Tuupakankuja 1 Phone: + 358 - (0)9 - 296 64 41
SF-01740 Vantaa Fax: + 358 - (0)9 - 29 64 21 8
France B.P. 50 Phone: + 33 - (0)1 - 30 72 32 22
F-95132 Franconville Fax: + 33 - (0)1 - 30 72 32 49
Germany Postfach 10 02 25 Phone: + 49 - (0)201 - 217 70
D-46002 Essen Fax: + 49 - (0)201 - 217 74 54
Ghana P O B 10071 Phone: + 233 - 21 77 45 12
Accra North Fax: + 233 - 21 77 61 47
Great Britain P O Box 79 Phone: + 44 - (0)1442 - 26 12 02
Hemel Hempstead Fax: + 44 - (0)1442 - 24 05 96
Herts HP2 7HA
Greece 78, Kifissou Avenue Phone: +30 - (0)1 - 342 6600
GR-182 33 Ag. I. Rentis Fax: +30 - (0)1 - 345 4783

27
Country Address Phone and fax number
Hong Kong Unit 2103 Citimark Phone: + 852 - 24 88 01 03 (Service)
28 Yuen Shun Circuit Fax: + 852 - 2488 9863, 21 72 42 48
Siu Lek Yuen
Shatin, New Territories
Hong Kong
India Sveanagar Phone: + 91- (0)20 -712 64 16
Bombay Pune Road Fax: + 91 - (0)20 - 712 65 87
Dapodi
Pune 411 012
Indonesia P O Box 7021/JKS CCE Phone: +62 - (0)21 - 780 10 08
Jakarta 12075 Fax: +62 - (0)21 - 780 18 37
Iran PO Box 13145-1311 Phone: +98 - (0)21 - 93 7710-19
Tehran 13454 Fax: +98 - (0)21 - 92 73 14
Ireland Kylemore Road Phone: +353 - (0)1 - 450 5978
Bluebell Fax: +353 - (0)1 - 456 7686
Dublin 12
Italy Casella Postale 10076 Phone: + 39 - (0)2 - 61 79 91
I-20110 Milano MI Fax: + 39 - (0)2 - 66 01 32 99
Japan New Nishi-shimbashi Bldg. 3F Phone: + 81 - (0)436 - 24 62 31
2-11-6 Nishi-shimbashi Fax: + 81 - (0)436 - 24 62 55
Minato-ku Tokyo 105-0003
Kenya PO Box 400 90 Phone: + 254 - (0)2 - 82 52 65/6
Nairobi Fax: + 254 - (0)2 - 82 52 15
Korea C-P.O. Box 8354 Phone: + 82 - (0)2 - 52 28 23 4-8
Seoul Fax: + 82 - (0)2 - 522 82 39
Malaysia Lot 6-36 & 2-38 Phone: + 60 - (0)3 - 511 33 33
Pesiaran Tengku Ampuan Fax: + 60 -(0)3 - 511 99 08
Lion Industrial Park
40400 Shah Alam
Selangor Darul Ehsan
Mexico Apartado Postal Box 104 Phone: + 52 - 5 - 626 06 00
Tlalnepantla Fax: + 52 - 5 - 565 62 65, 626 06 80
Edo. De Mexico
Morocco P O Box 13 844 Phone: + 212 - 2 - 600 040
20 300 Casablanca Fax: + 212 - 2 - 60 05 22
Norway P O Box 334 Phone: + 47 - 64 - 86 03 00
N-1401 Ski Fax: + 47 - 64 - 86 03 22
Peru Apartado 662 Phone: + 51 - 1 - 224 87 05 (Service)
Lima 100 Fax: + 51 - 1 - 224 77 12 (Service)
Philippines P.O. Box 1373 Phone: + 63 - (0)2 - 823 8178-80
1200 Makati City Fax: + 63 - (0)2 - 823 9139
Poland 29 Krasinskiego Str. Phone: + 48 -(0)32 - 256 1661
P-40-019 Katowice Fax: + 48 -(0)32 - 256 1661
Portugal Apartado 14 Phone: + 351 - (0)1- 416 85 00
P-2796 Linda-a-Velha Fax: + 351 - (0)1 - 418 0782 (Service)
Codex

28
Country Address Phone and fax number
Saudi Arabia P O Box 7330 Phone: + 966 - (0)2 - 663 42 22
Jeddah 21462 Fax: + 966 - (0)2 - 660 37 23
Singapore Jurong Point Phone: + 65 - (8)62 - 28 11
P O Box 438 Fax: + 65 - (8)62 - 56 28 (Service)
Singapore 916415
South Africa P O Box 14110 Phone: + 27 - (0)11 - 821 90 00
Witfield 1467 Fax: + 27 - (0)11 - 821 92 02
Spain Apartado 24 Phone: + 34 - (9)1 - 627 91 00
E-28820 Coslada Fax: + 34 - (9)1 - 627 9239
Madrid
Sweden S-10523 Stockholm Phone: + 46 - (0)8 - 743 92 30
Fax: + 46 - (0)8 - 743 92 47
Switzerland Büetigenstrasse 80 Phone: + 41 - (0)32 - 374 15 00
CH-2557 Studen/Biel Fax: + 41 -(0)32 - 374 15 15
Taiwan No. 16-11, Wu Lin Phone: + 886 - (0)3 - 4 79 31 64
Wu Lin Village Fax: + 886 - (0)3 - 479 6820
Lung Tan
Tao Yuan Hsien 325
Thailand 1696 New Petchburi Road Phone: + 66 - (0)2 - 652 90 06
Bangkapi Fax: + 66 - (0)2 - 652 81 94
Huay Kwang
Bangkok 10320
Turkey Istasyon Arkasi Phone: + 90 - (0)216 - 395 24 60
81700 Tuzla Fax: + 90 - (0)216 - 395 23 01
Istanbul
Venezuela Apartado 76111 Phone: + 58 - (0)2 - 256 23 11
Caracas 1070-A Fax: + 58 -(0)2 - 271 13 93
Vietnam 24, Ly Tu Trong Street Phone: + 84 - 8 - 822 2914
District 1 Fax: + 84 - 8 - 822 2884
Ho Chi Minh City
Zambia P O Box 70267 Phone: + 260 - (0)2 - 65 14 47/ 51
Ndola Fax: + + 260 - (0)2 - 65 11 57
Zimbabwe P.O. Box CY 935 Phone: + 263 - (0)4 - 62 17 61 5
Fax: + 263 - (0)4 - 62 17 94

Target group and objective

The maintenance instructions are intended for mechanics and per-
sonnel in maintenance and service. The user should have under-
gone Atlas Copco's training courses for the equipment concerned.

The objective of these maintenance instructions is to detect and

rectify faults at an early stage so that breakdowns, costly second-
ary damage and accidents can be prevented. Regular maintenance
is a precondition for planning necessary interruptions in operation

29
 such as reconditioning and repairs. This allows maintenance to be
carried out when most suitable with regard to production instead of
causing complete breakdown.

Hydraulic systems

General
Hydraulic systems are sensitive to impurities and pollutants. The
environment in which rock drilling equipment usually works is
generally unsuitable as a place for repairing hydraulic components.
Work on the hydraulic system at the worksite should therefore be
limited to what is absolutely essential, i.e. only the replacement of
components. When changing valves, the unit concerned should be
securely strapped in place and firmly supported. The components
should then be repaired in a suitable environment, see Hydraulic
workshops .

Observe the following points to avoid breakdowns and interrup-

tions in operation due to fouled hydraulic oil:

• Keep the rig clean. Hose it down at regular intervals, preferably

with a grease solvent as an additive
• Before opening any connection, clean the area round it.
• Use clean tools and work with clean hands.
• Always plug hydraulic connections immediately after they have
been detached.
• Use clean protective plugs.
• Hydraulic components like hoses, valves, motors, etc. must
always be stored with suitable protective plugs fitted in place.
• Spare parts for hydraulic components must always be kept in
sealed plastic bags.
• Change filter cartridges as soon as the filters indicate clogging.

Repairing hydraulic components

Repairing and/or reconditioning hydraulic components should be
carried out by expert personnel and in a suitable place. The follow-
ing alternatives are possible:

• Suitable premises for hydraulic repairs to be arranged at the

workplace. Repairs to be carried out by your own specially
trained personnel, the manufacturer's technicians or Atlas
Copco personnel.
• Components to be sent to the manufacturer's local agent for
repair.

30
 • Component repairs are carried out by Atlas Copco. Repair
instructions are available for the most important and most com-
plicated hydraulic components.

Hydraulic workshops
Workshops used for the repair of hydraulic components must:

• be separate from activities which generate dust and particles,

such as welding, grinding, the transportation of vehicles, etc.;
• have their own suitable washing equipment which is required
for repairing the components;
• have the necessary tools, both standard and special, and that are
only used in the hydraulic workshop.
• have a ventilation system that does not admit dust into the
premises.
• have well-trained mechanics.

Replacement of hydraulic hoses

A high percussion pressure, vibrations and other mechanical inter-
ference puts high demands on the hydraulic hoses.

When replacing hydraulic hoses, make sure they are replaced with
hydraulic hoses:

• with correct crimped couplings

• of the correct quality
• with the right dimension
All pressurised hydraulic hoses have crimped couplings and
should therefore be purchased ready made from Atlas Copco.
Qualities and hose dimensions are specified in the spare parts cata-
logue for each rig. Make also sure that hose couplings are clean, in
good condition and properly tightened.

Welding

Note
It is important to consult Atlas Copco for approval of welding and
choice of electrodes.
The following must be observed when welding:

• Turn off the supply of current to the unit.

• Disconnect the cables from the generator and battery.

31
 • Grind off rust and paint from the area that is to be welded and
carefully prepare the joint.
• Weld in a dry area.
• Connect the welding earth cable to a clean surface as close as
possible to the welding area. Avoid welding close to bearings
and bushes. If these cannot be removed, connect earth cables on
both sides of the weld.
• Alterations and reinforcements must not be made without previ-
ous consultation with Atlas Copco.
• Do NOT do any welding on the hydraulic oil reservoir, valve
block, compressed air receiver or compressed air lines.
• Always keep a fire extinguisher for oil fires near at hand during
all types of welding, cutting and grinding. Screen off the work
area from flammable materials.
• Always protect hoses, cables and electric components.
• Grind off spatter after welding. If possible, also grind the sur-
face of the weld smooth and treat it with anti-corrosion paint.

Electrode recommendations
Use only intact and clean electrodes that have been stored in a dry
place. The generally recommended type of electrode is ESAB OK
48.00, ESAB OK 48.30 or the equivalent in accordance with the
standard below:

Table 1.2. Electrode recommendations

ISO: 2560 E51 5B 120 20 H
SS: 14 3211 H10
DIN 1913: E51 55 B10
AWS: A/SFA 5.1 E 7018

The use of MIG welding equipment is perfectly acceptable. The

generally recommended type of electrode is ESAB-OK Autorod
12.51 or the equivalent in accordance with the standard below:

Table 1.3. MIG electrodes

SS: 14 3403 3423
DIN 8559: SG 2
AWS: A/SFA 5.18: ER 70 S-6

If in any doubt, contact Atlas Copco for advice.

32
Tightening torque in bolted joints.
All joints are tightened to torque as specified in Atlas Copco
Standard 4369 K unless specified otherwise. If so, this will be
specified in the maintenance instructions for the component in
question.

Table 1.4. Atlas Copco Standard 4369 K.

Size Strength Torque in Toler-
class Nm. ance ±
M6 8.8 9 1
M8 8.8 23 2
M10 8.8 46 5
M12 8.8 80 10
M14 8.8 125 15
M16 8.8 205 20
M20 8.8 395 40
M24 8.8 675 70
M12 x 1.25 10.9 135 6
M16 x 1.25 10.9 315 15
M18 x 1.25 10.9 460 20
M6 12.9 15 2
M8 12.9 39 4
M10 12.9 78 8
M12 12.9 135 15
M14 12.9 210 25
M16 12.9 345 35
M20 12.9 670 70
M24 12.9 1150 120

Markings and plates

Signs are placed on the larger carrier components. Always quote
the type designation and serial number when ordering spares or
enquiring about the carrier. The type designation and serial number
are specified on a separate document, DRI (Drill Rig Identifica-
tion). Spares can always be ordered from Atlas Copco.

33
Dismantling and assembly

CAUTION
Take great care when strapping and lifting
heavy objects.

Can cause personal injuries .

The lifting must be carried out over the centre

of gravity.
Only use straps that are intact and intended
for the load they must bear.
Fasten the straps in the correct loops, where
there are loops
1250 0042 38

Before transport in shafts or the like it may be necessary to remove

the drilling rig in larger or smaller parts. Observe the following
when dismantling, lifting and refitting:

• Before dismantling, hose the entire rig clean with water and/or
detergent containing a grease solvent.
• Observe the strictest cleanliness when dismantling hydraulic,
compressed air and water flushing hoses. Immediately plug all
hoses, nipples and hydraulic oil pipes, or seal and protect them
from dirt in some other suitable way.
• Mark hoses, pipes and other connections, where this has not
already been done, to make reassembly easier and prevent mix-
ups.
• Use properly secured lifting tackle of generous dimensions.

Note
When a rig is scrapped, all materials that are harmful to the envi-
ronment must be disposed of in a manner prescribed by the author-
ities.

Fault finding
Fault finding is a logical sequence of activities to locate a fault,
thereby making it possible to rectify the fault as soon as possible.

Always try to investigate the location of the fault in order to limit

fault finding to a certain system or function.

34
Starting with an auxiliary battery

Note
Owing to the surge of current, the batteries could explode if a
fully-charged battery is connected to a completely flat one.
The connections to the carrier's batteries must on no account be
removed while in operation as this could give rise to faults occur-
ring in the generator.
For this reason, proceed as follows:

1. Turn off the RCS system with button (0) on panel A76.

Figure 1.1. Panel A76

2. Check that the auxiliary starting batteries (1) have the same
voltage as the batteries on the chassis.

1250 0064 41

1 Auxiliary batteries
2 Rig batteries
Figure 1.2. Starting assistance

3. First connect the positive terminal of the auxiliary battery to the

positive terminal of the chassis battery (2).

35
 4. Then connect the negative terminal of the auxiliary battery (1)
to earth on the chassis (not to the chassis battery's negative ter-
minal).

5. Once the engine has started, first remove the starter cable
between the chassis and the negative terminal on the auxiliary
battery (1).

6. Then remove the cable between the positive terminals of the

batteries.

36
2. Lubricants, coolants and propellants

Introduction
This chapter contains recommendation on hydraulic fluids, lubri-
cants, diesel oils and coolants. The following applies in addition to
these recommendations:

• Never mix oils of varying type and grade.

• Dispose of excess oil in an environmentally-friendly manner
prescribed by the authorities.
If in doubt concerning hydraulic fluids, lubricants, etc., get in
touch with your Atlas Copco representatives.

Hydraulic oil

Hydraulic systems
Use mineral based or synthetic (polyalpha olefine or diester)
hydraulic oil with good rust, wear, oxidizing and foam inhibitive
properties and good air and water separation ability. Select an oil
with viscosity grade (VG) and viscosity index (VI) specified in the
table below. Oil with high viscosity index is less temperature
dependent.

Table 2.1. Recommended viscosity grades and viscosity index

Normal operat- Minimum start- Maximum tem- Viscosity grade Viscosity index
ing temperature ing temperature perature in hy- (VG) (ISO 3448) VI
in hydraulic oil in hydraulic oil draulic oil
reservoir, °C reservoir, °C reservoir, °C
(viscosity 25-50 (viscosity min.
cSt) 1000cSt)
+ 50 to + 70 +5 + 80 ISO VG 100 Min. 100
+ 45 to + 60 -5 + 75 ISO VG 68 Min. 100
+ 35 to + 50 - 10 + 65 ISO VG 46 Min. 100
+ 25 to + 40 - 15 + 55 ISO VG 32 Min. 100
+ 10 to + 25 - 25 + 35 ISO VG 15 Min. 100

37
Lubrication oil

Rock drilling machine (ECL lubrication system)

Use a mineral-based pneumatic tool oil with additives against
wear, ice formation and oil mist. The viscosity grade should be
suitable for the ambient temperature as follows

Table 2.2. Recommended viscosity grades

Ambient temperature °C Viscosity grade (ISO 3448)
- 30 to 0 ISO VG 32 - 68
- 10 to + 20 ISO VG 68 - 100
+ 10 to + 50 ISO VG 100 - 150

Diesel engine
Engine oils have different properties and are classified in different
grades. The API (American Petroleum Institute) or ACEA (Asso-
ciation des Constructeurs Européens d’Automobiles) classification
systems are normally used.

The following grades are allowed for API oils.

CC, CD, CE, CF, CF-4 and CG-4

The following grades are allowed for ACEA oils.

E2-96, E3-96 and E4-98

Since engine oils change their viscosity, the ambient temperature is

decisive to the choice of viscosity grade (SAE classification). A
temporary drop below the temperature limit will impede cold start-
ing but not lead to engine damage. Any transgression for a long
period of time should be avoided to prevent wear.

Table 2.3. Recommended viscosity grades

Upper temperature Viscosity SAE Lower temperature
+30 5W/30 (Synthetic) -30
+35 5W/40 -30
+30 10W/30 -20
+35 10W/40 -20
+35 15W/40 -15
+35 20W/50 -5

38
Hydraulic transmission
Different types of oil can be used in the hydraulic transmission.

• Transmission oils to CAT TO-4 and Allison C-4 specifications.

• Straight engine oils to API CD and Allison C-4 specifications
• Universal oils to API CD and Allison C-4 specifications
• Multigrade engine oils to API CD and Allison C-4 specifica-
tions.
The above oils may be mixed with each other.

• Dexron IID oil or Dexron IID equivalents

Dexron IID and Dexron IID equivalents must not be mixed with
the other oils.

Table 2.4. Recommended viscosity grades

Lowest tempera- Highest tempera- Viscosity SAE
ture °C ture °C
-30 +20 SAE 0W20
-20 +10 SAE 10W
-15 +20 SAE 20
0 +35 SAE 30
+5 +45 SAE 40

Wheel axle centre and hub reduction gears

Use transmission oil with grade classification API GL-5 LSA and
viscosity grade SAE 85W-90.

Compressor
Use compressor oil or hydraulic oil. It must be a mineral oil of
high quality with additives to inhibit oxidation, foaming and wear.
The viscosity grade must suit the ambient temperature and fulfil
ISO 3448 as follows.

Table 2.5. Recommended viscosity grades and viscosity index

Ambient temperature Viscosity grade (ISO 3448) Viscosity index
°C
More than + 25 ISO VG 68 Min. 95
± 0 to +25 ISO VG 46 Min. 95

39
Reeling units
Gears
For lubrication of the gear on cable and hose reels use engine oil.
The oil must be of good quality with viscosity SAE 20W-40.

Lubrication grease

Rock drilling machine

Table 2.6. Recommended lubrication grease, rock drilling machine

Application Type of grease Properties
Drilling machine gear NOTE: Having regard to the NLGI number: 2
housing temperature inside the gear Drop point: 250 °C
housing: high-temperature Base oil viscosity: 110cSt at 40 °C
grease with ashless thickener
Operating temperature: - 20 to +150 °C
and oxidation and rust inhibiting
additives as well as good water
resistance.

Feeder

Table 2.7. Recommended lubrication grease, feeder

Application Type of grease Properties
Feeder sliding Molybdenum disulphide
surfaces
Cradle hinge Universal grease with EP addi- NLGI number: 2
tives Drop point: 180 °C
Base oil viscosity: 150cST/40°C
Operating temperature: -30 to +110°C

Boom

Table 2.8. Recommended grease, boom

Application Type of grease Properties
Grease nipples Universal grease with EP addi- NLGI number: 2
tives Drop point: 180 °C
Base oil viscosity: 150cST/40°C
Operating temperature: -30 to +110°C

40
Drill steel support

Table 2.9. Recommended lubrication grease

Application Type of grease Properties
Grease nipples Universal grease with EP addi- NLGI number: 2
tives Drop point: 180 °C
Base oil viscosity: 150cST/40°C
Operating temperature: -30 to +110°C

Carrier

Table 2.10. Recommended grease, transmission

Application Type of grease Properties
Grease nipples, cen- Universal grease with EP addi- NLGI number: 2
tral lubrication system tives Drop point: 180 °C
Base oil viscosity: 150cST/40°C
Operating temperature: - 30 to +110 °C

RCS and electrical systems

Table 2.11. Recommended contact grease

Application Type of grease Properties
Contacts Contact grease with additives NLGI number: 1-2
to prevent corrosion and oxida- Drop point: 200 °C
tion. Operating temperature: - 40 to +130 °C

Service platform

Table 2.12. Recommended lubrication grease, service platform

Application Type of grease Properties
Grease nipples Universal grease with EP addi- NLGI number: 2
tives Drop point: 180 °C
Base oil viscosity: 150cST/40°C
Operating temperature: - 30 to +110 °C

41
Rod handling equipment

Table 2.13. Recommended lubrication grease, rod handling

equipment
Application Type of grease Properties
Grease nipples Universal grease with EP addi- NLGI number: 2
tives Drop point: 180 °C
Base oil viscosity: 150cST/40°C
Operating temperature: - 30 to +110 °C

Propellants

Diesel engine
The diesel engine must be driven on commercial diesel fuel with a
sulphur content less than 0.5 %. A higher sulphur content will
involve tighter oil change intervals.

Use diesel fuel complying with one of the following specifications.

• DIN EN 590
• BS 2869: A1 and A2
• ASTM D 975-88: 1-D and 2-D
• NATO Code F-54 and F-75
At low temperatures, paraffin deposits in the diesel can cause
blockages resulting in disturbances in the fuel system. A special
winter diesel should therefore be used with ambient temperatures
below 0°C.

Coolants

Diesel engine cooling system

It is important that the water used in the diesel engine cooling sys-
tem is the right quality. The values in the following table must not
be exceeded.

Table 2.14. Recommended water quality

Water quality Min. Max.
pH value at 20°C 6.5 8.5
Chloride ion content (mg/dm3) - 100
Sulphate ion content (mg/dm3) - 100

42
 Water quality Min. Max.
Total hardness (°dGH) 3 20

An anti-freeze additive will protect against corrosion, cavitation

and freezing. Use anti-freeze that is free from amines, nitrites and
phosphates. Anti-freeze concentration in the coolant must be kept
between the following minimum and maximum limits.

• Min = 35% by volume

• Max = 45% by volume
The following tables show the freezing point for different mixtures
of anti-freeze and types of engine.

Table 2.15. Deutz BF4M 1013 C engine

Freezing Anti-freeze, volume Anti-freeze, concentra-
point (°C) (litres) tion (% by volume)
-22 4.8 35
-28 5.4 40
-35 6.1 45

Table 2.16. Deutz BF6M 1013 C engine

Freezing Anti-freeze, volume Anti-freeze, concentra-
point (°C) (litres) tion (% by volume)
-22 5.7 35
-28 6.5 40
-35 7.3 45

Table 2.17. Deutz BF6M 1013 CP engine

Freezing Anti-freeze, volume Anti-freeze, concentra-
point (°C) (litres) tion (% by volume)
-22 5.9 35
-28 6.8 40
-35 7.6 45

Air conditioning
R134a refrigerant it used in the cooling system for the air condi-
tioning. The amount of refrigerant is 1.6 kg.

43
3. Feeder

Safety

WARNING
Risk of personal injury

When servicing or maintaining, the

components which can move or fall down
should be securely chocked or strapped.

1250 0042 36

6000-series

1250 0046 95

Figure 3.1. BMH 6000 and BMHT 6000

The hydraulic feeders on the BMH/BMHT-6000 series are princi-

pally intended for drift and tunnel drilling. They are fitted on
hydraulic booms of type BUT 32 and BUT 35. The feeders are

44
 available in different versions depending on the drilling machine
being fitted on them. The different numbers have the following
meaning.

Example: BMH 6618 and BMHT 6616/10

The first number states the type of feed: 6 = 6000 series

The second number states the type of drilling machine for which
the feeder is intended:

• 3 = COP 1238
• 6 = COP 1432/1532
• 8 = COP 1838
The third and fourth numbers state the length of drill steel in feet :
16 = 16 feet

The fifth and sixth numbers state the length of the short drill steel
in feet and only applies to the telescopic feeders (BMHT).

Technical data

6000-series

Lengths

Note
The total length of the feed depends on the type of drilling machine
and the length of drill steel for which it is intended. By adding the
following length to the length of the drill steel (XX) (XX/XX), it is
possible to obtain the overall length of the feed.
BMH 63XX 1580mm
BMH 66XX 1211mm
BMH 68XX 1580mm
BMHT 63XX/XX 1588mm
BMHT 66XX/XX 1254mm
BMHT 68XX/XX 1588mm

Weights

Note
Only the weight of the shortest and longest standard feed is speci-
fied for each type of feed.
BMH 6312 - BMH 6320 425 - 540kg

45
 BMH 6612 - BMH 6620 424 - 550kg
BMH 6812 - BMH 6820 430 - 545kg
BMHT 6314/08 - BMHT 6318/10 635 - 680kg
BMHT 6614/08 - BMHT 6618/10 600 - 640kg
BMHT 6814/08 - BMHT 6818/10 640 - 685kg

Fitting the rock drill/rotation unit

Preparation
Preparatory measures

1. Clean the feeder free from rust inhibitor.

Assembly
1. Remove burrs, paint or other coatings from the cradle and the
contact surfaces on the rock drilling machine.

2. Remove the mounting bolts from the cradle.

3. Position the rock drill with any shims on the cradle and refit the
bolts. Make sure the drilling machine fits firmly in place.

4. Screw on the drilling machine. Tighten the bolts (four pcs.)

alternately until a torque of 200 Nm (20 kgf m) has been
attained.

5. Connect and fit the hoses to the drilling machine.

6. Adjust slide rails and hoses according to the directions in this

instruction manual.

Check after four hours

1. Check and tighten all bolted joints.

2. Check and adjust the tension of the ropes.

3. Check all hoses for leaks.

4. Tighten and adjust the tension of the hoses if necessary.

5. Check and adjust the slide rail alignment on the feed beam.

46
Drilling machine hoses

Location of hoses
Depending on the drilling machine fitted on the feeder, the hoses
should be positioned in the water-hose drum and the feed hose
retainer as described below.

Table 3.1. Hose designations

New, existing hose designa- Older, existing hose desig-
tions nations Explanation
AL1 L1 Air lubrication
D1 D1 Draining
HDP1 PD1 Reflex damper
HP1 S1 Percussion in
HT1 TS1 Percussion return
RRL1 R1 Rotation left
RRR1 R2 Rotation right
WF2 V1 Flushing

Table 3.2. Hose location

Water-hose drum Feed hose retainer
HDP1/PD1 WF2/V1

HDP1/PD1

AL1/L1 D1
WF2/V1 AL1/L1
D1 HP1/S1
RRL1/R1

RRL1/R1

HP1/S1

HT1/TS1 RRR1/R2 HT1/TS1

RRR1/R2

1250 0043 31
1250 0043 32

Figure 3.2. COP 1838 Figure 3.3. COP 1838

47
Water-hose drum Feed hose retainer

Figure 3.4. COP 1838 (feeder with bulk- Figure 3.5. COP 1838 (feeder with bulk-
head lead-through) head lead-through)
WF2/V1

WF2/V1

AL1/L1
HP1/S1 AL1/L1
RRR1/R2 HDP1/PD1
HP1/S1

RRR1/R2
RRL1/R1
HDP1/PD1
RRL1/R1 HT1/TS1

HT1/TS1

1250 0043 29 1250 0043 30

Figure 3.6. COP 1432/1532 Figure 3.7. COP 1432/1532

AL1/L1 WF2/V1

WF2/V1

HP1/S1 D1
AL1/L1
RRR1/R2 HP1/S1
D1

RRR1/R2

RRL1/R1

RRL1/R1
HT1/TS1 HT1/TS1

1250 0047 11 1250 0047 10

Figure 3.8. COP 1238 Figure 3.9. COP 1238

48
Adjusting the hoses
1. Loosen the bolts on the hose retainer slightly when adjusting
and tensioning the hoses.

2. Tension the hoses and make sure they are not crossed.

Haul and return ropes

Locations

B
C

A D

1250 0046 97

A Adjustment for haul rope

B Adjustment for return rope
C Scraper plate
D Haul rope tensioner
E Holder for intermediate drill steel support
Figure 3.10. Locations

Replacing the haul rope

1. Operate the drilling machine to about half its length of travel.

2. Slacken the tension on the ropes, bolt A and nut B.

3. Remove the haul rope from its front attachment on the drilling
machine cradle.

4. Remove the scraper plate C from the intermediate drill steel

support.

49
 5. Loosen the intermediate drill steel support holder E so that the
intermediate drill steel support can be lifted.

6. Remove the rope from the rope tensioner D in the rear part of
the beam.

Make sure the new rope is fitted in the same hole as the old one.
7. Fit the new rope and bolt the scraper plate back on.

8. Adjust the ropes as described below.

Adjusting haul and return ropes

1. The haul rope is adjusted with bolt A and the return rope with
nut B.

2. The cradle position on the feed beam should be adjusted when it

is in its rear position and when the drill steel with bit is fitted on
the drilling machine.

3. Adjust the ropes so that the bit is behind the dowel. The meas-
urement M1 is specified in the list of spare parts.

1250 0064 89

Figure 3.11. Adjustment measurement M1

Tension of return rope

1. Position a plank between the rock drill cradle and the intermedi-
ate drill steel support.

2. Run the cradle forward until it stops against the plank. Keep the
feed force applied.

3. Tension the return rope so there is no risk of it jumping out of

the cable drum. Do not tension the cable too tightly. There
should be a couple of centimetre's of slack remaining when the
cable is correctly tensioned.

50
Adjusting the cradle on the feed beam
The cradle plates for the drilling machine, the intermediate drill
steel support and the water-hose drum are guided along the feed
beam by means of holder A. Each pair of holders is locked in posi-
tion with bolts B. The bolt holes in the holders are in the form of
angled grooves. The cradle can be adjusted on the feed beam by
shifting the holders lengthways. Make sure the holders are turned
the same way as in the illustration so that the outer part of the
angled grooves is facing to the rear of the beam. Make sure the
feed is in the horizontal position and the drill steel is fitted in the
drilling machine.

D
A
C

B
1250 0064 90

Figure 3.12. Adjusting the cradle holders

1. Remove the bolts B securing the holders.

2. Start by adjusting the upper holders so the cradle is lying

straight on the beam and is 5 - 7 mm above the beam. In this
way, the drilling machine adapter will be at the correct height.
m5mm
1m

1250 0064 91

Figure 3.13. Adjustment measurement

51
 3. Then shift the lower holders lengthways until a clearance of 1
mm has been attained between the lower holder and feed beam.

4. Tighten the bolts B.

5. Check by running the cradle along the entire beam. The pres-
sure required to run the cradle forwards should be max 30 bar
with the hydraulic oil at operating temperature. If the pressure
exceeds 30 bar, this means that the holders are too tight and
must be readjusted.

6. Replace damaged hoses and tighten leaking connections. The

hoses are correctly adjusted when they do not hang down when
the feeder is in the horizontal position.

Adjusting the feed beam on the telescope feeder

The upper beam is guided on the lower by means of similar holders
to the ones used for the cradle. Check that the holders are turned so
that the outer part of the angled groove is facing to the rear. Put the
feeder in horizontal position and run the upper beam along the
lower beam to about half its length of travel.

1. Remove the bolts B securing the holders A.

2. Start by adjusting the upper holders so that the upper beam is

positioned straight on the lower and the measurement is 5 - 7
mm.

3. Then shift the lower holders lengthways until a clearance of 1

mm has been attained between the lower holder and feed beam.

4. Tighten the bolts B.

5. Check by running the beam along its entire length of travel. The
pressure required to run the beam forwards should be max 30
bar with the hydraulic oil at operating temperature. If the pres-
sure exceeds 30 bar, this means that the holders are too tight and
must be readjusted.

52
 5mm
A

m
1m
B
1250 0046 96

Figure 3.14. Adjusting the holder for the telescope feeder

Replacing the slide pieces in the holder

Each holder has a replaceable slide piece. The slide piece C is kept
in place by three keys D. The slide pieces must be replaced at reg-
ular intervals so that the steel in the holder does not wear against
the beam. Replace if there is less than 1 mm of wear allowance on
the slide piece. It is a good idea to change all the slide pieces at the
same time, even if some of them are slightly thicker.

D
A
C

B
1250 0064 90

Figure 3.15. Replacing slide pieces

1. Prise off the slide pieces C from the holder using a screwdriver
and remove the keys D.

2. Slide a new slide piece into the holder track and fit the new
keys.

3. Make sure the holders are refitted correctly in the cradle and are
adjusted according to the directions.

53
Replacing slide rails
Slide rails should be replaced if they are worn or severely
scratched.

1250 0020 11
A

Figure 3.16. Replacing slide rails

1. Remove the cradle for the drilling machine, the intermediate

drill steel support and the water hose drum from the beam.

2. Remove the old slide rails A by prising the lower edges of the
bars outwards using a screwdriver.

3. Clean the beam surfaces thoroughly.

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

5. Refit the drilling machine cradles, intermediate drill steel sup-

port and water-hose drum. Adjust the holders on the cradles as
described in the instructions.

Adjusting different drill steel lengths for the telescope

feeder
The use of different drill steel lengths is made possible by moving
a mechanical stop mechanism on the lower feed cylinder.

1. Run the lower feed cylinder backwards towards the mechanical

stop mechanism.

2. Undo the six hexagonal socket screws A and move one of the
screws to the top of the mechanical stop mechanism.

3. Operate forward or reverse to the required drill-steel length.

Remember that the drill bit B must be behind the rubber dowel.

54
 4. Replace the hexagonal socket screw A to its ordinary position
and tighten the mechanical stop mechanism.

1250 0020 12

Figure 3.17. Adjusting the length stop

Feed cylinder

Dismantling the feed cylinder

CAUTION
Hazardous hydraulic oil pressure.

Risk of personal injury.

Operation of hydraulic oil system can involve great danger.

.Make sure the system is made pressure-free first.
1250 0022 19

CAUTION
Hazardous hydraulic oil and water pressure.

Can cause personal injury.

Never replace high pressure hoses with hoses of a lesser

.quality or with hoses that have a detachable coupling.
1250 0022 24

55
 1. Operate the drilling machine cradle to about half the feed
length.

2. Relieve the tension on the haul and return ropes, bolt A and nut
B.

3. Remove the hose drum by undoing the 4 bolts in the centre of it

and lifting off the entire drum.

4. Detach the hoses at the hose retainer.

5. Undo bolts C and D on cradle plates E and F.

C
E

SP
D
G H
N
F
A
K
M
L I
1250 0020 87

Figure 3.18. Dismantling the feed cylinder.

6. Remove bolt A completely. Remove also end piece G and the

end plate H.

7. The cylinder and fork can now be pulled backwards out of the
beam.

8. If necessary, dismantle the fork I by knocking away the pin K.

Avoid dismantling the spacer L. If it must be dismantled, meas-

ure SP first so that the spacer can be refitted in the same posi-
tion.
Measurement SP is specified in the list of spare parts.

56
Tension bushing for spacer

Description
The spacer at the front of the cylinder is held in place with a ten-
sion bushing. In order for the feeder to function correctly, the
spacer measurement SP must be correct. This measurement varies
depending on the feed length and type of feeder, see relevant
spare parts catalogue.

1250 0065 30 SP
Figure 3.19. Spacer and tension bushing

Dismantling
1. Remove the plastic plugs M from their holes.

2. Unscrew the bolts N from the bushing.

3. Fit the bolts into the threaded holes and pull them alternately
until the bushing parts.

Assembly
1. Assemble the bushing as illustrated but do not tighten the bolts.

2. Fit the spacer and bushing into the sleeve and make measure-
ment SP is the same as before.

3. Tighten the bolts N alternately until a torque of 38 Nm (3.8 kgf

m) is attained.

Long-term storage
1. Clean the feeder thoroughly.

2. Lubricate as directed, see maintenance schedule Feeder.

3. Protect unpainted surfaces with rust inhibitor.

4. Store the feeder in a dry and clean environment.

57
4. Boom

BUT 35 G

8 7
6
5

9 4
1
3
1250 0105 70

2
1 Attachment plate
2 Rear boom cylinders
3 Telescopic unit
4 Front boom cylinders
5 Boom head
6 Rotation unit
7 Feed lookout cylinder
8 Feed extension cylinder
9 Bulkhead lead-through
Figure 4.1. Boom

The hydraulic boom is of telescopic type with 360° feed rotation. It

features three-point suspension at front and rear. Each three-point
suspension unit includes two hydraulic cylinders which, through
series connection in pairs, provide parallel feed both vertically and
horizontally.

A tilt cylinder enables the feeder to be positioned for roof and

cross-cut drilling.

The rotary motion is obtained by a hydraulic rotation unit and

transferred via a stub shaft to the feeder.

Boom BUT 35 G is available in two different basic versions,

model M (medium) and model L (large). Both models are available
for left-mounted and right-mounted feeder and with or without
bulkhead lead-through.

58
 3
1 2
1250 0105 74

1 Rear boom section

2 Intermediate boom section
3 Front boom section
Figure 4.2. BUT 35 G model M, left-mounted feeder

3
1 2
1250 0105 73

1 Rear boom section

2 Intermediate boom section
3 Front boom section
Figure 4.3. BUT 35 G model L, left-mounted feeder

Technical data

BUT 35 G

Model M (medium)

Weight

Note
All weights are in respect of boom, excluding feeder and rock drill.
Complete boom, including hydraulic
hoses 3060 kg
Rear boom section (1) 1700 kg
Intermediate boom section (2) 410 kg
Front boom section (3) 640 kg

Length
Telescope contracted 7252 mm
Telescope extended 8852 mm

59
 Model L (large)

Weight

Note
All weights are in respect of boom, excluding feeder and rock drill.
Complete boom, including hydraulic
hoses 3200 kg
Rear boom section (1) 1840 kg
Intermediate boom section (2) 410 kg
Front boom section (3) 640 kg

Length
Telescope contracted 7952 mm
Telescope extended 9552 mm

Bolted joints

Tightening torques
The following table specifies the bolted joints requiring a special
tightening torque. Other bolted joints can be tightened to the
torque specified in Atlas Copco standard K4369, see maintenance
instructions General.

Note
All bolted joints in the following table should be lubricated with
Molycote 1000 thread grease or other thread grease having a fric-
tion coefficient of 0.11 µ.

60
 14 5
19 1 10

13
16 13
6 7, 18 8 15
11
3
2 12
1250 0107 03

2 9
11

Figure 4.4. Bolted joints, BUT 35 G model M

14 5
19 1 10

13
16 13
17 6 7, 18 8 15
11
2 3
12
1250 0107 04

2 9
11

Figure 4.5. Bolted joints, BUT 35 G model L

Table 4.1. Tightening torques

Tolerance +/- Quan-
No. Bolted joints Thread Torque Nm Nm tity
1 Bolt, rear boom link M20 365 36 2
2 Expander shaft, rear cylinder link M20 290 50 2
3 Expander shaft, rear cylinder M20 290 50 4
4 Expander shaft, telescope cylinder M16 195 20 1
5 Expander shaft, feed extension cylinder M16 195 20 1
6 Bolt, bearing housing-rear boom body M16 315 31 16
(model M)
Bolt, bearing housing-extension (model
L)
7 Bolt, telescope-front boom attachment M16 315 31 12

61
 Tolerance +/- Quan-
No. Bolted joints Thread Torque Nm Nm tity
8 Bolt, front boom link M20 365 36 1
9 Bolt, front boom link M16 187 18 1
10 Expander shaft, front cylinder M16 195 20 4
11 Expander shaft, front cylinder link M16 195 20 2
12 Bolt, front boom attachment-rotation M16 315 31 15
unit
13 Expander shaft, feed lookout cylinder M16 195 20 2
14 Bolt, feed holder-attachment shaft M12 128 13 4
15 Lock nut, feed extension cylinder M24 290 50 1
16 Bolt, rotation unit-cover M12 128 13 4
17 Bolt, extension-rear boom body M16 315 31 16
18 Bolt, telescope-intermediate boom sec- M12 128 13 12
tion
19 Bolt, attachment plate-boom console M24 630 60 18

Note
The bolts in bolted joint number 19, attachment plate-boom con-
sole, must be of strength class 12.9. The strength class for other
joints is given in the spare parts list for the boom.

62
Bulkhead lead-through

Hose location

HD FL
AL
HP FL
AF BFL BAN BRR F
BFR BRL FR
F
HT WF BE BE FR
RRL FE
RG WAM
F FE
RGF RRR
WC
DS
RGR F HDP
SR
DS
RA M LS
SR
RA LS

1250 0064 65

AF Air flushing
AL Air lubrication
BAN Anti-parallel holding
BE Boom telescope
BFL Left boom cylinder front
BFR Right boom cylinder front
BRL Left boom cylinder rear
BRR Right boom cylinder rear
DS Hydraulic drill-steel support, option
F Feed
FE Feed extension
FL Feed lookout cylinder
FR Feed rotation
HD Percussion drain
HDP Reflex damper, drilling machine
HP Percussion in
HT Percussion tank
LS Automatic drilling machine return
M Electric cable, option RAS
RA Rod handling arm, option RAS
RG Gripper claw, option RAS
RGF Front gripper claw, rod handling, option RAS
RGR Rear gripper claw, rod handling, option RAS
RRL Rotation left, drilling machine
RRR Rotation right, drilling machine
SR Stinger, option
WAM Water mist, option
WC Water lubrication feeder, option
WF Water flushing
Figure 4.6. Hose location in bulkhead lead-through

Starting to use a new boom

When starting to use a new or reconditioned boom, or one that has
been out of service for a long period, the following steps should be
taken:

63
 1. Lubricate the boom as described in the maintenance schedule. It
is important for lubrication to be effective right from the start.

2. Thoroughly clean all piston rods and sliding surfaces that have
been treated with corrosion inhibitor.

3. Check and retighten all bolted joints and expander shafts at least
once every shift during the first week the boom is in use.

4. Make sure the pressure in the hydraulic circuits is correctly

adjusted. The pressure should be 195-220 bar in the high-pres-
sure circuit and 40 bar in the pilot circuit.

5. Check all operating movements to ensure that all hydraulic cyl-

inders travel to their end positions.

6. Also check that no hoses can be caught up or pinched and that

no oil leakage occurs.

Slinging and hoisting

Safety

CAUTION
Take great care when strapping and lifting
heavy objects.

Can cause personal injuries .

The lifting must be carried out over the centre

of gravity.
Only use straps that are intact and intended
for the load they must bear.
Fasten the straps in the correct loops, where
there are loops
1250 0042 38

Hoisting
1. Check that the lifting equipment is designed for the load it is to
carry. For weight details, see section Technical data.

2. Apply the slings so that lifting is performed over the centre of

gravity, see section Slinging.

64
 3. Hoist carefully. Make sure the boom does not start to swing and
that the slings do not start to slide off.

Slinging

Tp

3000
1250 0107 09

Figure 4.7. Slinging BUT 35 G, model L

Dismantling the boom

Safety

WARNING
Risk of personal injury

When servicing or maintaining, the

components which can move or fall down
should be securely chocked or strapped.

1250 0042 36

Note
No modification or reinforcement work on the boom should be per-
formed without first consulting Atlas Copco Rock Drills AB.

65
 Dismantling the feeder

A A
1250 0105 76

Figure 4.8. Dismantling the feeder

1. Fit slings round the feeder before dismantling it so that it cannot

fall down.

2. Detach all hoses from the feed hose retainer.

3. Unscrew the feed extension cylinder from the feeder.

4. Remove the feeder from the boom by unscrewing the holders

(A) from the feed holder.

Dismantling the boom

The boom can be shortened by separating it between the rear boom
section (telescope tube flange) and intermediate boom section
(front cylinder attachment).
1250 0105 75

Figure 4.9. Dismantling the boom body

1. Fit a sling round the front boom beam or support it on stands

before starting dismantling work.

2. Detach the hydraulic hoses from the cylinders and plug the
hoses and nipples.

66
 3. Disconnect any sensor cables.

4. Then undo and remove the twelve bolts (A) and washers.

Expander shafts
Most of the cylinder brackets and links are fitted with expander
shafts. Play can be eliminated by tightening a nut. The slotted
bushings will then be forced up on the tapered shaft so that the
joints will be free from play.

Dismantling
1. Fit a sling round that part of the boom that is held by the
expander shaft or rest it on supports before starting to dismantle
the shaft.

2. Undo nut (A) and withdraw bolt (B).

3. Screw in a bolt that fits the threads in the bushings (C) and
tighten it until one of the bushings loosens.

4. Remove the other bushing and shaft (D).

B
C

C
1250 0020 16

Figure 4.10. Expander shaft

Assembly
1. Fit the shaft (D) in the cylinder lug or link. Lubricate the shaft
before assembly.

2. Fit the two bushings (C). Make sure that they are located sym-
metrically at the attachment point.

3. Fit the bolt (B) and nut (A) in the expander shaft and tighten.
The nut should only be tightened until there is no play. If it is
tightened too much, the attaching lug may crack. Only use the
recommended tightening torques specified in the torque table,
see section Bolted joints.

67
Boom telescope

Dismantling the boom telescope

Safety

CAUTION
Take great care when dismantling the boom
telescope.

Can cause personal injuries.

Chock up under the rotary device and front

boom beam correctly before the boom
1250 0042 40
telescope is dismantled .

Dismantling the boom

The boom must be separated before the telescope device can be
dismantled for maintenance or replacement.

Figure 4.11. Dismantling the boom

1. Extend the telescope to its front end position.

2. Rotate the feed beam up and down.

3. Lower the boom until the feed beam rests on the ground.

4. Position supports firmly under the rotation unit and front boom
beam before dismantling the telescope.

5. Remove the bolts (A) from the front boom beam.

68
Dismantling of telescope and bearing housing
The figure below shows the BUT 35 G model M. The method of
dismantling the telescope and bearing housing is the same as for
model L. The only difference is that the bearing housing (B) on
model L is screwed into the extension segment instead of in the
rear boom body.

A 1

2
1250 0105 77

Figure 4.12. Dismantling of telescope and bearing housing

1. Retract the telescope to the rear end position.

2. Fit slings round the bearing housing. Use an overhead travelling

crane or hoist, etc.

3. Detach the hydraulic hoses (C).

4. Unscrew the bearing housing bolts (B).

5. Remove the expander shaft (D).

6. Carefully withdraw the telescope tube, cylinder and bearing

housing.

69
Checking the bushings in the bearing housing

C
D
G H B A

1250 0042 97

A Telescope tube
B Cover
C Bushings
D Bearing housing
G Washer
H Seal
Figure 4.13. Checking the bushings in the bearing housing

Thoroughly inspect the telescope device for signs of damage and

wear.

1. Extend the telescope tube (A).

2. Remove the washer (G) and seal (H) and then undo the cover
(B).

3. Measure the play between the telescope tube (A) and the two
upper bushings (C). If the play (I) is greater than 1 mm, disman-
tle the bearing housing (D) and change the worn bushings.

D
A

1250 0043 28

Figure 4.14. Play between the telescope tube and bushings

70
Checking the keys
1. Check the keys (E) carefully. If they are deformed, the damaged
area should be ground smooth so that future damage to the slide
rails (F), bearing house (D) and bushings (C) can be avoided.

E E

1250 0042 96

C D C

C Bushing
D Bearing housing
E Keys
F Slide rails
Figure 4.15. Telescope device

Checking the slide rails

1. Remove the cover (B).

2. Place the feeder on a support and rotate the boom so that the
load is taken up on only one side of the keys.

71
 3. The slide rails (F), see above figure, can then be removed from
the bearing housing and inspected. Change them if they are
worn or scratched.

C
D
G H B A

1250 0042 97

A Telescope tube
B Cover
C Bushing
D Bearing housing
G Washer
H Seal
Figure 4.16. Bearing housing

Rotation unit

Safety

CAUTION
Take great care when dismantling the rotary
unit.

Can cause personal injuries.

Chock up under the feeder correctly so it is

steady.
1250 0042 39

General
The rotation unit consists of a rotary actuator and a bearing hous-
ing attached to the feed holder attachment shaft

72
 C

E
1250 0109 89

A Feed holder
B Attachment shaft
C Rotation unit
D Bearing housing
E Feed lookout cylinder
Figure 4.17. Rotation unit

Function of the rotation unit

The rotation unit converts the linear motion of the piston (B) into
rotary motion.

The rotary actuator consists of a housing (A) with a ring gear (C)
and two moving parts: a piston (B) and a shaft (D). The shaft has
splines that engage with the internal splines of the piston. The
external splines of the piston engage with the ring gear splines.

The piston moves back and forth in the housing and the splines
rotate the shaft.

73
 B

1250 0058 32

Figure 4.18. Function of the rotation unit

74
Reconditioning rotary actuators

Dismantling of rotary actuator from boom

1. Rotate the feeder 90° until it and the rock drill are under the
boom. Position supports firmly under the feeder to hold it stead-
ily in place.

1
2
3

5 6

8
9

10
11
1250 0107 34

Figure 4.19. Dismantling the feeder

2. Dismantle the expander shaft (11) of the feed lookout cylinder.

3. Remove the bolts (1) and protection (2).

75
 4. Remove the bolts (3) and sensor (4).

This point applies only to rigs with the RCS electronic control
system and one of the ABC Regular or ABC Total options.
5. Remove the bolts (5) and the outer cover (6).

6. Remove the bolts (7), the inner cover (8) and the shim (9).

7. Detach the hydraulic hoses to the feeder. Plug all hoses and con-
nections.

8. Carefully lift the boom straight up so that the sliding bearings

(10) in the bearing housing are not damaged.

9. Rotate so that the bearing housing (E) reaches its original posi-
tion.

10.Apply slings round the bearing housing (E).

11.Remove the bolts (A), hose retainer (B) and cover (C).
1250 0107 35

A
D B
Figure 4.20. Removing the cover and hose retainer

12.Remove the bearing housing by unscrewing the bolts (D).

13.Remove the hydraulic hoses from the overcentre valve and plug
the hoses and connections.

76
 14.Apply slings round the rotary actuator and remove it from the
boom head by undoing the bolts (F).

1250 0109 90

Figure 4.21. Removing the rotary actuator

Constituent parts of the rotary actuator

102
105
05
113
04
207
204
206 100
304
205

302
202
203
300
200
201
111 03.1
211
210
211
111 301
302
03.2
302

205
112 304
01 206

112 02
1250 0107 07

Figure 4.22. Constituent parts of the rotary actuator

77
 Table 4.2. Constituent parts of the rotary actuator
Pos. no. Description Pos. no. Description
01 Housing 200 Inner piston seal
02 Shaft 201 Inner piston seal
03.1 Piston skirt 202 Outer piston seal
03.2 Piston 203 Outer piston seal
04 Cover 204 O-ring
05 Retaining ring 205 Shaft seal
206 Seal
100 Locking pin 207 Thrust ring
102 Bolt 210 O-ring
105 Plug 211 Thrust ring
111 Lubricating nipple
112 Grease relief valve 300 Wear ring
113 Locking pin 301 Wear ring
302 Wear ring
304 Washer

Removing the rotary actuator

Note
When assembling the component parts of the rotary actuator, the
splined parts (shaft and piston) must be refitted in their original
positions.
There are two permanent position marks:

• One mark for piston-ring gear

• One mark for shaft-piston
1250 0109 87

Figure 4.23. Permanent marking piston-ring gear

78
 1250 0109 88

Figure 4.24. Permanent marking shaft-piston

Assembly of the rotary actuator will be facilitated if additional

positioning marks are made during dismantling.

1. Place the rotation unit on a clean workbench.

2. Detach all hydraulic connections.

3. Remove the overcentre valve and associated components.

4. Mark the relative positions of the retaining ring (05), cover (04)
and shaft (02) using a scriber or pen.

5. Unscrew the bolts (102) and plugs (105). Screw two of the bolts
(102) in the threaded holes of the retaining ring (05). By means
of the bolts, remove the retaining ring from the shaft splines
(ring gear).
1250 0109 82

B A 05
102

105
102
05

Figure 4.25. Removing the retaining ring

79
 6. Screw two bolts with washers or sleeves in the cover (04) and
use a tommy bar or the like to unscrew the cover from the shaft.

04

1250 0109 83

Figure 4.26. Removing the cover

In certain cases the cover may be screwed in extremely hard. An

iron bar can then be welded to the cover to provide greater lev-
erage.
7. Screw two bolts in the shaft (02) flange. These bolts enable the
shaft to be turned with the aid of a tommy bar or the like. Turn
the shaft clockwise. It will start to rotate out of the housing.

Do not turn the shaft so much that it no longer engages with the
piston. Before the shaft is unscrewed all the way out its position
relative to the piston must be marked, see next point.
02

A
1250 0109 84

Figure 4.27. Removing the shaft

80
8. Using a pen, mark the position of the shaft relative to the piston,
i.e. mark one of the shaft splines and the corresponding groove
in the piston. See example in the following figure.

A
1250 0109 85

Figure 4.28. Marking shaft-piston

9. Unscrew the shaft all the way out of the housing.

10.Use a plastic drift and hammer to drive the piston (03.2)

(including piston skirt (03.1)) out of the housing (01).

Auxiliary marks must be made to ensure that the piston will be

refitted in its correct position. For this to be possible, however,
the piston must first be released fully from the ring gear. Hold
the piston in this position and use a pen to mark the housing
(01), piston skirt (03.1) and piston (03.2).
01

03.1

03.2
1250 0109 86

Figure 4.29. Marking housing-piston skirt-piston

After marking, the piston can be removed from the housing.

Exercise care to avoid damaging the piston and housing.

11.The piston and piston skirt need not be dismantled further

unless it is suspected that the O-ring (210) may be damaged. If
the O-ring (210) is to be changed mark the relative positions of

81
 the piston and piston skirt and then remove the wear rings (300
and 301). Press out the locking pins (100) and unscrew the pis-
ton from the piston skirt.

Change the O-ring (210) and reassemble piston and piston skirt.

12.Unscrew the grease nipples (111) and valves (112).

13.Remove all seals and bearings.

14.Clean all parts thoroughly and check them for wear.

The maximum thickness of the wear rings (300, 301 and 302)
should be 3.098 mm. The washers (304) should have a maxi-
mum thickness of 3.048 mm.

Assembly of rotation unit

1. Thoroughly clean all parts and blow them dry with compressed
air. Make sure that all position marks are still clearly visible.

2. Carefully inspect the threads on the shaft (02) and cover (04)
and rub down any burrs with abrasive cloth.

3. Screw the cover on the shaft.

4. Lubricate all seals and contact surfaces with hydraulic oil.

Always change the seals and bearings when assembling rota-

tion units.
Never use sharp tools when fitting seals.
5. Fit the wear rings (300 and 301) on the piston.

Fitting the piston is the most difficult part of reassembling the

rotary actuator. It may therefore be a good idea to practice this
without any seals on the piston.
6. Stand the housing (01) upright with the flange upwards. Fit the
piston in the housing. Use the markings to make sure it is in the
right position. Lay the housing down in a horizontal position

82
 when the piston has engaged with the ring gear and check at the
other end of the housing that the position of the piston coincides
with the permanent markings.

1250 0109 87

Figure 4.30. Permanent markings piston-ring gear

Screw the piston in fully so that the piston skirt bottoms against
the ring gear.

7. Grease the washers (304).

8. Fit a set consisting of washer (304) and seals (205) and (206) on
the shaft (02) and another set on the cover (04).

04

206
304
205

205
1250 0107 08

304
206

02

Figure 4.31. Fitting washers and seals

83
 9. Stick masking tape on the ring gear of the shaft so that the pis-
ton seals will not be damaged when the shaft (02) is fitted.

1250 0107 37

Figure 4.32. Shaft ring gear and threads

10.Fit the shaft in place so that its marking is opposite the piston
skirt marking. Then remove the masking tape.

11.Apply thread paste to the threaded part of the cover (04) and
screw it on the shaft. Tighten to a torque of 800-950 Nm.

12.Apply grease generously to the shaft ring gear. Also grease the
bright metal surfaces of the cover.

13.Fit the retaining ring (05) on the shaft and try to find a position
where its through hole comes opposite the threaded hole of the
cover (04). It may be necessary to loosen or tighten the cover
slightly to achieve this.

14.Apply Loctite 242 (or the equivalent) to the bolts (102) and
tighten them to a torque of 116 Nm. Apply sealing compound to
the plugs (105) and screw them flush into the retaining ring.

15.Pump grease into the grease nipples (111) to remove any impu-
rities and to check that they are in working order. Wipe off sur-
plus grease.

16.Screw the grease nipples (111) and valves (112) in place.

17.Fit the hydraulic connections and overcentre valve.

Action after rotary actuator assembly

After mounting of the rotary actuator a check for oil leakage
should be performed. If possible, connect up the rotary actuator in
a hydraulic test bench and give it a trial run before fitting it on the
boom.

84
 1. Pressurize port P2 at 210 bar. No oil should leak out of port P1
or round the cover.

2. Pressurize port P1 with 210 bar. No oil should leak out at port
P2 or round the shaft flange.

3. Pump grease into the grease nipples (111) until it comes out
through the vales (112). Repeat this after having run the rotary
actuator through a number of cycles.

4. Run at least 15 cycles and check that no oil leakage occurs.

Mounting of rotary actuator on boom

1. Apply slings round the rotary actuator and mount it on the
boom head using the bolts (F).
1250 0109 90

Figure 4.33. Mounting of rotary actuator on boom

2. Connect the hydraulic hoses to the overcentre valve.

85
 3. When mounting the bearing housing it is important to ensure
that the stop position for feed rotation is correct.

A A
1250 0109 93

B B

45 ° 45 °

A Bearing housing in horizontal position

B Bearing housing rotated in under boom to stop position
Figure 4.34. Stop position for feed rotation

a. Rotate the rotary actuator to the stop position.

b. Then rotate it in the opposite direction so that the pattern of

holes on the rotary actuator's shaft flange is displaced two
holes.

86
 c. With the rotary actuator rotated to this position the bearing
housing (E) can be mounted hanging vertically. Tighten the
bolts (D) to a torque of 315 Nm.

D
E
1250 0109 94

Figure 4.35. Mounting the bearing housing

4. Mount the cover (C) and hose retainer (B) using the bolts (A).
Tighten the bolts (A) to a torque of 128 Nm.
1250 0109 92

B
Figure 4.36. Mounting of cover and hose retainer

87
 5. Mount the feeder by rotating the bearing housing through 90°.
Lower the boom straight down against the feed holder's attach-
ment shaft (12). Take care to avoid damaging the sliding bear-
ings (10) in the bearing housing.

1
2
3

5 6

8
9

10
11

12
1250 0109 91

Figure 4.37. Mounting the feeder

6. Mount shims (9) and inner cover (8). Tighten the bolts (7) to a
torque of 128 Nm.

7. Mount the inner cover (6) using the bolts (5). Tighten the bolts
(5) to a torque of 75 Nm.

8. Mount the sensor (4) using the bolts (3).

88
 This point applies only to rigs with the RCS electronic control
system and one of the ABC Regular or ABC Total options.
9. Mount the protection (2).

10.Mount the feed lookout cylinder with the aid of the expander
shaft (11). Tighten the expander shaft (11) to a torque of 195
Nm.

11.Lift the boom and rotate the feeder through 90°. Refit the
hydraulic hoses.

Adjusting the feed lookout cylinder

Note
When mounting the feed lookout cylinder, start from the basic set-
ting of 782 mm between the expander shaft centres. Then continue
with fine adjustment of the feed lookout cylinder as described
below:

89
 782

A
B
1250 0105 79

Figure 4.38. Adjusting the feed lookout cylinder

1. Position the boom horizontally.

2. Position the rotation unit bearing housing horizontally using a

spirit level (placed vertically on the rotation unit flange).

3. Operate the rotation unit to bring the feed holder into a horizon-
tal position.

4. When the boom is in this position, the feed holder can be tilted
with the feed lookout cylinder. When the feed lookout cylinder
piston rod is all the way inside the cylinder, the feed holder
should be horizontal.

5. To adjust, slacken the locking screws (A) and screw the piston
rod in or out using an open-ended spanner on the piston rod
flats (B) until the feed holder is horizontal.

90
Directional control - angle sensor
Directional control is covered in another section of the mainte-
nance instructions, see maintenance instructions Directional con-
trol.

91
5. Engine

Engine unit Deutz 1013 C

1250 0064 39

Figure 5.1. Engine

Engine type (A), engine number (B) and engine data are shown on
the type plate (C) affixed to the crankcase. The engine number is
also stamped on the crankcase at the arrow.

Lift up the cover to see these numbers.

Figure 5.2. Engine type plate

Note
Engine type and engine number must be specified on spare part
orders.

92
Technical data
Deutz BF4M 1013C
Max. power at 2300 rpm 115KW
Max. torque at 1400 rpm 572Nm
Swept volume 4.76dm 3
Valve clearance
Inlet 0.3 +0.1 mm
Outlet 0.5 +0.1 mm
Idling speed 800rpm
Cooling Water-cooled
Fuel injection Bosch
Generator (Bosch) 35A
28V
Starter motor 4KW
24V
Weight 490Kg

Deutz BF6M 1013C

Max. power at 2300 rpm 170KW
Max. torque at 1400 rpm 847Nm
Swept volume 7.14dm 3
Valve clearance
Inlet 0.3 +0.1 mm
Outlet 0.5 +0.1 mm
Idling speed 800rpm
Cooling Water-cooled
Fuel injection Bosch
Generator (Bosch) 55A
28V
Starter motor 4KW
24V
Weight 670Kg

Tightening torques
Table 5.1. Tightening torques, Deutz 1013 diesel engine
Bolted joints Tightening torque (Nm) Comments
Valve cover 8.5
Set screw, rocker arm 21

93
Bolted joints Tightening torque (Nm) Comments
Engine mounting, flywheel side 187 M16 x 40, 8.8 A4C
Engine mounting, fan side 187 M16 x 40, 8.8 A4C
Intake manifold 8.5
Exhaust manifold 21
Oil drain plug 50
Injector mounting 16 Torx
Injector line 30 M14 x 1.5
Oil sump (cast) 29
Oil sump (sheet metal) 21

Safety

94
Fuel system
Changing fuel filter

Figure 5.3. Fuel filter

The diesel engine has two fuel filters. The engine diesel filter (1)
and a pre-filter (2) located between the diesel tank and engine. The
pre-filter has a loose insert that must be cleaned every month. A
damaged pre-filter insert must be changed.

The diesel engine filter (1) must be changed and cleaned:

1. Close the fuel cock.

2. Loosen the fuel filter (1) using a suitable tool and unscrew it.

3. Collect any residual fuel.

Figure 5.4. Changing fuel filter

4. Clean the filter holder sealing surface.

5. Lightly oil the new fuel filter rubber seal.

95
 6. Screw in the filter by hand until the gasket is home.

Figure 5.5. Changing fuel filter

7. Tighten the filter an additional half turn.

8. Open the fuel cock.

9. Check that the fuel filter does not leak.

Bleeding the fuel system

The fuel system must be bled when the engine is started for the
first time or when the tank has been run dry.

1. Switch on the ignition.

2. Place a receptacle to collect any fuel under the filter.

3. Open the bleed screw (1).

1
1250 0102 21

Figure 5.6. Fuel filter bleed screw (1)

96
 4. Use hand pump (2). Pump until the fuel flowing out is free of
air.

1250 0102 22
Figure 5.7. Location of hand pump (2)

5. Torque tighten the bleed screw (1) to 15 Nm.

6. Continue to pump until the resistance increases.

7. Start the engine.

8. Check that the fuel filter bleed screw (1) is not leaking.

Draining the fuel tank

Always fill the fuel tank with clean diesel oil and fuel of the cor-
rect grade for the temperature.

1. Loosen the bottom plug about one turn and allow the water to
run out.

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

1250 0020 28

Figure 5.8. Draining the fuel tank

97
Air system
General
It is important to keep the air filter and air cleaner in good condi-
tion so that the exhaust gases are as clean as possible. Repeated
dismantling and assembly can damage the gasket between the
insert and the filter housing. Smoke and poor engine performance
can be an indication of clogged filters.

1. A clogged air filter is indicated on the operator panel. See oper-

ator's instructions Repositioning: Control panel functions.

Changing filter insert

N.B.
The safety cartridge must not be cleaned and reused.

1. Loosen the filter cover by undoing the retaining clips.

2. Remove the dirty filter insert (A).

3. Check the adhesive gasket for cracks or other damage.

4. Clean the insert (A) or replace with a new one.

5. Change also the safety cartridge (B) if necessary.

6. Refit the filter insert and filter cover.

1250 0020 37

Figure 5.9. Changing filter insert

98
Cleaning the filter insert

N.B.
The filter insert and safety cartridge must be changed after
cleaning five times. Safety cartridges must be changed after a
year's operation. Do not blow the filter housing clean with com-
pressed air.

1. Carefully tap the front of the filter insert (A) against the palm of
your hand or some other soft object a few times, or blow the fil-
ter insert clean with dry compressed air.

2. Make sure the filter insert is not damaged.

3. Illuminate the filter insert with a torch to see if it is damaged.

4. Refit the filter insert.

Cleaning the dust valve

1. Empty the dust valve (1) by squeezing the slit together in the
direction of the arrow.

2. Clean the slit at regular intervals.

3. Remove any accumulation of dirt by squeezing the upper part of

the valve.

Figure 5.10. Cleaning the dust valve

Cooling system

Coolant level
1. Coolant level (1) must be above the Kalt-Cold mark when the
engine is cold.

99
 2. Top up with coolant if the level is below the min. mark or if the
coolant level warning indicator is activated, see topping up the
cooling system.

Figure 5.11. Checking the coolant level

Cleaning the cooling system

1. Place a receptacle under the heat exchanger (2) to collect the
dirt.

Figure 5.12. Cleaning the cooling system

2. Remove the upper inspection cover on the heat exchanger.

3. Cleaning with compressed air.

a. Blow through the heat exchanger with compressed air from

below (3) and then from above (1).

b. Flush out any dirt that has come loose with a water jet.

Note
Do not damage the cooling ribs.
4. Cleaning with cold detergent.

a. Squirt normal cold detergent into the heat exchanger and

allow to act for about 10 minutes.

100
 b. Flush clean through (3) first and then through (1) with a
sharp water jet.

Note
Do not spray on sensitive engine components such as the genera-
tor, cables or electrical parts.
5. Fit the inspection cover.

6. Warm up the engine to evaporate residual water.

Draining the cooling system

N.B.
Take care when draining hot coolant. Risk of burns.

1. Place a suitable receptacle under the drain plug (3).

Figure 5.13. Draining the cooling system

2. Unscrew the cap (1).

3. Unscrew the drain plug (3) completely.

4. Drain off the coolant.

101
Topping up/bleeding the cooling system
1. Unscrew the cap (1).

Figure 5.14. Topping up the cooling system

2. Unscrew the drain plug (3) to the last groove (arrow).

3. Undo the air screws (2) and (4).

4. Top up with coolant to the top of the filler pipe (the temperature
valve must be open if fitted).

5. Tighten the air screws (2) and (4).

6. Tighten the drain plug (3).

7. Fit the cap (1).

8. Check the water level when the engine has cooled down after
running the first time.

102
Oil system
Topping up with engine oil
1. Fill up with oil through filler hole (C). See maintenance
instructions Lubricants, coolants and propellants.

A
B C
1250 0037 66

Figure 5.15. Topping up with oil

2. Check the oil level on the dipstick (A).

Changing oil
1. Place the rig horizontally.

2. Warm up the engine. Oil temperature approx. 80°C.

3. Stop the engine.

4. Place a receptacle at the drain cock.

5. Screw out the oil drain plug.

6. Drain the oil.

7. Screw in the oil drain plug with a new gasket and tighten it.

8. Fill up with oil. See maintenance instructions Lubricants, cool-

ants and propellants.

9. Start the engine and allow it to idle for abut two minutes.

103
 Figure 5.16. Changing oil

Checking oil level

1. Stop the engine.

2. Check the oil level against the marked line on the stick.

3. Top up with oil to the top line if necessary.

Figure 5.17. Oil level check

Changing oil filter

1. Loosen the oil filter using a suitable tool and unscrew it.

2. Collect the oil.

Figure 5.18. Changing oil filter

3. Clean the filter holder sealing surface.

104
 4. Lightly oil the rubber gasket on the new oil filter.

5. Screw in the filter by hand until the gasket is home.

Figure 5.19. Changing oil filter

6. Screw in the filter half a turn.

7. Check the oil level.

8. Check the oil pressure.

9. Make sure the oil filter does not leak.

Figure 5.20. Changing oil filter

Belts
Tension gauge
Check the belt tension with a tension gauge.

105
 1. Press down the arm (1) in the gauge.

Figure 5.21. Belt gauge

2. Place the guide (3) on the belt (2) between the two belt pulleys,
making sure the stop fits laterally.

3. Press the button (4) at right angles to the belt (2) so that the
spring can be felt or heard releasing.

4. Carefully lift up the gauge without changing the position of arm

(1).

5. Read off the value at the intersection (arrow) of the scale (5)
and the arm (1).

6. Readjust the tension if necessary.

Tensioning belts
Fan belt
1. Undo the intercooler guard to expose the belts.

106
 2. Undo the bolts (1) and (2).

Figure 5.22. Fan belt

3. Tension the belt by inserting a square spanner into the square

and turning in the direction of the arrow until the correct belt
tension is attained.

4. Tighten the bolts (1) and (2).

Generator
1. Undo the bolts (1) and (2).

Figure 5.23. Generator belt

2. Move the generator (3) in the direction of the arrow by turning

the bolt (2) until the belt tension is correct. The maximum tight-
ening torque of 28 Nm at the gear must not be exceeded when
rack tensioning.

3. Tighten the bolts (1) and (2).

107
Coolant and fuel pump
1. Undo the bolts (1) and (2).

Figure 5.24. Fuel pump

2. Press the fuel pump (3) in the direction of the arrow until the
correct belt tension has been attained.

3. Tighten the bolts (1) and (2).

Table 5.2. Belt tensioning

Generator / fan 400 N / Re-tensioning 250 N
Fuel pump, coolant pump 400 N / Re-tensioning 250 N

Changing belt on coolant / fuel pump

Change belts on a stationary engine only.

1. Undo the bolts (1) and (2).

Figure 5.25. Coolant pump

2. Press the fuel pump (3) in the direction of the arrow.

3. Pull off the belt and fit a new one.

108
 4. Press the fuel pump (3) in the opposite direction to the arrow
until the correct belt tension has been attained.

5. Tighten the bolts (1) and (2).

Changing generator belt

1. Undo the bolts (1) and (2).

Figure 5.26. Tensioning generator belt

2. Move the generator (3) in the opposite direction to the arrow by

turning the bolt (2) until the generator goes free.

3. Pull off the belt, fit a new one and tension it.

4. Tighten the bolts (1) and (2).

Valve clearance
1. Detach the ventilation valve and turn it to one side.

2. Remove the valve cover.

3. Adjust the crankshaft according to the adjustment schedule.

4. Allow the engine to cool down for at least 30 minutes before

adjusting the valves. Oil temperature below 80 °C.

109
 5. Check the valve clearance (1) between the rocker arm (2) and
the valve (3) with a feeler gauge (6). It should be possible to
insert the feeler gauge with only slight resistance.

Figure 5.27. Valve adjustment and crankshaft adjustment

6. Adjusting valve clearance

a. Undo the lock nut (4).

b. Adjust the set screw (5) with a screwdriver (7) so that the
valve clearance is correct once the lock nut has been tight-
ened.

7. Check the adjustment on all cylinders

8. Fit the valve cover. Change the gasket if necessary.

9. Turn back the ventilation valve into position and fasten it.

110
Alternating current generator

Safety

WARNING
The method by which the voltage check is measured
to ground must not under any circumstances be
applied to the alternator.
1250 0042 60

Instructions
1. Do not break connections between battery, generator and regu-
lator when the engine is running.

2. If the engine must be started and run without the battery, the
cable between the regulator and generator must be detached
before starting the engine.

3. Do not mix up the battery connections.

4. If the charge lamp is broken, it must be changed immediately.

5. Do not spray water directly on the generator when cleaning the

engine. Warm up the engine to evaporate residual water.

Lifting device
1. Make sure all connections to the engine have been detached.

2. Use only suitable lifting devices when moving the engine.

111
 Figure 5.28. Lifting

Fault finding

1. Problems usually arise due to defective operation and mainte-

nance.

2. Check that all maintenance instructions have been adhered to if

a problem arises.

3. If you cannot determine the cause of a problem, get in touch

with your closest DEUTZ service centre.

Table 5.3. Fault finding table

Symptom
1 Engine difficult to start or does not start at all
2 Engine starts but does not run smoothly and
stops
3 Engine overheats, temperature switch triggers
4 Poor engine performance
5 Engine misfires
6 No (or low) engine oil pressure
7 Excess engine oil consumption
8 Engine produces blue smoke
9 Engine produces white smoke
10 Engine produces black smoke

Check that... 1 2 3 4 5 6 7 8 9 10
the engine is decoupled (if possible) X

112
Check that... 1 2 3 4 5 6 7 8 9 10
the start temperature limit is reached X X
the solenoid is not faulty X X
the oil level is not too low, top up if necessary X X
the oil level is not too high, reduce if necessary X X X X
the pitch of the engine is too great, adjust if necessary X X X
the drive lever is not in the intermediate position, adjust if nec- X
essary
the air filter is dirty, change if necessary X X X
the air filter indicator is not faulty X X X
the smoke limiter is not faulty X X
the boost air outlet does not leak, change if necessary X X X
the coolant water pump is not faulty, clean if necessary X
the intercooler is not dirty, clean if necessary X X
the coolant water heat exchanger is not dirty, clean if necessary X
the cooling fan is not faulty (damaged or without belt), change if X X X X X
necessary
the cooling air is not heated X X
the battery is not faulty (or flat) X
the cable terminal is not loose or oxidized X
the starter motor is not faulty (gear does not engage), adjust if X
necessary
the valve clearance is correct X X X X X
the injector line does not leak, clean or change if necessary X X X X
the air line is not blocked X
the glow plug is not faulty, change if necessary X X
the injector is not faulty, change if necessary X X X X X X X
there is no air in the fuel system X X X
the fuel filter is not dirty X X X X
the oil filter is not faulty, change if necessary X
the correct engine oil grade is used, change if necessary X X X
the correct fuel grade is used, change if necessary X X X X
there are no coolant water problems, top up if necessary X

Deutz instruction manual

Note
Consult the Deutz instruction manual if further information on the
engine is required. The instruction manual can be ordered via
Atlas Copco.

113
6. Transmission

Locations

1
3

2
1250 0112 53

1 Boom shaft
2 Engine shaft
3 Hydraulic transmission
Figure 6.1. Transmission

Technical data

Wheels

M2 rigs
Tyres (boom and engine section) 12.00 x 20 X-mine D2 Miche-
lin
Rims (boom and engine section) 8.00 x 20
Tyre pressure 10bar
Tightening torque, wheel nuts 570Nm

L2 rigs
Tyres (boom and engine section) 14.00 x 20 XKA Michelin or
12.00 x 20 XKA Michelin
Rims (boom and engine section) 8.00 x 20
Tyre pressure 10bar

114
 Tightening torque, wheel nuts 570Nm

Steering
Control valve Danfoss OSBP 800 LS
Gear pump:
Displacement 40.6cm 3 /rev
Max. working pressure 175bar
Steering cylinder 125/63-400
Steering wheel turns, lock-to-lock 6.0 turns from full left lock to
full right lock

Drive shafts
Shaft type M2 rigs Clark Hurth 176/271
Shaft type L2 rigs, boom shaft Clark Hurth 176/273
Shaft type L2 rigs, engine shaft Clark Hurth 176/274
Max. load 15000 kg
Weight 600 kg

Hydraulic transmission
Transmission type Clark 24 000 long drop

Fitting tyres and rims

When fitting tyres and rims, check that:

• the tyre is pumped to the correct pressure.

• contact surfaces between the hub and rim are clean so that the
correct tightening torque can be obtained.
• the wheel nuts are tightened to the correct torque.

Drive shafts

Checking oil level in central gear

1. Make sure the rig is standing level.

115
 2. Unscrew plug (A) and check that the oil level reaches up to the
hole.

A
1250 0020 43

Figure 6.2. Drive shaft centre

3. Top up with oil as necessary. See maintenance instructions

Lubricants, coolants and propellants.

Changing oil in the final drive

Note
Oil changing should be carried out after operating the machine
while the oil is still hot.
1. Unscrew the three plugs (B).

B
B
B
1250 0020 42

Figure 6.3. Changing oil

2. Drain the oil into a receptacle.

116
 3. The oil will drain faster if plug (A) is also unscrewed.

A
1250 0020 43

Figure 6.4. Drive shaft centre

4. Refit the plugs (B) and tighten them.

5. Fill with new oil through the hole for plug (A) until the oil
reaches the hole.

6. Screw in and tighten plug (A).

Checking oil level in hub gear

1. Make sure the rig is standing level.

2. Rotate the wheel so that the two level markings (A) on the hub
are horizontal.

3. Remove screw (B) and check that the oil reaches up to the hole.

Figure 6.5. Hub gear

117
 4. Top up with oil as necessary. See maintenance instructions
Lubricants, coolants and propellants.

Changing oil in hub gear

Note
Oil should be changed after operating the machine while the oil is
still hot.
1. Rotate the hole so that plug (B) reaches its lowest point.

Figure 6.6. Hub gear

2. Unscrew plug (B).

3. Drain the oil into a receptacle.

4. Rotate the wheel so that the two level markings (A) on the hub
are horizontal.

5. Fill with new oil through the hole for plug (B) until the oil
reaches the hole.

6. Screw in and tighten plug (B).

118
Hydraulic transmission

Safety

WARNING
Make sure the engine is switched off during all
maintenance work.
Hot engine parts can cause personal injury.
Take care when draining hot oils/fluids, risk of
.burn injuries.
1250 0022 15

Checking oil level

Note
Allow the oil to reach normal operating temperature (80-95 °C)
before checking the level.
1. Check the oil with the dipstick (A) while the engine is idling,
800-850 rpm.

2. Top up as necessary to the “full” mark on the dipstick through

filler pipe (A). See maintenance instructions Lubricants, cool-
ants and propellants.

A
1250 0020 38

Figure 6.7. Checking oil

119
Changing filter and oil

Note
Allow the oil to reach normal operating temperature (80-95°C)
before replacing the filter and oil.
1. Drain the oil from the transmission housing when it has reached
normal operating temperature by opening the plugs (B). Screw
the plugs back in place.

2. Remove filter (C) and fit a new one in its place.

3. Fill the transmission housing with oil at (A) to the "low" mark
on dipstick (A). See maintenance instructions Lubricants, cool-
ants and propellants.

4. Start the diesel engine and let it idle, 750-800 rpm, to fill up the
torque converter and lines.

5. Check the oil level again with the engine idling and top up to
the "low" mark on the dipstick (A).

6. Check the oil again once it has reached normal operating tem-
perature, 80-95 °C.

7. Fill with oil to the "full" mark on the dipstick.

1250 0020 39 B
Figure 6.8. Changing oil in the transmission

120
Lubricating the chassis

Propeller shafts
1. Pump grease into the grease nipples in the centre (A) of the uni-
versal joints. See maintenance instructions Lubricants, cool-
ants and propellants.

B
A

1250 0112 58

Figure 6.9. Propeller shaft lubrication points

2. Make sure the grease appears.

Central lubrication of chassis

The chassis is equipped with a central lubrication system that
lubricates the engine shaft pendulum suspension, steering links
and articulated joint (B) from one nipple (A).

1. Pump grease into grease nipple (A). See maintenance instruc-

tions Lubricants, coolants and propellants.

2. Make sure grease comes out at all locations (B).

121
 A
B
B

1250 0020 41

Figure 6.10. Central lubrication

Towing

Safety

WARNING
The brakes do not work on the rig.
Connect the carriage beam between the rig and the
carriage before the brakes are released or the propeller
shaft is detached. Otherwise there is a risk that the rig
will begin to roll.
.
.Make sure the carriage and the carriage beam can
withstand the load they are pulling.
1250 0022 26

Before towing
• The carrier cannot be started by towing. An attempt to do so
could seriously damage the hydraulic transmission.
• The carrier should only be towed if absolutely necessary.
• A drawbar must always be used for towing.
• The carrier must never be towed farther than 1 km or at a speed
greater than 5 km/h.
• The brakes must be released and the propeller shafts discon-
nected before towing.

122
 Note
If the diesel engine is not working, the steering cylinder must also
be disconnected hydraulically, see disconnecting the steering cyl-
inder below.

Release the brakes

1. Undo lock nut (A).

2. Screw in bolt (B) until the brake releases. Lock the bolt with the
nut so that it cannot work loose.

3. Release the brakes on all four wheels.

A
B

1250 0042 57

Figure 6.11. Releasing the parking brake

Removing propeller shafts

1. Mark the flanges on the propeller shafts so they can be refitted
in the same way.

2. Remove the bolted joints (B) and remove the propeller shafts.

B
A
1250 0112 58

Figure 6.12. Remove the propeller shaft

123
Disconnecting the steering cylinder
1. Detach both hoses to the steering cylinder.

2. Plug the hoses and protect the cylinder well against dirt, e.g.
with a plastic bag.

Do not plug the unions on the cylinder as oil must be allowed to

run out. Protect them against dirt entering the cylinder and
allow the oil to be collected for disposal in an appropriate way.

After towing

Steps to take
1. Refit the propeller shafts.

2. Connect the hoses to the steering cylinder.

3. Apply the brakes. Undo lock nut (A) and unscrew the bolt until
it protrudes 47 mm.

A
B

47mm
1250 0020 05

Figure 6.13. Setting the brake screw.

4. Remove the drawbar between the chassis and the towing vehi-
cle.

5. Check the brakes after towing. See maintenance instructions

Brake system: Checking service brake pressure.

124
7. Brake system

Safety

WARNING
Risk of hydraulic pressure.

Can cause personal injury.

Make sure the system is made pressure-free before any

.work commences. To ensure the system is pressure-free,
.
press the brake pedal down 30-40 times after the system
has been switched off.
1250 0022 21

General

1
3

2
1250 0112 53

1 Boom shaft
2 Engine shaft
3 Hydraulic transmission
Figure 7.1. Transmission

125
Technical data

Brake system

Service brakes
System Dual independent circuits.
Hydraulic disc brakes in oil
bath on all wheels.
Hydraulic pressure 80 +5/-0 bar

Parking/emergency brake
System SAHR (Spring Applied
Hydraulic Released)
Max. hydraulic pressure 35 bar

Checking brake pressure

Service brake pressure

1. Connect a pressure gauge to the brake system test outlet (A) on
the axle.

A
1250 0020 21

Figure 7.2. Checking service brake pressure

2. Start the diesel engine.

3. Depress the brake pedal and read the pressure shown on the
pressure gauge. The pressure must be 80 +5/-0 bar.

The pressure is factory set and cannot be adjusted.

126
 4. Stop the diesel engine and disconnect the pressure gauge from
the pressure test outlet.

5. Check the service brake pressure on the boom and engine axles.

Parking brake pressure

1. Connect a pressure gauge to the brake system pressure test out-
let (B).

1250 0020 22

Figure 7.3. Checking parking brake pressure

2. Start the diesel engine.

3. Release the parking brake while reading off the pressure on the
pressure gauge. The pressure should be 35 bar. The pressure can
be adjusted on the pressure regulator (13) under the control plat-
form.

13

1250 0061 56
7

Figure 7.4. Regulating parking brake pressure

4. Stop the diesel engine and disconnect the pressure gauge from
the pressure test outlet.

127
Bleeding the brakes
N.B.
The fluid in the brake system must not contain any air if the
brakes are to attain full effect. Make sure the rig is standing on a
level surface with the wheels chocked.

1. Attach plastic hoses to the nipples (C).

C
1250 0020 23

Figure 7.5. Bleeding the brakes

2. Start the diesel engine.

3. Open the nipples (C) about half a turn.

4. Fully depress the brake pedal (do not pump).

5. Tighten the nipples when there is no air in the fluid.

6. Turn off the diesel engine and remove the plastic hoses.

Checking brake discs

The brakes must be applied when checking brake disc wear. The
discs can be checked in connection with changing oil in the final
gear.

1. Undo the level plugs on the final drive, two for each brake.

128
 2. Check the distance between the brake discs. Check the distance
from both level plugs. Use a drift or similar tool with diameter
4.5 mm.

1250 0021 36

min 4,5 mm

Figure 7.6. Checking brake disc wear

3. If the distance between the discs is less than 4.5 mm, they must
be changed. A new disc is 4.9 mm thick

Adjusting the brakes

N.B.
Make sure the rig is standing on a level surface and supported on
its jacks.

1. Start the diesel engine and release the parking brake.

2. Undo bolt (A) and remove the lock plate (B) on both sides of
the shaft and from both the boom and engine shaft.

C B

+
-

1250 0020 24

Figure 7.7. Adjusting the brakes

129
 3. First screw the adjusting screw (C) anticlockwise to take up any
play. Continue to turn anticlockwise until a torque of 40 Nm is
attained.

4. Then screw the adjusting screw (C) clockwise three turns.

5. Refit the lock plates (B) and the bolts (A).

Function check, parking brake

N.B.
This test must not be performed for longer than four (4) seconds
as there is a risk of overheating the hydraulic system.

1. Make sure the parking brakes are applied.

2. Start the diesel engine and engage 2nd gear.

3. Increase the diesel engine speed to max.

4. Check to see if the rig moves. If the rig moves, the brakes must
be adjusted immediately.

Note
The parking brake is applied if the oil pressure in the engine or
hydraulic transmission drops too much. This will also be indicated
by the warning lamps on the operator panel.

Function check, service brakes

N.B.
This test must not be performed for longer than four (4) seconds
as there is a risk of overheating the hydraulic system.

1. Start the diesel engine.

2. Depress the brake pedal and hold it down.

3. Release the parking brake.

4. Engage 2nd gear.

5. Gradually increase the speed of the diesel engine to max.

6. Check to see if the rig moves. If the rig moves, the brakes must
be adjusted immediately.

130
Checking accumulator charge pressure

WARNING
Dangerous hydraulic oil pressure

Can cause personal injury.

Even when the engine is still, there is an accumulated

pressure in the brake circuit of up to 150 bar. If the
system is opened without being unloaded, oil will spray
out at high pressure.
1250 0022 28

1. Connect a pressure gauge to the pressure test outlet at (DS2).

DS2

1250 0061 55

Figure 7.8. Checking service brakes

2. Depressurise the system by depressing the brake pedal 30-40

times.

3. Disconnect fuse F112 in fuse box (A50) and crank the starter
motor. The pressure gauge will indicate a rapid increase in pres-
sure to the lowest pressure with which an accumulator is
charged.

4. The pressure will subsequently rise very slowly. The accumula-

tors are charged to 60-70 bar.

5. An accumulator with charge pressure lower than 35 bar is faulty

and must be changed.

6. For identifying which accumulator to change, see section

Checking the accumulators.

131
Checking brake pressure control valve
1. Connect a pressure gauge to the pressure test outlet at DS2.

DS2

1250 0061 55

Figure 7.9. Checking brake pressure control valve

2. Start the engine and let it run until max. brake pressure is
attained.

3. Stop the diesel engine and brake repeatedly. The "low brake
pressure" lamp should come on when the pressure has dropped
to 110 bar.

4. Start the diesel engine and brake repeatedly with the engine
idling. When the pressure has dropped to 125 bar, the brake sys-
tem control valve should engage so the pressure rises again to
max. for the brake system, 150 bar.

5. Stop the engine when max pressure is attained.

6. Brake hard four times, i.e. depress the pedal fully and release
completely each time. If the brake pressure drops below 90 bar
after braking hard four times, there is a fault in the brake sys-
tem. This can be caused by:

a. air in the brake lines.

b. there is no charge pressure in an accumulator or the pressure

is too low, e.g. due to a broken diaphragm, see section
Checking accumulator charge pressure.

7. Continue to brake hard until the pressure drops below 80 bar

and the parking brake is applied.

8. For identifying uncharged accumulators, see section Checking

the accumulators.

132
Checking the accumulators
After detecting that there is no charge pressure in one or more
accumulators or the pressure is too low, each accumulator can be
checked individually in a depressurised system as follows.

N.B.
Note that the system may still be pressurized even when the brake
pressure gauge (where fitted) indicates zero pressure.
Thorough cleanliness must be observed during all work on the
brake system. Clean all relevant contact points before starting
work. Protect hoses and unions with plugs and caps as they are
detached.

1. Stop the engine.

2. Depress the brake pedal repeatedly (30-40 times) until the fluid
stops flowing through the brake valve. This can be noticed
when the hissing sound heard when the brake pedal is depressed
ceases.

3. Connect a pressure gauge to the pressure test outlet in the accu-

mulator circuit being checked. All the accumulators must be
checked individually. Watch out for any pressure remaining in
the brake system.

1250 0061 54

Figure 7.10. Measuring points in accumulator circuit

4. Carefully remove the connecting hoses on the accumulator

block and plug them in all the accumulator circuits except the
one being checked first.

5. Disconnect fuse F112 in fuse box (A50) and crank the starter
motor. The pressure gauge at pressure test outlet (11) will first
show a rapid increase in pressure to the pressure the accumula-
tor is charged with. This pressure should be at least 35 bar. If

133
 this charge pressure is not attained, the accumulator must
be scrapped and replaced with a sound one. See section
Scrapping an accumulator. The system must then be depressu-
rised before any measures are taken, after which it must be
rechecked.

6. Disconnect the tested accumulator and connect the next accu-

mulator to be checked. Repeat steps 4-6 and so on.

7. Start the engine and let it run at high speed until full brake pres-
sure is attained.

8. Reduce engine speed to idling. Bleed the brake system, see sec-
tion Bleeding the brakes.

Scrapping an accumulator

WARNING
Accumulators that are to be scrapped must be
rendered harmless.
A scrapped accumulator which is not punctured
should be handled like a pressure vessel.
Take care when draining the accumulator.
1250 0045 79

1. An accumulator can be scrapped by unscrewing the protective

cap at the top.

134
2. Then, carefully unscrew the plug (P) with a hex key wrench,
one turn at a time, to release any pressure.

1250 0020 26

Figure 7.11. Scrapping an accumulator

135
8. Control system

RCS
The RCS (Rig Control System) is a control system that controls
and monitors drilling functions and other functions on the rig. The
control system is based on the CAN (Controller Area Network)
technique.

The following figure shows an example of what a control system

could look like. The number of electronic modules varies from one
rig to another, depending on how many booms the rig has and the
options with which it is equipped.

D121 D100 D200 D221

CAN 2 CAN 2

CAN 1

D120 D220
D551

D506
D103 D203 D250
D150
CAN 1

D102 D202
D501 D503

D500 D502
D101 D201
CAN 1

D550 D552

D510 D511
1250 0094 14 D520

Figure 8.1. System overview, 2-boom rig

• Operator panel 1: D500, D501

• Operator panel 2: D502, D503 (option)
• Application modules: D100, D200 and D506
• Fuse boxes: D150, D250, D550, D551 and D552
• Rig module (I/O module): D510 (D513 on diesel hydraulic rigs)
• Boom modules (I/O modules): D101, D102, D201 and D202
• RAS modules (I/O modules): D103 and D203 (option)
• Resolver modules: D120, D121, D220 and D221 (option)
• Platform modules (I/O modules): D511 (option)
• Control panel, service platform: D520 (option)

136
 The operator panel (the rig can have more than one operator pan-
els) is the main computer that distributs all the information to the
application modules. The application modules process and regu-
late iformation from the operator panel, I/O modules and resolver
modules and distributes the relevant information to the I/O mod-
ules. The I/O modules distribute the relevant signals to the respec-
tive valves to obtain the correct motion or function, at the same
time as they receive information from the various system sensors,
such as the pressure and flow sensors. The resolver modules are
fitted only if the rig has ABC Basic, ABC Regular, ABC Total or
RAS and are used to convert information from angle and length
sensors in the booms so that it can be processed by the application
modules. See also location on the rig in maintenance instruction
Component locations.

Logging in

Note
The service menus in these instructions are intended for service
personnel who have completed Atlas Copco's control system train-
ing programme. Incorrect handling could result in system malfunc-
tion.
A user code issued only to authorised service personnel is required
to access the service menus. Select the user box in the main menu
and press Enter.

A box will then appear in which you state your authorization code
and confirm it by pressing Enter. The message "User valid" is
shown. Then press the Escape key.

Note
If the code is not entered correctly the message “User unknown”
will be shown instead.

137
 Figure 8.2. Main menu and code input box

Menu overview

Menu structure
The control system comprises a number of different menus for set-
ting parameters, diagnostics, etc. The following illustration and
table show the structure of the control system menus. Several of
the menus deal with standard functions found on all rigs while oth-
ers are connected to an option and are therefore only found on rigs
that have that particular equipment.

The direct selection menus are menus associated with a button on

the operator panel. By pressing one of these buttons you can jump
straight to the associated menu, irrespective of where you are in
the menu structure.

For information on direct selection menus, see operator's instruc-

tions Control system.

138
Menus, basic system and options
Main menu

1 2 3 4 5 6 7 8 9

1.1 2.1 3.1 4.1 6.1 7.1 8.1 9.1

1.2 2.2 3.1.1 4.2 6.2 7.2 8.2 9.2
1.2.1 3.1.2 4.3 6.3 7.3 8.3 9.3

1.3 3.1.3 7.4 8.4 9.4

1.4 3.1.4 7.5 8.4.1
1.5 3.1.5 8.4.2
1.7 3.1.6
3.1.9
3.1.11
3.2
3.3
1250 0093 91
3.4

Figure 8.3. Menu structure

Table 8.1. Menus, basic system and options

1 Fault finding 2 Boom 3 Drilling
1.1 Modules 2.1 Parameters 3.1 Parameters
1.2 Levers 2.2 Actuations 3.1.1 Feed, flow
1.2.1 Lever calibration 3.1.2 Feed, pressure
1.3 Guards 3.1.3 Percussion
1.4 Event log 3.1.4 Rotation
1.5 Configuration 3.1.5 Times
1.7 Other guards (option) 3.1.6 Other
3.1.9 Return pressure (COP 1432
only)
3.1.11 BMHT (telescope feeder)
3.2 Sensors
3.3 Actuations
3.4 Lubricating oil
4 Rig 5 Administration 6 Service platform (option)
4.1 Parameters 6.1 Parameters
4.2 Sensors 6.2 Lever
4.3 Actuations 6.3 Actuations

139
7 RAS (option) 8a Angle indication (option) 9 Auto (option)
7.1 Parameters 8b Contour control (option) 9.1 Anchoring
7.2 Actuations 8a.1 Sensors 9.2 Positioning
7.3 Cradle positions 8b.1 Parameters 9.3 Sensors
7.4 Position sensors 8b.2 Position sensors 9.4 Actuations
7.5 Other sensors 8b.3 Sensors
8b.4 Calibration
8b.4.1 Laser calibration
8b.4.2 Other calibration

Settings

General
In general all settings are made separately for each boom (if the rig
has more than one boom). Accordingly, the menus have an options
list from which you can choose a boom (Boom 1, Boom 2, etc.).
The options list is denoted by a boom icon.

If a parameter is not boom specific but applies to all booms or to

the entire rig, there will be a rig icon by this parameter.

The speed of the hydraulic cylinders is set separately for each cyl-
inder. These menus have an options list from which you can
choose the desired cylinder (Boom telescope, feeder extension,
etc.). The options list is denoted by a cylinder icon.

Pressure and flow settings for drilling are divided between a

number of menus. Many of these setting can be made specifically
for various types of drill bit (Button bit, Cross bit and Reaming
bit). The parameters that can be set dependent on the type of drill
bit are denoted by a drill bit icon. The menus include an options
list for selecting the type of drill bit.

On rigs with twin service platforms, certain settings can be made

independently for each platform. These menus include an options
list from which the platform can be chosen (Service platform 1 or
Service platform 2). The options list is denoted by a platform icon.

The following icons can appear in the menus indicating whether

information and settings apply to the entire rig or whether they are
specific to certain parts.

140
 Table 8.2. Symbols
Symbol Explanation
Boom. This icon indicates that the information shown
only applies to one of the rig's booms. The boom icon is
linked to an options list from which the desired boom can
be selected.
Drill bit. This icon is shown beside various parameters to
indicate that these are drill-bit specific. The icon is linked
to an options list from which the desired type of drill bit
can be selected.
Rig. This icon is shown beside various parameters indi-
cating that these apply to the entire rig and cannot be set
individually for each boom, for example.

Cylinder. Cylinder settings (boom and service platform)

are made individually for each cylinder. The cylinder icon
is linked to an options list from which the desired cylinder
can be selected.

Service platform. This icon indicates that the information

displayed only applies to one of the rig's service plat-
forms. The icon is linked to an options list from which the
desired service platform can be selected.

Numerical values
Many settings are made by changing a numerical value, e.g. setting
the date and time on the Administration menu.

Figure 8.4. Date and time on the Administration menu

1. Move the cursor to the current numerical value using the cursor
keys. The entire value will be highlighted.

2. Press ENTER. One individual number will now be highlighted

in another colour.

3. Increase the value with the up-arrow key and lower the value
with the down-arrow key.

In certain cases the numerical value may have several digits. In

such cases, change one digit at a time. Use the left and right
arrow keys to move the cursor to the desired digit.

4. Confirm the changed numerical value by pressing Enter.

141
On / Off
Certain menus contain “On” / “Off” values. In the following exam-
ple the parameter is set to “Off” and we wish to change this to
“On”.

1. Move the cursor to the value “Off” using the cursor keys and
press ENTER.

A list with two alternatives - “On” and “Off” - is displayed.

Figure 8.5. On / Off setting

2. Highlight “On” using the cursor keys and press ENTER.

The setting is now changed to “On”.

142
Administration

Administration menu

Figure 8.6. Administration menu

Save and retrieve parameters

“Save parameters” is used when all settings have been made and
you want to save a safety copy on a PC card.

Before you can save information on an empty PC card it must be

formatted in a PC. Formatting must be what is known as “full-for-
matting”.

“Retrieve parameters” is used when you want to load parameters

into the control system from a PC card.

If the system has more than one operator panel, operator panel 1
(D500-D501) must always be used when retrieving/saving infor-
mation from/to PC cards.

1. Insert the PC card into the front slot (1) of the card reader.

2. Toggle with the cursor keys to “Save parameters” or “Retrieve

parameters” and press ENTER.

A text box will appear on the screen and when the operation is
complete “OK” will be displayed.
3. Extract the PC card by pressing the button to the left of the card
in the card reader (3).

143
 3

2
1250 0046 29 1
Figure 8.7. PC card reader

Allocation time
If you do not press any buttons or move any levers within a certain
space of time (allocation time), the operator panel will be deacti-
vated. To reactivate the panel, press one of the pump start and
boom selection buttons on the left button unit.

1250 0094 17

Figure 8.8. Pump start and boom selection button

Date and time

The date and time may need to be set on a new rig or if new soft-
ware has been loaded.

144
Sensors

Sensors menu (Drilling)

Figure 8.9. Sensors menu (Drilling)

Lubrication oil menu

Figure 8.10. Lubrication oil menu

145
Sensors menu (Rig)

Figure 8.11. Sensors menu (Rig)

Calibration of pressure sensor

The sensor menus are used for sensor calibration. If a sensor is
changed, the new sensor must be calibrated. The sensor menus are
most often called Sensors and can be found under the respective
area in the menu structure (Drilling, Rig, etc.) One exception is the
Lubrication oil menu which lies under Drilling. See also section
Menu overview.

1. Make sure the relevant system is depressurized.

2. Set the coefficient for the sensor in question to 100 and the off-
set to 0.

3. Read off the value from the sensor in question. If, for example,
the value is 17.0 bar, the offset should be set to 170. (Measured
value x 10 = offset)

4. Connect a pressure gauge to the sensor in question.

5. Start the pump and pressurise the sensor.

6. The sensor value on the display should agree with the pressure
reading from the pressure gauge. Calibrate the sensor value by
adjusting the coefficient.

146
Calibrating flow sensor B250
Flow sensor B250 is only found on rigs with the Measure While
Drilling (MWD) option.

1. Make sure the relevant system is depressurized.

2. Set the coefficient for the sensor in question to 100 and the off-
set to 0.

3. Read off the value from the sensor in question. If, for example,
the value is 17.0 l/min, the offset should be set to 170. (Meas-
ured value x 10 = offset)

4. Check the offset by reducing it slightly. The sensor value should

then increase 0.1 - 0.3 bar.

5. Start the pump and move the drilling lever to the left to start
auto rotation.

6. The sensor value on the display should agree with the flow
reading from the flow gauge. Calibrate the sensor value by
adjusting the coefficient.

Calibrating flow sensor B252

Flow sensor B252 is only found on rigs with the Measure While
Drilling (MWD) option.

1. Make sure the relevant system is depressurized.

2. Set the coefficient for the sensor in question to 100 and the off-
set to 0.

3. Read off the value from the sensor in question. If, for example,
the value is 17.0 l/min, the offset should be set to 170. (Meas-
ured value x 10 = offset)

4. Check the offset by reducing it slightly. The sensor value should

then increase 0.1 - 0.3 bar.

5. Start the pump.

6. Measure the speed of the adapter with a tachometer.

7. The sensor value on the display should agree with the tachome-
ter reading. Calibrate the sensor value by adjusting the coeffi-
cient.

147
Actuations

Actuation menus
Use the actuation menus to actuate manually a certain function or
to test a certain function during troubleshooting. The actuation
menus are called Actuations and can be found under each area
(Drilling, Rig, etc.).

Actuations menu (Boom)

Figure 8.12. Actuations menu (Boom)

148
Actuations menu (Drilling)

Figure 8.13. Actuations menu (Drilling)

Actuations menu (Rig)

Figure 8.14. Actuations menu (Rig)

149
Actuations menu (Service platform)

Figure 8.15. Actuations menu (Service platform)

Actuation of desired value

1. Highlight the desired function using the cursor keys and press
ENTER.

2. Specify the desired actuation value. The value may be in milli-

amps (mA) or “On” or “Off”.

3. Check the box “Actuate desired value”. Press and hold ENTER.
The desired value is now actuated as long as ENTER is held
depressed.

The actuated value is shown in the “Actuated value” column.

Functions that are actuated with “Off” or ”On” are given the
values 0 or 1 respectively.

150
Parameters

Lubricating oil

Lubrication oil menu

Figure 8.16. Lubrication oil menu

Min air pressure

“Min air pressure” specifies the lowest air pressure permitted for
the drilling machine lubrication.

Min oil pressure

“Min oil pressure” specifies the lowest oil pressure allowed for the
drilling machine lubricating oil. A lower pressure can indicate that
the pump is out of order.

Max oil pressure

“Max oil pressure” is the highest pressure allowed for the drilling
machine lubricating oil. A higher pressure can indicate that the
drilling machine lubricating oil hose is blocked.

Time before measurement

“Time before measurement” is the frequency for measuring the air
pressure and oil pressure.

151
Time before alarm / Time before drill stop
“Time before alarm” specifies how long drilling can continue after
drilling machine lubrication has ceased to work. Once this time is
reached, an error message (alarm) is displayed.

“Time before drill stop” specifies how long drilling can continue
after drilling machine lubrication has ceased to work. When this
time is reached, drilling is automatically stopped. This parameter
only exists if the rig has a Lubrication Warning Kit and replaces
“Time before alarm”.

Boom

Parameters menu (Boom)

Figure 8.17. Parameters menu (Boom)

Rigs with hydraulic parallel holding

In the Parameters (Boom) menu, you can set boom cylinder
speed. The “Left back” and “Right back” cylinders are for parallel
holding, i.e. when the rear and front cylinders and engaged. “Left
front” and “Right front” cylinders are used for when the anti-paral-
lel button is depressed, i.e. the front cylinders are engaged.

When setting the velocity of the cylinders the hydraulic oil should
have reached normal operating temperature (40-50° C).

First, select the desired boom and cylinder from the options list at
the top right-hand corner of the menu.

152
 “Lowest valve current” is the opening value required for the cylin-
der to start to move and is usually around 320 mA. The “Highest
valve current” determines the maximum speed of the cylinder. The
basic setting for “Highest valve current” is 600 mA. The lowest
and highest valve currents must be set for both directions (“Cylin-
der in” = piston rod side, and “Cylinder out” = piston side).

“Speed”, “Reference speed” and “Actuation” parameters and the

“Calibration aid” box are only found on rigs with electronic paral-
lel holding.

Rigs with electronic parallel holding

When setting the velocity of the cylinders the hydraulic oil should
have reached normal operating temperature (40-50° C).

The calibration aid on the menu can be activated if the hydraulic

pump for the boom in question is running.

1. Position the boom so that it is pointing straight ahead.

2. Position the rotation unit so that the shaft is vertical.

3. Select the desired boom and cylinder from the options list at the
top right-hand corner of the menu.

4. Activate the calibration aid.

5. Always start by setting “Lowest valve current”, i.e. the smallest

possible lever movement to run the cylinder.

Read off the lowest valve current required for the cylinder to
move from “Actuation” at the bottom of the menu. Enter this
value as the “Lowest valve current”.
6. Set the “Highest valve current” by running the cylinder at full
lever movement.

Compare the cylinder speed (“Speed” parameter) with the “Ref-

erence speed”. Adjust the “Highest valve current” so that cylin-
der speed is as close as possible to reference speed.

The maximum valve for the “Highest valve current “ is 600

mA.

7. Repeat the procedure for all cylinders and in both directions

(“Cylinder in” = piston rod side of cylinder, and “Cylinder out”
= piston side of cylinder).

8. Activate the calibration aid.

153
Feed, flow

Feed, flow menu

Figure 8.18. Feed, flow menu

Feed speed, manual collaring

“Feed speed, manual collaring” is the highest feed speed desired in
the collaring phase. The value of “Feed speed, manual collaring”
must always be greater than “Lowest feed speed”.

Feed speed, automatic collaring

“Feed speed, automatic collaring” is the speed desired after a drill
jam or if rock contact is lost.

Feed speed collaring locked

“Feed speed collaring locked” (button 29 on operator panel
depressed) is the feed pressure desired for collaring.

Feed speed, drilling

“Feed speed, drilling” must be set to 600 mA.

154
Lowest feed speed
“Lowest feed speed” is the actuation value required for the drilling
machine cradle to move. If the actuation value is too low, it will be
necessary to move the lever a long way before feed is activated,
and too high a value can produce creep. It is important to find an
actuation value where percussion starts before feeding.

Highest feed speed

“Highest feed speed (forward/reverse feed)” is to be set to 600
mA.

Feed speed, return

Set “Feed speed, return” (feed backward) to 600 mA.

Feed pressure

Feed, pressure menu

Figure 8.19. Feed, pressure menu

Feed pressure, collaring

It is suitable to adjust “Feed pressure collaring (after rock contact)”
during collaring.

1. Lock collaring by depressing the button for locked collaring on

the operator panel.

155
 2. Set the pressure between 30 - 50 bar, depending on the type of
feeder, drill bit diameter, etc.

Feed pressure, drilling

It is suitable to adjust “Feed pressure, drilling” during drilling.

1. Check that the locked collaring function is not activated. The

LED on the locked collaring button should not be on.

2. Set the pressure to between 65 - 100 bar depending on the type

of feeder, drill bit diameter, percussion pressure, etc.

Normally it is only necessary to adjust the pressure if there are

large variations in the rock.

Pressure for rock contact sensor

The control system senses the feed pressure and determines when
the system is to use automatic drilling. The rock contact sensor
pressure should be 5-10 bar lower than collaring feed pressure or
the system will be unable to use automatic drilling (drilling feed
pressure, drilling percussion pressure) and will remain in collaring
drilling mode (collaring feed pressure, collaring percussion pres-
sure).

Highest feed pressure

“Highest feed pressure” depends on the type of feeder:

• Feeder BMH 6000 = 85 bar

1. Set the correct feed pressure (85 bar).

2. Place a sturdy plank in the feed beam between the front drill-
steel support and the intermediate drill-steel support.

3. Switch to the Drilling operator menu with the F1 key.

4. Run the drilling machine towards the plank and hold the lever
in that position.

5. Read the pressure from the feed pressure gauge on the operator
menu.

If the pressure reading differs from the set value (85 bar), check
that the feed pressure sensor (B133) is in working order and
correctly calibrated.

Feed pressure, return

1. Run the drilling machine to its rear end position with the drill-
ing lever and hold the lever in this position.

156
 2. Switch to the Drilling operator menu with the F1 key.

3. Read the pressure from the feed pressure gauge on the operator
menu. The pressure must be 180 - 200 bar.

If this pressure differs from the set value (180 - 200 bar), check
that the feed pressure sensor (B133) is functioning properly and
is correctly calibrated.

Valve current for collaring feed pressure

“Valve current for collaring feed pressure” is the feed current
required to produce the same pressure as for “Feed pressure, col-
laring”. In this case, rock contact has not yet been made.

Min valve current

“Min valve current” must be lower than “Feed pressure, collaring”
but must not be so low that feed ceases.

Max valve current

Set “Max valve current” so that “Highest feed pressure” can be
obtained.

Percussion

Percussion menu

Figure 8.20. Percussion menu

157
Percussion pressure, collaring
It is suitable to adjust the pressure during collaring.

1. Lock collaring by depressing the button for locked collaring on

the operator panel.

2. Switch to the Drilling operator menu with the F1 key.

3. Check the pressure on the percussion pressure gauge on the

operator menu. “Percussion pressure, collaring” should be 130
bar.

If the pressure gauge reading differs from the set value (130
bar), check that the percussion pressure sensor (B100) is work-
ing properly and is correctly calibrated.

Percussion pressure, drilling

The pressure is best adjusted during drilling.

1. Check that the locked collaring function is not activated. The

LED on the locked collaring button should not be on.

2. Switch to the Drilling operator menu with the F1 key.

3. Check the percussion pressure on the pressure gauge in the

operator's menu. The “Percussion pressure, drilling” depends
on the rock drill model as follows.

• COP 1838 ME: 180-210 bar

• COP 1838 HF: 230-250 bar
If the pressure gauge on the operator menu differs from the set
value, check that the percussion pressure sensor (B100) is func-
tioning properly and is correctly calibrated.

Limit, percussion pressure (FPCI)

“Limit, percussion pressure (FPCI)” is the feed pressure that must
be reached for percussion to switch from “Percussion pressure,
collaring” to “Percussion pressure, drilling” or vice versa. (FPCI =
Feed Pressure Controlled Impact.) A suitable setting is between 50
- 65 bar, depending on the type of feeder, drill bit diameter, etc.

Percussion pressure button

The operator panel has a button to start percussion and water flush-
ing for undoing drill bits or drill steel. “Percussion-pressure but-
ton” is the percussion pressure needed when the button is
activated. A suitable value is 10 bar above “Percussion pressure,
drilling”.

158
Rotation

Rotation menu

Figure 8.21. Rotation menu

Rotation speed LEFT

1. Start the pump and depress the button on the operator panel for
water flushing off.

2. Move the drilling lever to the left (rotation drilling) and hold the
lever in this position until the automation cuts in.

3. Measure the rotation speed and if necessary adjust. The speed is

dependent of drill bit diameter and drill bit type.

The higher the value (mA) the higher the speed.

Recommended rotation speed:

• COP 1838 HF 02 = 120-450 rpm

• COP 1838 ME 05 = 120-370 rpm
• COP 1838 HF 05 = 120-330 rpm
• COP 1838 HF 06 = 120-280 rpm
• COP 1838 ME 07 = 120-230 rpm
• COP 1838 HF 07 = 120-225 rpm
4. Halt rotation by pressing the drilling lever rocker switch.

5. Stop the pump.

159
Rotation speed RIGHT
1. Start the pump and depress the button on the operator panel for
water flushing off.

2. Move the drilling lever to the right (unthreading rotation) and

measure the rotation speed.

3. Adjust the desired rpm (150-160 rpm).

The higher the value (mA) the higher the speed.

4. Halt rotation by moving the drilling lever to the neutral posi-
tion.

5. Stop the pump.

Rotation pressure, drilling (RPCF) and Activation pressure, anti-jamming

The idling rotation pressure, i.e. the pressure attained when the
drilling lever is moved straight left, is used as a starting point for
all rotation pressure parameters. The control system constantly
monitors this pressure, which varies depending on the temperature
of the hydraulic oil, for example. For the anti-jamming and Rota-
tion Pressure Controlled Feed (RPCF) functions to follow the vari-
ations in idling rotation, pressure-variable values rather than fixed
values are set. Otherwise the RPCF function (or anti-jamming pro-
tection) could be activated due to low hydraulic oil temperature.

The idling rotation pressure can be read from the Drilling opera-
tor menu (“Input rota pressure”).

If the drill bit tends to jam in the borehole or if the rotation pres-
sure increases due to poor flushing of the borehole, a worn or dam-
aged drill bit, or the like, RPCF will reduce the feed force
gradually to “Feed pressure, collaring”. Percussion pressure will
also change over from “Percussion pressure, drilling” to “Percus-
sion pressure, collaring”. If the rotation pressure continues to rise,
the anti-jamming protection will eventually change the feed direc-
tion from forward to reverse to prevent jamming.

The RPCF function is activated when the rotation pressure =

“Idling rotation pressure” + “Rotation pressure, drilling (RPCF)”.

The anti-jamming protection is activated when the rotation pres-

sure = “Idling rotation pressure” + “Rotation pressure, drilling
(RPCF)” + “Activation pressure, anti-jamming”.

Example:

• Idling rotation pressure = 30 bar

• Rotation pressure, drilling (RPCF) = 25 bar
• Activation pressure, anti-jamming = 15 bar

160
 In this case, the anti-jamming protection would change the direc-
tion of feed from forward to reverse when the rotation pressure
rises to 30+25+15=70 bar.

The RPCF function, in this same example, would modulate the

feed pressure from the rotation pressure reaching 30+25=55 bar
and up to 70 bar, from which the anti-jamming function takes over.

The “Rotation pressure, drilling (RPCF)” and “Activation pres-

sure, anti-jamming” parameters are best set during drilling by stud-
ying the rotation pressure and feed pressure on the pressure gauge
on the Drilling operator menu.

• If the rotation pressure is lower than “Idling rotation pressure”

+ “Rotation pressure, drilling (RPCF)”, the feed pressure will
be that set for “Feed pressure, drilling”.
• If the rotation pressure is greater than “Idling rotation pressure”
+ “Rotation pressure, drilling (RPCF)”, the feed pressure will
be that set for “Feed pressure, collaring”.

Max rotation pressure, anti-jamming

“Max rotation pressure, anti-jamming” is the greatest permitted
rotation pressure before the anti-jamming protection is activated.
This pressure should be 110 bar.

Resume pressure, after anti-jamming

Once the anti-jamming function has been activated and the drilling
machine backed off, the rotation pressure must sink by a certain
amount before the drilling machine returns to drilling. This pres-
sure drop, “Resume pressure, after anti-jamming”, is set here.

161
Times

Times menu

Figure 8.22. Times menu

Collaring time
“Collaring time” is the desired duration for collaring before
switching to full drilling once the drilling lever has been moved to
the automatic position. The recommended collaring time is 3000-
5000 ms.

Percussion time, bit cleaning

“Percussion time, bit cleaning” is the time that percussion should
be operative for automatic cleaning of blocked drill bits.

162
Other

Other menu

Figure 8.23. Other menu

Pressure gauge filter constant

Set the inertia (sensitivity) of the drill pressure gauges in the Drill-
ing operator menu. Low filter constant gives stable and slow
movement of the pressure gauges. High filter constant gives fast
movement of the pressure gauges.

Lowest water pressure

“Lowest water pressure” is the lowest input water pressure to the
rig that is required to prevent damage to the water pump.

Frequency, lubrication
Setting for the number of pulses per minute for the drilling
machine's lubrication pump.

Auto return
Select here whether or not the drilling machine will return auto-
matically.

163
Flush distance from hole bottom
The “Flush distance from hole bottom” parameter is only used on
ABC Total rigs and is the distance that the cradle should back off
before water or air flushing is turned off, measured from the speci-
fied hole depth.

Extended collaring time

The “Extended collaring time” parameter is only used on ABC
Total rigs and is the time during which you wish collaring settings
to remain. (Collaring before rock contact.) This can be set between
0 and 10 seconds. 0 means that the function is switched off.

Increase of damper press. for rock contact

When drilling with ABC Total (automatic drilling) the control sys-
tem records the idling damper pressure for every hole. When
damper pressure rises to the preset value it is assumed that rock
contact has been made. The pressure should be 3-5 bar. If rock
contact is not obtained the system will not start regulating feeder
and percussion pressure.

Telescope feeder

BMHT Menu

Figure 8.24. BMHT Menu

164
Feed pressure
“Increase, feed pressure” is the extra pressure applied directly for
the telescope feeder's lower feed beam while drilling, i.e. “Feed
pressure, drilling” + this pressure.

“Max increase, feed pressure” is the additional pressure that can be

applied to the lower beam if it is required to maintain the correct
rotation pressure.

Counter pressure, COP 1432

Counter pressure menu (drilling machine COP 1432)

Figure 8.25. Counter pressure menu

Regulation of counterpressure
There are two alternatives for controlling percussion counter pres-
sure, with or without regulation.

• If “Regulation of counterpressure” is deactivated (Off), a fixed

current (“Min valve current, counter pressure”) will be applied
to the restrictor valve. Consequently, this alternative provides
reaction regulation of the counter pressure.
• If “Regulation of counterpressure” is activated (On), the restric-
tor valve will be regulated to attain the desired value that has
been set for the counter pressure.

Counter pressure
If regulation of counter pressure has been selected (see above), the
desired value of this pressure must also be specified.

165
 The desired value of the percussion counter pressure can be set
between 6 and 20 bar. The counter pressure determines the percus-
sion rate, lower counter pressure gives higher percussion rate and
higher drill rate. A low counter pressure, however, will increase
the drilling machine flow requirement.

Min valve current counter pressure

The current applied to the restrictor valve if regulation of counter
pressure has been deactivated.

Rig

Parameters menu (Rig)

Figure 8.26. Parameters menu (Rig)

Min air pressure load

The air pressure at which the compressor should start to run
(deliver air).

Max air pressure load

The air pressure that the compressor should reach before switching
off (stop delivering air).

166
Oil temperature, cooler
When the hydraulic oil pressure rises to the preset value (50 °C),
the water valve (Y174 or Y 113) will be activated. Water will then
circulate through the hydraulic oil cooler.

Oil temperature, alarm

When hydraulic oil temperature rises to the preset value (60 °C),
the operator is alerted by a message on the display.

Oil temperature, pump stop

When hydraulic oil temperature rises to the preset value (70 °C),
the electric motors will be switched off and a message will appear
on the display.

Service platform

Parameters menu (Service platform)

Figure 8.27. Parameters menu (Service platform)

Cylinder speed
You can set the speed of the service platform cylinders on the
Parameters (Service platform) menu. Cylinder “Left back”,
“Right back” and “Parallel tip” are used for running the service
platform with parallel holding.

First, select the desired cylinder from the options list at the top
right-hand corner of the menu.

167
 “Lowest valve current” is the opening value required for the cylin-
der to start to move. “Highest valve current” is the maximum
speed desired for the cylinder. The lowest and highest valve cur-
rents must be set for both directions (in = piston rod side, out = pis-
ton side).

Fault finding

Modules

Modules menu

Figure 8.28. Modules menu

Module status
The menu Modules shows whether the various components in the
control system are in contact with each other. If they are, the com-
ponent number should have OK below it. Below component D500
(OP panel), D100, D200 (APP module) is a digit indicating the
percentage of load the component has. If there is a fault in any sys-
tem component or if CAN communication is broken, this will be
shown as "no contact".

The menu window has an “Output test” button. This function can
be used to check that there are no short or open circuits on the I/O
module outputs. The pumps must be switched off when this test is
performed.

168
Levers

Lever menu (Fault finding)

Figure 8.29. Lever menu (Fault finding)

Lever function
Under this menu you can check lever function by moving the lever
in X and Y directions. If the lever works the lever's actuation value
should be displayed (0 - 127).

If a lever is changed, or if the lever produces an actuation value

less than 115 or greater than 128 units, all levers must be calibrated
from the Lever calibration menu.

The function of the rocker switch can also be tested by pressing the
left or right side of the lever knob. Left or right should be dis-
played on the screen.

169
Lever calibration menu (Fault finding)

Figure 8.30. Lever calibration menu (Fault finding)

Lever menu (Service platform)

Figure 8.31. Lever menu (Service platform)

Calibration
The following calibration procedure must be performed for all
levers on the operator panel.

1. Change the value in the “Calibration” box to “On”.

170
 2. Move the lever to its various end positions, holding it in each
position for at least two seconds. This also applies to the rocker
switch on the lever, if the lever has such a switch.

3. Then change the value in the “Calibration” box back to “Off”.

4. Change also the value in the “Calibration test” box to “Off”.

Calibration test
To check that lever calibration has been performed, a calibration
test can be conducted. Activate the calibration test by changing its
status to “On”. Check the actuation of each lever by observing the
bars on the display. Actuation should be 0-100% in X, Y and Z
axes.

XY dead zone
The dead zone for the lever in the XY axes is the smallest lever
movement which must be exceeded before the lever becomes
active. Recommended value: 10-15%.

Z dead zone
“Dead zone Z” is the dead zone for the lever's toggle button
(applies only to levers with toggle button). 0% means that the but-
ton becomes active when touched. Recommended value is 50-
60%.

171
Guards

Guards menu

Figure 8.32. Guards menu

Other guards menu

Figure 8.33. Other guards menu

172
Guards' status
The status of the various guards, “On” or “Off”, can be read on the
Guards menu, and for rigs with additional alarms also from the
Other guards menu. The marking and connector of each guard on
the module to which it is connected is also specified.

Configuration

Configuration menu

Figure 8.34. Configuration menu

Software information
This menu provides information about system software and the
“Rig number” (rig serial number).

Configuration file status can also be read from this menu: “Valid”
or “Invalid”. A valid configuration file means that the rig software
agrees with the rig equipment e.g. number of booms, number of
operator panels and additional equipment.

173
Event log

Event log menu

Figure 8.35. Event log menu

Save event log

The event log saves the 100 most-recent events that have been
logged by the software. To view the log, press ENTER and then
use the up and down arrow keys to scroll through the log.

Turning off the control system also deletes the event log. If it is
desired to save the log for a later occasion it can be saved on a PC
card.

1. Insert a PC card in the front slot (1) of the card reader.

2. Move the cursor to “Save log” and press ENTER.

The log is saved as a text file (.txt) and can be opened in a

standard text editor. The log is given the file name El + time
when the file was saved. El is short for Event Log.
3. Extract the PC card by pressing the button (3) to the left of the
card in the card reader.

Loading new software

If the system has more than one operator panel, operator panel 1
(D500-D501) must always be used when loading new software
from PC cards.

174
In certain cases a new “boot program” must be loaded in conjunc-
tion with the new software. The boot program is loaded as
described below. The boot program must always be loaded first.

N.B.
All settings are deleted when new software is loaded. Before
loading new software the parameter settings must therefore be
saved on a PC card. See the section Save and retrieve parame-
ters.
It is also a good idea to jot down the values in the statistics log as
these are erased when new software is loaded. The statistics log
can be saved on a PC card, but there is no way to reload the val-
ues into the system.

1. Turn off the control system with button (0) on panel (A76).

Figure 8.36. Panel A76

175
 2. Insert the PC card with the new software in the rear slot of the
card reader (2)

2
1250 0046 29 1
Figure 8.37. Card reader

3. Start the control system with button (1) on panel (A76).

The system now reads in the new software and when it is fin-
ished a message is displayed on the screen.

4. Extract the PC card and turn off the control system again.

5. Restart the control system.

6. If the same settings as before are required and they are saved on
a PC card then they can now be read into the system.

176
9. Hydraulic systems

Safety

CAUTION
Hazardous hydraulic oil pressure.

Risk of personal injury.

Operation of hydraulic oil system can involve great danger.

.Make sure the system is made pressure-free first.
1250 0022 19

CAUTION
Hazardous hydraulic oil and water pressure.

Can cause personal injury.

Never replace high pressure hoses with hoses of a lesser

quality
. or with hoses that have a detachable coupling.
1250 0022 24

Technical data

Hydraulic systems M2 C and L2 C

Pumps, electric

Percussion pump
Type Axial plunger pump
Model A10V
Displacement (COP 1838 ME) 71cm 3 /rev
Displacement (COP 1838 HF) 100cm 3 /rev

Positioning pump
Type Axial plunger pump
Model A10V
Displacement 71cm 3 /rev

177
 Rotation pump
Type Gear pump
Model P330
Displacement (M2 C/ L2 C Mark 1)48cm 3 /rev
Displacement (M2 C/ L2 C Mark 2,
3 and 4) 56.5cm 3 /rev

Compressor pump (M2 C/L2 C Mark 2, 3 and 4)

Type Gear pump
Model P315
Displacement 17.8cm 3 /rev

Pump, diesel

Pump for positioning/steering and brake

Type Dual gear pump
Model P315
Displacement, positioning 20.3cm 3 /rev
Displacement, steering and brake 40.6cm 3 /rev

Tank module
Tank including oil, electric motors,
hydraulic pumps, etc.
Weight 1800kg

Hydraulic oil reservoir

Capacity min 200 max 250litres

Filter

Return oil filter

General
The return oil filter cleans the oil before it is returned to the tank.

A return oil filter comprises a tube containing three filter inserts.

The tubes are mounted inside the hydraulic oil reservoir.

178
 The filter elements (1) should be changed according to the mainte-
nance schedule but if the operator panel indicates “Clogged filter”
all return oil filters must be changed immediately.

1250 0094 24

Figure 9.1. Location of filter inserts, return oil filter

Note
The filter cartridges cannot be cleaned but must be replaced when
they are clogged.

Changing the return oil filter

The filter inserts can be dismantled by removing the cover and lift-
ing them up.

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

A
B

C
1250 0020 53

Figure 9.2. Changing filter

2. Lift off the cap (B) and change the O-ring (C) if it is damaged.

179
 3. Lift up the whole filter canister by the handle.

4. Detach the overflow valve (E) by pressing down and turning the
handle anti-clockwise.

5. Take out the filter cartridges (D) and replace with new ones.

6. Refit the overflow valve and filter canister and screw on the
cap.

Breather filter

General
There is a breather filter (A) on the rig that is used to compensate
pressure differences in the tank that would otherwise occur when
the level in the tank changes due to e.g. operating the jacks.
1250 0021 15

Figure 9.3. Breather filter

The breather filter must be replaced as set forth in the maintenance

schedule and also if it is severely fouled.

Note
If the breather filter becomes covered in oil it will be ruined. This
can happen if the tank is overfilled. The filter must then be
changed.

180
Changing the breather filter
1. Wash clean on and around the filter (A).

1250 0021 15

Figure 9.4. Breather filter

2. Unscrew the old filter.

3. Fit a new filter.

4. Tighten the filter by hand.

Oil sampling
An oil sample gives a good indication of how well the hydraulic
system has been maintained.

The system is equipped with nipples that are used together with
special equipment to take oil samples. The nipples are located on
the delivery line from the percussion pump and positioning pump.

The oil sampling nipple has part number 3177 3016 00. The nipple
can also be used as a pressure test outlet for a pressure gauge.

181
Changing oil

Draining
1. Underneath the hydraulic oil tank is a ball valve. On the ball
valve there is a plug. Remove the plug.

1250 0020 54

Figure 9.5. Ball valve underneath hydraulic oil tank

2. Screw a hose to the ball valve and place the other end of the
hose into an empty oil drum.

3. Drain the oil from the tank by opening the ball valve.

4. Close the ball valve once the oil has stopped running out of the
hose.

5. Unscrew the hose.

6. Screw back the plug to protect the ball valve.

General
If filter changing has been carried out in accordance with the
instructions and oil cooling presents no problems the hydraulic oil
need not be changed. On the other hand, if samples indicate that
the oil is oxidized or contains a lot of water, it must be changed.
See maintenance intervals Percussion hours.

182
Filling up

General
New oil must only be filled with the filler pump fitted on the
machine. This is because the oil must be filtered before reaching
the tank. This is achieved automatically if the filler pump is used.

Note
Take into account that the position of the cylinders will affect the
level in the tank. Make sure all the cylinders are retracted.
If the tank is overfilled, the breather filter will be destroyed. In this
case, the filter must be changed. See section Filter: Breather filter.

Filling manually
1. Check the return oil filter, see section Filter: Return oil filter.

2. Make certain all connections and hoses that are used to fill oil
are clean.

3. Pump manually using hand pump (A).

B
C
1250 0094 19

A Hand pump
B Oil level glass
C Thermometer
Figure 9.6. Hydraulic oil tank hand pump

4. Check the level in oil level glass (B).

5. Stop pumping when the correct level is attained.

The correct level is obtained when oil becomes visible in the

upper part of the oil level glass.

183
Electric filling, option
1. Check the return oil filter, see section Filter: Return oil filter.

2. Make certain all connections and hoses that are used to fill oil
are clean.

3. Press button (S195) to start pump (A).

M102
A50

S195

1250 0094 18

A Electric pump
B Oil level glass / Oil level tube
C Thermometer
S195 Button, start electric pump
Figure 9.7. Electric filling, hydraulic oil tank

4. Check the oil level in the level glass / level tube (B).

5. Release button (S195) when the correct level is attained.

The correct level is obtained when oil becomes visible in the

upper part of the oil level glass.

Draining condensation from the hydraulic oil tank

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

184
 Before draining the hydraulic oil tank, the system must stand
unused for approx. 12 hours so that any condensation has had time
to sink to the bottom of the tank. The water can then be drained off
through the ball valve on the bottom of the tank.

1250 0020 54

Figure 9.8. Ball valve underneath hydraulic oil tank

1. Underneath the hydraulic oil tank is a ball valve. On the ball

valve there is a plug. Remove the plug.

2. Place a receptacle under the ball valve.

3. Open the ball valve and allow the water to run out.

4. Close the valve when the water has been replaced with oil.

5. Screw back the plug to protect the valve.

185
Pumps

Power unit pumps

P1

P2

P3
P4
1250 0064 42

P1 Percussion pump (Model A10V)

P2 Positioning pump (Model A10V)
P3 Rotation pump (Model COM P330B/315A, combination pump)
P4 Compressor pump (See above, P3 combination pump, for model)
Figure 9.9. Power unit pumps

Checking pump rotation direction

An arrow on the pump coupling housing indicates the correct
direction of rotation.

1250 0046 24

Figure 9.10. Pump rotation direction

186
 1. Start the pump and stop it again at once so that it rotates only a
few turns. Check the direction in which the motor-pump cou-
pling rotates.

2. If the pump rotates in the wrong direction, reverse two of the

phase leads in the electric motor connection cable.

This work is to be carried out by authorized electricians.

Starting a new or reconditioned pump

If the rig has been idle for a long time, or if a major intervention
has been made in the system (replacing or reconditioning compo-
nents in the hydraulic system for example) the following steps are
to be carried out:

1. Fill the pump casing with oil.

2. Bleed air from the pump casing, see section Pumps: Bleeding
the pumps.

3. Circulation-pump the system, see section Pumps: Circulating

the pump.

Bleeding the pumps

1. Make certain that all hoses are connected to the pump.

2. Check the level of the hydraulic oil in the oil level glass on the
hydraulic oil tank. If filling is needed, see section Changing oil.

3. Remove plug (B).

187
 The pump housing is now filled with oil via drain hose (A) con-
nected between pump and tank.

A
B
C

1250 0046 20 2
Figure 9.11. Hydraulic pump

4. Screw plug (B) into place when oil starts to run out of the plug
hole.

The pump casing is now half full.

5. Loosen drain hose (A) somewhat.

The upper part of the pump casing will be filled while air
escapes.

6. Tighten hose (A) when clean oil with no air bubbles runs out of
it.

The pump casing is not completely full.

Hydraulic motors

Starting a new or reconditioned hydraulic motor

If the rig has been idle, or if a major intervention has been made in
the system such as replacing or reconditioning components in the
hydraulic system, the following points are to be carried out:

188
 1. Fill the hydraulic motor at (A) with oil.

1250 0071 02

Figure 9.12. Hydraulic motor

2. Run the hydraulic motor for a few minutes.

3. Bleed the hydraulic motor by carefully opening the plug (A) a

few turns.

4. Close plug (A) when pure oil without air runs out from (A).

The hydraulic motor is now filled with oil.

Settings

Safety

CAUTION
Hazardous hydraulic pressure.

Can cause personal injury.

Pressure settings are always done on a pressurised

.system. Always take great care to avoid personal injury.
Pressure settings must only be carried out by trained
staff.
1250 0022 31

General
The following are basic settings that must be made manually. For
other pressure and flow settings, see maintenance instructions
Control system.

189
 Locations of valves and sensors on rig, see maintenance instruc-
tions Component locations.

Percussion pump

Stand-by pressure

Note
This is always set by the pump supplier.
Normally, the stand-by pressure need not be checked or adjusted.
If you suspect that the pump is not supplying a sufficient flow to
the system, however, it may be a good idea to check the stand-by
pressure and adjust it if necessary.

N.B.
There is a risk of damaging the pump if the pressure is adjusted
too high.

1. Connect a pressure gauge (0-60 bar) to the pressure test outlet

(3).

2. Back off set screw (2) and start the pump without activating any
function.

3. Screw in the set screw (2) to 20 bar.

4. Stop the pump.

A E
B
3

1 C

1250 0046 19 2

Figure 9.13. Stand-by pressure, percussion pump

190
Max. pressure
1. Before the maximum pressure of the percussion pump can be
set, the value of the ”percussion pressure button” must be
increased to 300 bar in the menu Drilling, Parameters, Per-
cussion .

2. Detach the hydraulic hoses to the drilling machine percussion

and connect a circulating pump cock that is fully open.

3. Connect a pressure gauge (0-400 bar) to the pressure test outlet

(3).

A E
B
3

1 C

1250 0046 19 2
Figure 9.14. Setting max. percussion pump pressure

4. Unscrew adjusting screw (1) a few turns.

5. Start the pump and press and hold the button for "release drill
bit" (button 4) on the left button unit of the operator panel.
Carefully close the circulation pump cock and check that the
pressure does not exceed 280 bar. If so, close the cock fully.

191
 If the pressure exceeds 280 bar, adjust overflow valve (E).

1 2 3 4 5

6 7 8 9 10

11 12 14 15

16 17 19 20

21 22 24 25
1250 0090 48

26 27 29

Figure 9.15. Left button unit

6. Check the overflow valve by screwing in adjusting screw (1)

and making sure that the pressure cannot exceed 280 bar. If nec-
essary, adjust using adjusting screw (E).

7. Adjust the max. pressure to 250 bar with the adjusting screw (1)
and lock the setting.

8. Reset the value of the “Percussion pressure button” in the Per-

cussion menu.

Positioning pump

Stand-by pressure

Note
This is always set by the pump supplier.
Normally, the stand-by pressure need not be checked or adjusted.
If you suspect that the pump is not supplying a sufficient flow to
the system, however, it may be a good idea to check the stand-by
pressure and adjust it if necessary.

192
 1. Connect a pressure gauge (0-60 bar) to the pressure test outlet
(4).

A
B
C

4
1
1250 0099 03 2
Figure 9.16. Positioning pump

2. Back off set screw (2) and start the pump without activating any
function.

3. Screw in the set screw (2) to 20 bar.

4. Stop the pump.

Max. pressure
1. Connect a pressure gauge (0-400 bar) to the pressure test outlet
(4).

A
B
C

1250 0046 20 2
Figure 9.17. Setting max. positioning pump pressure

193
 2. Start the pump. Check that the overflow valve in the positioning
circuit (located in the L90 block for positioning) opens at
approx. 280 bar by screwing in adjusting screw (1) to see that
the pressure cannot exceed approx. 280 bar. A faulty overflow
valve cannot be adjusted but must be changed.

3. Adjust the max. pressure to 210 bar with adjusting screw (1)
and lock the setting.

Rotation pump

Max. pressure
1. Connect a pressure gauge (0-400 bar) to pressure test outlet (5).

1250 0066 73

Figure 9.18. Power unit pumps

2. Detach the hydraulic hoses to the rotation motor on the drilling

machine and connect a circulating pump cock that is fully open.

194
3. Screw out the adjusting screw (A) completely on the pressure
control valve.

A
1250 0066 72

Figure 9.19. Pressure control valve, rotation circuit

4. Start the hydraulic pump and activate auto rotation by moving

the drilling lever to the left.

5. Carefully close the circulation pump cock and read off the pres-
sure. If the pressure exceeds 130 bar, the adjusting screw must
be screwed out farther.

6. When you are sure that the pressure does not exceed 130 bar,
close the circulation pump cock and set 130 bar using the pres-
sure control valve adjusting screw (A).

7. Stop the pump.

8. Reconnect the hydraulic hoses on the drilling machine rotation

motor.

9. Check that the drilling machine rotates in the correct direction

when drilling. The drill rod should rotate to the left when the
lever is moved to the left.

195
Drilling machine damper pressure
1. Disconnect the drilling machine damper pressure hose and con-
nect a calibrated pressure gauge (0-60 bar) to (1).

1250 0099 23

Figure 9.20. Connecting the damper pressure gauge

2. Close the flow regulator cock (A) completely.

1250 0046 22

Figure 9.21. Adjusting damper pressure

3. Start the pump.

4. Make sure the shank adapter is in its forward position.

5. Adjust the oil flow to the damper with the flow regulator by
opening cock (A) carefully until the pressure shown on the pres-
sure gauge reaches 30-35 bar and then lock the cock with the
lock screw. (The hydraulic oil should be at normal operating
temperature, approx. 35-40°C.)

6. Stop the pump, disconnect the pressure gauge and reconnect the
damper pressure hose.

Setting rotation pump flow

The flow in the rotation pump determines the rotation speed.

196
 1. Affix a reflective strip to the drill rod.

2. Start auto rotation by moving the drilling lever to the left.

3. Measure the speed of the drill rod with a tachometer.

4. Adjust the speed in the menu Drilling, rotation rpm left. A

higher value gives a higher rpm, see maintenance instructions
Control system.

Pressure reducing function for positioning pump

Note
The basic pump settings must be made before setting the pressure
reducing function.
When only one of the pumps, pump 1 or pump 2, is activated while
drilling, the positioning pressure will be reduced to 160 bar when
the percussion pressure exceeds 170 bar or when both pumps are
running but only the drilling machine on one boom is drilling with
a percussion pressure exceeding 170 bar. When both drilling
machines area drilling with a percussion pressure above 170 bar,
the positioning pressure will not be reduced.

1. Connect a pressure gauge (0-400 bar) to the pressure test outlet

(2).

3 2

4
1250 0066 71

Figure 9.22. Setting the positioning pump pressure reducing

function

2. Screw out the set screw (3) completely.

3. Plug the delivery hose to the percussion.

197
 4. Start the pump.

5. Shut off the water to the drilling machine.

6. Press the percussion pressure button and read the pressure

gauge. Adjust with set screw (4) to 160 bar.

7. Reduce the actuation value of the percussion pressure button

to 170 bar, see maintenance instructions Control system.

8. Screw in the adjusting screw on valve (3) until the positioning

pressure changes to 210 bar.

9. Reset the original value of the percussion pressure button .

Positioning pressure with diesel power

Set with pressure control valve (Y203). Adjusted during diesel
operation to 235 bar.

1. Connect a pressure gauge (0-400 bar) to pressure test outlet (A).

1250 0064 48 A
Figure 9.23. Valve plate (Y203), rear frame of rig

2. Remove the protective cap (B), undo lock nut (1) and screw out
the adjusting screw (2) completely.

1
1250 0064 44 2
Figure 9.24. Adjusting

3. Start the diesel engine and activate the diesel engine positioning
pressure, see operator instruction Repositioning: Controls.

4. Set 235 bar with adjusting screw (2) and tighten lock nut (1).

198
Maximum pressure and speed of reeling units
In situations where it is not possible for the slip clutch on the reel
gear to unwind the hose/cable, the reel hydraulic motor can be
used for unwinding. The winding-on and winding-off speed can be
adjusted by means of restrictors located beneath valve (Y414) for
the cable reeling unit and (Y415) for the water-hose reeling unit.

1. Connect a pressure gauge (250 bar) to pressure reducing valve

(F).

1250 0064 45 A B
Figure 9.25. Valve section (Y414) and (Y415)

2. Adjust the pressure to 150 bar with the pressure reducing set
screw (B).

3. Start the reeling unit for winding-in and winding-out.

4. Adjust the winding-in/out speed using restrictors (A).

• The speed for reeling in can be adjusted 10-12 rpm ( 1 rev

each 5-6 seconds ).
• The speed for reeling out can be adjusted 5-6 rpm ( 1 rev each
10-12 seconds ).
During normal operation, the cable and hose reels must not be
operated hydraulically when being reeled out. The cable and
hose must be pulled out via the gear friction coupling.

Setting water pump speed

1. Check that the maximum water pump speed reading is 3000
rpm. Read the speed from the tachometer on the water pump
hydraulic motor coupling.

Take the following measures if the speed needs adjusting.

199
 2. Adjust the water pump speed using flow valve (A) until the
tachometer on the water pump hydraulic motor coupling reads
3000 rpm.

1250 0064 49

Figure 9.26. Valve section (Y162)

The output pressure will vary with the input pressure.

The water pressure must not exceed 25 bar when drilling. If it
does, the speed must be reduced.

200
Speed control for air flow

1-boom and 2-boom rigs

Standard rig
1. Connect a pressure gauge (6) to the air connection (7) on the
drilling machine.

7
8
6 1 2

4
1250 0045 81

Figure 9.27. Lubricating air

2. Screw out the setting screw used for pressure control valve (B)
all the way. It is located under valve (Y171). Start both pumps
and adjust the compressor speed using setting screw (B) to
attain a pressure of 3 bar at the drilling machine (6).

Both restrictors (D) must be screwed in completely (closed).

B
1250 0064 50
D
Figure 9.28. Valve section (Y171)

201
Rig equipped with air flushing, option
When air flushing is activated, the compressor speed accelerates in
order to improve performance during air flushing. This is control-
led by valve (Y173). When valve (Y173) is activated, the motor
speed must be 5500 rpm. (Check by means of the tachometer on
the compressor hydraulic motor coupling).

1. Screw in the set screw used for pressure control valve (B) all
the way. This pressure control valve is located beneath valve
section (Y171).

Both restrictors (D) must be screwed in completely (closed).

B
1250 0064 50
D

Figure 9.29. Valve section (Y171)

2. Connect a pressure gauge (6) to the air connection (7) on the

drilling machine.

7
8
6 1 2

10 9

4
1250 0045 80 5
Figure 9.30. Lubricating air

202
3. Unscrew the set screw for flow regulator (G) completely.

G
1250 0066 70

Figure 9.31. Flow regulator

4. Unscrew the set screw for the pressure reducing valve (E) com-
pletely. Connect a pressure gauge to the pressure reducing valve
outlet (F) and screw home the cock on the flow regulator (A).

F
A

1250 0066 69

Figure 9.32. Valve section (Y173)

5. Start pump 1 only.

6. Activate air flushing, see operator instructions Control system.

7. Adjust pressure reduction valve (E), located under (Y173), to

180 bar.

8. Adjust the compressor speed to 5500 rpm with the cock on the
flow regulator (A).

The speed can be checked with a tachometer on the compressor

hydraulic coupling.

203
 9. Screw in the set screw for flow regulator (G) 4 turns.

G
1250 0066 70

Figure 9.33. Flow regulator

3-boom rigs
When air flushing is activated, the compressor speed accelerates in
order to improve performance during air flushing. This is control-
led by valve (Y173). When valve (Y173) is activated, the motor
speed is to be 5500 rpm. (Check by means of the tachometer on the
compressor hydraulic motor coupling)

1. Connect a pressure gauge (6) to the air connection (7) on the

drilling machine.

7
8
6 1 2

10 9

4
1250 0045 80 5
Figure 9.34. Lubricating air

204
2. Unscrew the set screw for flow regulator (G) completely.

G
1250 0066 70

Figure 9.35. Flow regulator

3. Unscrew the set screw for the pressure reducing valve (E) com-
pletely. Connect a pressure gauge to the pressure reducing valve
outlet (F) and screw home the cock on the flow regulator (A).

F
A

1250 0066 69

Figure 9.36. Valve section (Y173)

4. Start pump 1 only.

5. Activate air flushing, see operator instructions Control system.

6. Adjust pressure reduction valve (E), located under (Y173), to

180 bar.

7. Adjust the compressor speed to 5500 rpm with the cock on the
flow regulator (A).

The speed can be checked with a tachometer on the compressor

hydraulic coupling.

205
 8. Screw in the set screw for flow regulator (G) 4 turns.

G
1250 0066 70

Figure 9.37. Flow regulator

Sensors

Setting pressure monitor B121

Pressure monitor B121 must be activated if the drilling is to cease
automatically when the hole is finished being drilled. The monitor
is activated by the cradle and the hydraulic limit switch on the
feeder.

1. Unscrew the adjusting knob on B121.

1250 0064 46

Figure 9.38. Pressure monitor (B121)

2. Run the feeder to its forward end position.

3. Screw in the adjusting knob on B121 until the feeder reverses.

Checking pressure sensors B100, B101, B132, B133

Pressure sensors B100 (Percussion), B101 (Rotation), B132
(Damper), B133 (Feeder) detect the pressure in the various pres-
sure circuits.

206
 33

00
01

32
B1

B1

B1

B1
1250 0064 47

Figure 9.39. Pressure sensor

1. Check that the pressure sensors have the correct power supply
+12 VDC and send the correct signals to the drilling system.

2. The terminal block included in the service bag must be used

when measuring the supply voltage, see maintenance instruc-
tions Service bag.

207
10. Air system

Safety

WARNING
Never attempt maintenance work while the
drill rig is in operation.

Before intervening in any of the systems,

make sure there is no pressure in the
hydraulic, water or air systems, and that
the electrical system is DEAD.
1250 0023 85

Compressor instructions

Compressor GAR 5
The rig compressor is a single-stage, hydraulic screw compressor.
The compressor starts when one of the rig's hydraulic pumps starts.

Compressed air from the compressor goes to an air reservoir that

also acts as an oil separator. In the air reservoir, most of the oil
found in the oil and air mixture will be removed through centrifu-
gal force. The remaining oil is separated in an oil separation ele-
ment in the air reservoir. The separated oil collects in the bottom of
the air reservoir, which acts as an oil tank.

208
 103
23 (B366)
6 24 25 111
18

21 (Y210)

17
5 110 104

15
2

1250 0099 05

Figure 10.1. Compressor GAR 5 with air reservoir

Table 10.1. Compressor components

Locations Description Locations Description
2 Adjusting screw, belt drive 103 Minimum pressure valve
5 Drive belts 104 Oil level indicator
6 Air filter 110 Oil filler plug
15 Hydraulic motor 111 Safety valve
17 Oil cooler
18 Oil filter
21 Solenoid valve, loading
23 Temperature switch
24 Shunt valve
25 Intake valve

Checking oil level

Always check the oil level during operation. The compressor must
be idling.

1. Unscrew the solenoid valve (Y210) and lift it off to unload the
compressor.

2. Check the oil level on the level indicator (104).

The oil level is sufficient when the black line on the level indica-
tor is in the green zone.

209
Oil and oil filter

Safety

WARNING
Hot fluids.

Danger of personal injury.

Use protective goggles and suitable protective

clothing when handling hot fluids.
1250 0104 09

Changing oil and oil filter

1. It is easier to drain the old oil if it is warm. Therefore, always
start by running the compressor warm.

2. Stop the compressor and wait a few minutes. The compressor

can be stopped by stopping all the hydraulic pumps on the rig.

3. Ensure the air reservoir is depressurised by carefully discon-

necting the hose (CPAP) on the air reservoir.

18

CPAP

110

OD

1250 0099 24

Figure 10.2. Compressor and air reservoir

4. Drain the oil by opening the drain valve located at the end of
hose (OD). Collect the oil in a receptacle.

5. Unscrew the oil filter (18) located on the compressor.

6. Clean the filter seat and lubricate the new filter gasket.

7. Screw the filter in place and tighten it by hand.

210
 8. Remove the filler plug (110) from the air reservoir and fill up
with fresh oil (approx. 4.8 litres). For recommended oil. see
maintenance instructions Lubricants, coolants and propellants.

9. Replace the filler plug and tighten it.

10.Check the oil level, see section Checking oil level above. Top
up with oil if necessary.

Air reservoir

Safety

WARNING
High air pressure in air reservoir

Risk of serious personal injury

Depressurise air reservoir before opening

1250 0098 58

Changing the separator element

1. Stop the compressor. The compressor can be stopped by stop-
ping all the hydraulic pumps on the rig.

211
 2. Ensure the air reservoir is depressurised by carefully discon-
necting the hose (CPAP).

x6
117

113

CPAP

1250 0099 06

Figure 10.3. Changing the separator filter

3. Unscrew the cap on the air reservoir (117).

4. Remove the separator element (113) and replace it with a new

one.

5. Screw on the cap (117) on the air reservoir.

Changing air filter

1. Stop the compressor by stopping all the hydraulic pumps on the
rig.

2. Remove the air filter (6). Discard the filter element if damaged.

3. Fit a new filter element.

4. Clean the dust separator in the air reservoir cap.

Adjusting drive belts

1. Undo the cover.

212
 2. Undo the hydraulic motor bolts (A).

1250 0099 07

Figure 10.4. Compressors without drive belt cover.

3. Adjust the belts with the belt tensioner nut (B).

If correctly adjusted, it should be possible to press down the belt

5 - 6 mm with a force of 25N half way between the two belt pul-
leys.

Safety valve
The air reservoir (oil separator) has a safety valve (111). If the rig
is not fitted with the air flushing option (with an extra compressed
air tank), there will be an additional safety valve for protecting the
drilling machine (drilling machines) against excess pressure.

The safety valve setting, part number and pressure setting are
stamped on the valves.

Adjustments are not allowed. Never run the compressor without

safety valve(s).

Pressure switch B188

Pressure switch B188 detects the pressure in the air circuit.

1. Make sure the pressure switch has the correct power supply +12
VDC and is providing the correct output signal to the drilling
system.

2. The terminal block included in the service bag must be used for
measuring the voltage supply, see maintenance instructions
Service equipment.

213
Freeze prevention measures

Draining the air tank

The air tank is fitted only on rigs with the air flushing option.

Note
To remove all water that has condensed in the air tank, the rig
must be level.

1250 0070 58

Figure 10.5. Air tank

1. Open the draincock on the air tank.

2. When the flow of water stops, close the draincock.

Fault finding

Fault finding, compressor

103
23 (B366)
6 24 25 111
18

21 (Y210)

17
5 110 104

15
2

1250 0099 05

Figure 10.6. Compressor GAR 5 with air reservoir

214
 23 24

18

1250 0099 08

18 Oil filter
23 Temperature switch
24 Shunt valve
Figure 10.7. Compressor GAR 5

Some possible faults and causes follow below. If in doubt, get in

touch with Atlas Copco.

Compressor will not start

• Temperature switch (23) triggered, temperature exceeding value
(approx. 115ºC) set with screw in centre of monitor.

Compressor starts but does not load

• Solenoid valve (Y210) faulty. Check the valve and replace if
necessary.
• Intake valve (25) stuck closed.
• Leak in control air lines.
• Minimum pressure valve (103) leaking (after circuit has been
vented).

Compressor will not unload, safety valve blowing

• Solenoid valve (Y210) faulty. Check the valve and replace if
necessary.

215
 • Intake valve (25) will not close.

Compressor air delivery or pressure lower than normal

• Air leak in connected equipment. Check and rectify.
• Air filter (6) blocked. Change filter element.
• Solenoid valve (Y210) faulty. Check the valve and replace if
necessary.
• Intake valve (25) will not open completely.
• Oil separator element clogged. Depressurise the air reservoir
and change the separator element.
• Safety valve (111) leaking. Change valve.
• Compressor element faulty.

Abnormal oil consumption or oil in outlet line

• Oil level too high. Depressurise the air reservoir and drain the
oil to the correct level.
• Incorrect oil causing frothing. Change to correct oil. Change oil
separator element.
• Faulty oil separator element. Check element and change if nec-
essary.

Safety valve blowing after loading

• Intake valve (25) faulty.
• Minimum pressure valve (103) faulty.
• Oil separator element clogged. Depressurise the air reservoir
and change the element.
• Faulty safety valve (111). Change safety valve.

Air outlet temperature higher than normal

• Air filter (6) blocked. Change filter element.
• Oil level too low. Top up with oil.
• Oil cooler (17) blocked. Clean cooler.
• Defective shunt valve (24). The shunt valve acts as a thermostat
and admits oil to the oil cooler at a certain temperature. The
shunt valve should start to open at approx. 65° C and should be
fully open at approx. 80° C.
• Faulty compressor element.

216
11. Water system

Technical data

Hose dimensions

Incoming water line

Hose dimension, 1-boom rig 25 mm
1 inches
Hose dimension, 2-boom rig 38 mm
1 1/2 inches
Hose dimension, 3-boom rig 51 mm
2 inches

Safety

WARNING
Hazardous water pressure.

Can cause personal injury.

Make sure the system is made pressure-free before any

.work commences.
1250 0022 20

Water pump

General
The water pump is hydraulically driven. The input water pressure
should be at least 6 bar. The input pressure is regulated with a
safety valve to 16 bar. If the hydraulic motor has been removed
from the pump, the motor splines must be lubricated in accordance
with lubrication recommendations.

217
Direction of rotation

Note
The direction of rotation of the water pump must be checked after
working on the hydraulic circuit.
1. Check that the direction of rotation of the water pump corre-
sponds with the arrow (A) on the pump.

1250 0070 37

Figure 11.1. Direction of rotation of water pump

2. If the direction of rotation is incorrect, the delivery and return

hoses on the motor and/or valve must be switched.

Setting flow switches.

The flow switches (B141) monitor the flow of water during drill-
ing, and also start the water pump.

1250 0056 70 B141

Figure 11.2. Flow switches B141

1. Open the black plastic cover from the guard.

2. Undo the screw on top of the switch.

218
 3. Adjust the sensor body (A) according to the adjustment interval
(B).

1250 0061 57

Figure 11.3. Adjusting the flow

There are two triangles on the sensor body: one white and one
red.

• A white triangle indicates adjustment interval for making con-

tact.
• A red triangle indicates adjustment interval (B) for breaking
contact.
Flow switch (B141) should be set as a making contact.

4. Once adjusted, refit the plastic cover and tighten the screw.

Note
The water flow switch must be adjusted so that the water pump
always starts on drilling.

Pressure sensor B136

Pressure sensor (B136) detects the pressure in the water circuit and
will stop the water pump if the pressure drops too low.

B136

1250 0020 59

Figure 11.4. Pressure sensor B136

219
 1. Check that the pressure sensor has the correct power supply of
+12 VDC.

The special terminal block included in the Atlas Copco service

bag must be used to measure the voltage supply.
2. Check that the pressure sensor also sends the correct signal to
the drilling system.

Cleaning the water strainer

The strainer must be cleaned regularly to prevent the pressure from
dropping too much.

1. Connect a water supply to the water inlet (4) on the rig

Connect the water supply to the water-hose reeling unit if the

rig is equipped with one.

3
1
2 4

1250 0020 60 5
Figure 11.5. Cleaning the water strainer

2. Make sure the connections are not fouled.

3. Open the main stop cock (3).

4. Flush the water strainer by opening cock (1)

5. If the water strainer is severely soiled, undo the end piece.

6. Remove the strainer drum.

7. Clean the strainer drum or replace with a new one.

Freeze prevention measures

Draining the water system

1. Start the control system.

2. Make sure the diesel engine and hydraulic pumps are turned off
to avoid the risk of damaging the water pump.

220
3. Connect air to water inlet (2).

3
1
2 4

1250 0020 60 5
Figure 11.6. Water inlet

4. Open cocks (1) and (3) to blow the water out through the reel-
ing unit.

5. Close cock (3).

6. Actuate boom one.

7. Move the drill lever directly left (rotation drilling) so that the
water valve opens and the compressed air expels the water from
the system.

8. Repeat the two steps above for the remaining booms.

221
12. Electrical system, IEC and Australia

Safety

WARNING
DANGER! High voltage.

Risk of serious injury.

Before intervening in the system, make sure

that it is DEAD.

Intervention in the electrical system is

restricted to qualified electricians only.
1250 0022 23

General

Safety standard
The electrical system complies with current regulations. Applied
directives and standards are specified in the Safety chapter. See
chapter Safety.

Low-voltage circuit
Low voltage refers to an alternating current with a voltage
greater than 50 V and less than or equal to 1000 V.

The rig's low-voltage circuit is a high-current circuit.

• Cable on reeling unit and collector

• Electric cubicle
• Electric motor(s) for hydraulic pump(s)
• Lighting (and extra low voltage)
• Operating circuits
• Service outlet
• Battery charger for carrier (also extra low voltage)
• Indicator lamps on electric cubicle

222
Extra low-voltage circuit
Extra low-voltage refers to an alternating current with a voltage
less than or equal to 50 V and direct current with a voltage less
than or equal to 120 V.

• Operating circuits
• Guards in the system
• Battery charger for carrier (also low voltage)
• Lighting (and low voltage)
• RCS system

Before starting
Check, before starting, all high-current connections in the electric
cubicle and the collector, as well as the electric motors. Also,
check that the plug is plugged in properly.

Cable marking
All the cables are marked with cable numbers corresponding to the
wiring diagram.

Replacement of components
Whenever changing components, make sure the new component
has the same Atlas Copco part number as the old one. Mark new
components with the same marking as the ones they replace.

Electric cubicle, high-current

Indicator lamps
For information on the electric cubicle indicator lamps, see opera-
tor's instructions Electrical system.

223
IEC standard

Inside
F01 F01 K51 P01 F25

1250 0104 10

K50 Q01

F01 Motor protection relay (one for each hydraulic pump unit)
F25 Earth fault breaker (personal protection)
K50 Phase sequence switch
K51 Earth fault relay (fire protection)
P01 Voltmeter and ammeter
Q01 Main switch
Figure 12.1. Electric cubicle A10, IEC standard

224
Australian standard

Inside
1F01 2F01 K51 P01 F25 F20

1250 0104 11

K50 Q01

1F01 Motor protection relay, hydraulic pump 1

2F01 Motor protection relay, hydraulic pump 2
F20 Earth fault breaker (personal protection)
F25 Earth fault breaker (personal protection)
K50 Phase sequence switch
K51 Earth fault relay (fire protection)
P01 Voltmeter and ammeter
Q01 Main switch
Figure 12.2. Electric cubicle A10, Australian standard

Voltmeter and ammeter

P01
1250 0104 12

V A1 A2 A3 T

Figure 12.3. Voltmeter and ammeter

The meter (P01) is a combined voltmeter, ammeter and hour meter.

Use the five buttons to select what is shown in the display. The
LEDs below the buttons indicate which buttons are activated.

Press button (V) to check that the input voltage to the rig complies
with the rated voltage specified on the rig's data plate.

225
 Press buttons (A1-A3) to display the current consumption of the
hydraulic pump motors. The number of buttons that are functional
varies from rig to rig depending on how many hydraulic pump
units the rig has. When the rig is in operation you can check that
the electric motors are not overloaded by comparing the meter
readings with the rated current specified on the motors' data plates.

Button (T) is for showing the running hours of the percussion unit
but has no function on RCS rigs. Information on percussion run-
ning hours can instead be obtained on the operator panel display.
See also maintenance instructions Control system.

Electrical system protection

Main switch

General
The main switch (Q01) is on the 3-phase circuit in the electric
cubicle. It has a knob for on and off. The main switch has as stand-
ard under-voltage protection, thermal overload protection and
magnetic short-circuit protection.

The switch can be reset after being triggered by turning the knob to
position 0 (OFF) and then back to position 1 (ON).

Note
On rigs with the Australian standard electrical system, the main
switch does not have under-voltage protection.

226
Main circuit breaker dip switches

0.4 L OFF I TEST

0.5 1.5 15V dc
0.6 2
0.7 I1 4 In= 400 A +
I3
0.8 6
8
_
0.9 InN= In/2
0.95 10
x In
1 x In 12

A 3s
1250 0006 75

B 6s t1
C 12s
D 18s I=6I1 SACE PR211

Q01

I1 Dip switches for setting overload protection

t1 Dip switches for setting overload duration
I3 Dip switches for setting short circuit protection
Figure 12.4. Main circuit breaker Q01

Overload protection
The overload protection setting is dependent on the supply voltage
and total electric motor output.

The setting is made with DIP switches (I1) on the main circuit
breaker. Next to the DIP switches is a mark indicating the different
setting alternatives. Check the following table to see what setting
to use.

The duration (t1) should be set to 18 seconds in all cases.

Table 12.1. Setting, main switch overload protection

Power supply Electric motors Setting
380 - 690 V 1 x 55 kW 0,4 x 400 A
380 - 690 V 1 x 75 kW 0,4 x 400 A
380 - 400 V 2 x 55 kW 0,6 x 400 A
380 - 400 V 2 x 75 kW 0,8 x 400 A

227
Power supply Electric motors Setting
440 V 2 x 55 kW 0,5 x 400 A
440 V 2 x 75 kW 0,7 x 400 A
500 V 2 x 55 kW 0,5 x 400 A
500 V 2 x 75 kW 0,6 x 400 A
550 V 2 x 55 kW 0,4 x 400 A
550 V 2 x 75 kW 0,5 x 400 A
660 - 690 V 2 x 55 kW 0,4 x 400 A
660 - 690 V 2 x 75 kW 0,4 x 400 A
1000 V 2 x 55 kW 0,4 x 320 A
1000 V 2 x 75 kW 0,4 x 320 A

Short circuit protection

The settings for the short-circuit protection depend on the method
of starting.

The setting is made with DIP switches (I3) on the main circuit
breaker. Next to the DIP switches is a mark indicating the different
setting alternatives.

For rigs with Y/D start, the short-circuit protection should be set to
4 x the switch's rated current (In).

For rigs with direct start, the short-circuit protection should be set
to 10 x the switch's rated current (In).

Phase sequence switch

If the phase sequence fault indicator lamp comes on, the following
measures must be taken by a qualified electrician.

The electrical system has a phase sequence switch (K50) to pre-

vent the electric motors from starting if the power supply has the
wrong phase sequence. If there is a phase sequence problem, an
indicator lamp on the electric cubicle will come on, see operator's
instructions Electrical system.

1. Turn off the main switch for the input cable and pull out the
plug.

2. Switch two of the phases in the consumer mains source.

Earth fault equipment

IEC standard
The electrical system has an earth fault relay (K51) and an earth
fault breaker (F25).

228
 The purpose of the earth fault relay (K51) is to protect the rig from
fires in the main circuit. This breaker is set by the supplier to 300
mA and 0.5 seconds.

The earth fault breaker (F25) provides personal protection. It is

included in the transformer circuit for the work lighting and serv-
ice outlet 230 V AC. This breaker is set to 30 mA and max. 40 ms.

The earth fault equipment should be tested regularly by a qualified

electrician.

The earth fault equipment settings are checked prior to delivery

and the equipment sealed.

Australian standard
The electrical system has an earth fault relay (K51) and two earth
fault breakers (F20 and F25).

The earth fault relay (K51) protects the outlet for the submersible
pump. This breaker is set by the supplier to 30 mA and max. 40
ms.

The earth fault breaker (F20) provides personal protection for the
power supply to the power supply cubicle (A40). This breaker is
set to 30 mA and max. 40 ms.

The earth fault breaker (F25) provides personal protection. It is in

the transformer circuit for the work lighting and service outlet 230
V AC. This breaker is set to 30 mA and max. 40 ms.

The earth fault equipment should be tested regularly by a qualified

electrician.

The earth fault equipment settings are checked prior to delivery

and the equipment sealed.

229
Motor protection

Electronic motor protection relay

1 2 3 4

6
1250 0104 15 7 5

1 Indicator for overheating

2 Indicator for phase loss and phase error
3 Indicator for overcurrent and thermal overload
4 Indicator for motor protection in operating position
5 Reset button
6 Setting rated current
7 Setting triggering time
Figure 12.5. Electronic motor protection relay (F01)

Each hydraulic pump motor has an electronic motor protection

relay (F01), which is equivalent to a thermistor relay and a thermo-
electric relay.

The motor protection has a green LED (4) that indicates that the
power supply is on and that the output relay is in operating posi-
tion. If the engine protection is triggered, the LED goes out.

The motor protection has three LEDs (1, 2 and 3) to indicate which
type of fault has triggered the protection.

LED (1) comes on when the permitted motor temperature is

exceeded (overheating).

LED (2) comes on in the event of a phase loss or a phase error.

LED (3) flashes when the permitted engine current is exceeded

(overcurrent). If this continues for a long period of time, the LED
will shine constantly and the motor protection will trigger due to
motor overload (thermal overload).

If the motor protection has been triggered

1. Check which LED (1, 2 or 3) is on and rectify the cause of the
stoppage.

a. LED (1) is on. Check that the electric motor is properly

cooled.

230
 b. LED (2) is on. Turn off the main switch for the input cable
and pull out the plug from the wall socket. Then check the
cables in the motor circuit and the electric motor.

c. If LED (3) flashes, this indicates that the motor current

exceeds the set rated current and that the motor protection
can soon be triggered.

If the LED starts to shine constantly and the motor protection

is triggered, check that the power supply complies with the
rated voltage on the rig's data plate. If the voltage is correct,
check the motor circuit, see item b above.

2. Once the cause of the stoppage has been rectified, reset the
motor protection with button (5).

Setting rated current

The motor protection must be set to the motor's rated current,
unless the motor has a service factor (SF) of 1.15. In this case, set
the value to 15% higher than the rated current (rated current x
1.15).

The rated current and service factor are specified on the motor's
data plate.

The motor protection has a basic setting of 20 A, which must be

considered when adjusting settings. In other words, the value you
enter must be 20 A lower than the rated current or 20 A lower than
the rated current x 1.15.

Adjust settings using the dipswitches on the engine protection.

Two examples follow.

231
 1. Electric motor with rated current of 85 A. Rated current - basic
value = 85 - 20 = 65 A.

OFF ON
+1

1
+2

2
+3

3
+5

4
+10

5
+20

6
+40

7
+80

8
1250 0104 16

Figure 12.6. Setting, example 1

2. Electric motor with rated current of 81 A and service factor

1.15. Rated current x service factor - basic value = (81 x 1.15) -
20 = 73 A.

OFF ON
+1
1

+2
2

+3
3

+5
4

+10
5

+20
6

+40
7

+80
8
1250 0104 17

Figure 12.7. Setting, example 2

232
Setting triggering time
The triggering time for the motor protection should be set to 18
seconds. Set using the dipswitches on the motor protection.

OFF ON
+2

1
+4

2
+8

3
+16

4
1250 0104 18

Figure 12.8. Setting triggering time, 18 seconds

Power supply cubicle

General
The power supply cubicle (A40) supplies the rig's 24 V system.
The cubicle has room for three power supply units (1, 2 and 3).
The number of power supply units depends on the number of
power consumers on the rig.

233
 POWER-ONE POWER-ONE POWER-ONE

POWER ON POWER ON POWER ON

O.V. SHUTDOWN O.V. SHUTDOWN O.V. SHUTDOWN

7 8
ALARM ALARM ALARM

1 2 3

1 2 + - - -
F124
K107

F100 15A

F101 15A

F102 15A

F104 15A

F105 15A
10 10 11 11 3 4 5 23 52 0

K110
N109
1250 0133 56

1 2 + - - -
F124

F100 15A

F101 15A

F102 15A

F104 15A

F105 15A
10 10 11 11 3 4 5 23 52 0

Figure 12.9. Power supply cubicle A40

Each power supply unit has three indicator lamps. If none of these
lamps are on, it is likely that the fuse (A) on the back of the unit
needs changing.

POWER-ONE

POWER ON

O.V. SHUTDOWN
A
ALARM
1250 0133 58

Figure 12.10. Fuse, back of power supply unit

Setting charge voltage

If one of the power supply units (1, 2 or 3) has been changed, the
charge voltage must be set on the new unit. Measure the set voltage
between 7(+) and 8(-) using a voltmeter, see the illustration above.
The set voltage should lie between 26.6 - 26.8 V DC.

1. Unscrew and remove the other power supply units, if there is

more than one unit.

2. Use a long screwdriver to adjust the charge voltage for each unit
as follows.

a. Power supply unit 1, adjust on potentiometer P11.

234
 b. Power supply unit 2, adjust on potentiometer P21.

c. Power supply unit 3, adjust on potentiometer P31.

P11

P21
POWER-ONE
PL20
POWER-ONE
P31
POWER ON POWER ON

O.V. SHUTDOWN O.V. SHUTDOWN

ALARM ALARM
POWER-ONE POWER-ONE

POWER ON POWER ON

O.V. SHUTDOWN O.V. SHUTDOWN

ALARM ALARM

1 3
1 3
K107

K110
N109

1 2 + - - -
F124
1250 0133 57

F100 15A

F101 15A

F102 15A

F104 15A

F105 15A

10 10 11 11 3 4 5 23 52 0

Figure 12.11. Setting charge voltage

3. Refit the other power supply units.

Cable recommendations
Table 12.2. Recommended cables for different rated voltages
Diameter
Rated voltage (V) Cable type Dimension (mm2) (mm) Length (m)
400 H07RN-F 4G150 67 60
440 H07RN-F 4G120 60 75
440 BUFLEX 3x150+3G25 52 100
460 - 500 H07RN-F 4G120 60 75
460 - 500 BUFLEX 3x150+3G25 52 100
500 - 550 H07RN-F 4G95 55 90
500 - 550 BUFLEX 3x120+3G25 46 135
660 - 700 H07RN-F 4G70 49 110
660 - 700 BUFLEX 3x95+3G16 42 155
1000 BUFLEX 3x50+3G10 32 275

235
Fault finding
Before starting fault finding, check that:

• all fuses are intact and turned on.

• the correct power supply is connected to the rig (see voltmeter).
• all warning lamps on the electric cubicle are in working order
(lamp test).

236
13. Electrical system, North America

Safety

WARNING
DANGER! High voltage.

Risk of serious injury.

Before intervening in the system, make sure

that it is DEAD.

Intervention in the electrical system is

restricted to qualified electricians only.
1250 0022 23

General

Safety standard
The electrical system complies with current regulations. Applied
directives and standards are specified in the Safety chapter. See
chapter Safety.

Low-voltage circuit
Low voltage refers to an alternating current with a voltage
greater than 50 V and less than or equal to 1000 V.

The rig's low-voltage circuit is a high-current circuit.

• Cable on reeling unit and collector

• Electric cubicle
• Electric motor(s) for hydraulic pump(s)
• Lighting
• Operating circuits
• Service outlet
• Battery charger for carrier (also extra low voltage)
• Indicator lamps on electric cubicle

237
Extra low-voltage circuit
Extra low-voltage refers to an alternating current with a voltage
less than or equal to 50 V and direct current with a voltage less
than or equal to 120 V.

• Operating circuits
• Guards in the system
• Battery charger for carrier (also low voltage)
• Lighting
• RCS system

Before starting
Check, before starting, all high-current connections in the electric
cubicle and the collector, as well as the electric motors. Also,
check that the plug is plugged in properly.

Cable marking
All the cables are marked with cable numbers corresponding to the
wiring diagram.

Replacement of components
Whenever changing components, make sure the new component
has the same Atlas Copco part number as the old one. Mark new
components with the same marking as the ones they replace.

238
Electric cubicle, high-current

Front

H06 H03 H02

Q01
1P01 2P01 P01

S11 S12
1250 0107 05

H02 Lamp pushbutton, motor overload

H03 Indicator lamp, phase sequence fault
H06 Lamp pushbutton, indicating main power and lamp test
1P01 Ammeter, electric motor 1
2P01 Ammeter, electric motor 2
P01 Voltmeter
Q01 Main switch
S11 Motor switch, electric motor 1
S12 Motor switch, electric motor 2
Figure 13.1. Electric cubicle A10, front

239
Inside
1Q02 2Q02 F25 K50 1K04 2K04

Q01

1F01 2F01
1250 0107 06

1F01 Electric overload protector, electric motor 1

2F01 Electric overload protector, electric motor 2
F25 Earth fault breaker
1K04 Thermistor relay, electric motor 1
2K04 Thermistor relay, electric motor 2
K50 Phase sequence switch
Q01 Main switch
1Q02 Circuit breaker, electric motor 1
2Q02 Circuit breaker, electric motor 2
Figure 13.2. Electric cubicle A10, inside

Electrical system protection

Main switch

General
The main switch (Q01) is on the 3-phase circuit in the electric
cubicle. It has a knob for on and off. The main switch has as stand-
ard under-voltage protection, thermal overload protection and
magnetic short-circuit protection.

The switch can be reset after being triggered by turning the knob to
position 0 (OFF) and then back to position 1 (ON).

Main switch short-circuit protection

The short circuit protection should be set to 10 x the breaker's rated
current (In).

240
Phase sequence switch
The electrical system has a phase sequence switch (K50) to pre-
vent starting the electric motor in the event of a phase fault in the
user's power socket. In case of a phase sequence fault, the indicator
lamp on the electric cabinet will come on, see section Electric
cubicle, high-current.

If the phase sequence fault indicator lamp comes on, the following
measures must be taken by a qualified electrician.

1. Turn off the main switch for the input cable and pull out the
plug.

2. Switch two of the phases in the consumer mains source.

Earth fault breaker

The earth fault breaker (F25) provides personal protection. It is
included in the transformer circuit for the work lighting and serv-
ice outlet 230 V AC. This breaker is set to 30 mA and max. 40 ms.

The earth fault breaker should be tested regularly by an authorised

electrician.

Motor protection

Electronic overload protection

Each hydraulic pump motor has electric overload protection (F01).

The overload protection must be set to the electric motor's rated

current x 1.15 by turning the knob (1) to the correct position. The
rated current is specified on the electric motor data plate.

The overload protection is reset with the RESET button (2).

241
 1

TRIP = 125% PWR

135

10 20 105
CLASS 90
75 45
TRIP 60

1250 0107 10

2
Figure 13.3. Electronic overload protection

Circuit breaker
Each hydraulic pump motor has a circuit breaker (Q02).

The circuit breaker short-circuit current must be set to 875A with

the know (A) as illustrated in the figure.

An activated circuit breaker is reset by moving switch (B) to posi-

tion 1.

1400 A
1200 A 1550 A

1000 A 1650 A
Min Max
875 A 1750 A

Min Max
I
250 A
0 250
600 V ~

I
1400 A
1200 A 1550 A

B
1000 A 1650 A
Min Max
875 A

0 250
1750 A

Min Max
1250 0107 39

Figure 13.4. Circuit breaker

242
Power supply cubicle

General
The power supply cubicle (A40) supplies the rig's 24 V system.
The cubicle has room for three power supply units (1, 2 and 3).
The number of power supply units depends on the number of
power consumers on the rig.

K110

1 2 3
1250 0104 85

7 8

Figure 13.5. Power supply cubicle A40

Each power supply unit has three indicator lamps. If none of these
lamps are on, it is likely that the fuse (A) on the back of the unit
needs changing.

POWER ON
A
O.V. SHUT-DOWN

ALARM
1250 0104 86

Figure 13.6. Fuse, back of power supply unit

243
Setting charge voltage
If one of the power supply units (1, 2 or 3) has been changed, the
charge voltage must be set on the new unit. Measure the set voltage
between 7(+) and 8(-) using a voltmeter, see the illustration above.
The set voltage should lie between 26.6 - 26.8 V DC.

1. Unscrew and remove the other power supply units, if there is

more than one unit.

2. Use a long screwdriver to adjust the charge voltage for each unit
as follows.

a. Power supply unit 1, adjust on potentiometer P11.

b. Power supply unit 2, adjust on potentiometer P21.

c. Power supply unit 3, adjust on potentiometer P31.

P21 P31

POWER ON

O.V. SHUT-DOWN
POWER ON

O.V. SHUT-DOWN
ALARM
ALARM

1
1
1250 0104 20

P11

Figure 13.7. Setting charge voltage

3. Refit the other power supply units.

Fault finding
Before starting fault finding, check that:

• all fuses are intact and turned on.

• the correct power supply is connected to the rig (see voltmeter).
• all warning lamps on the electric cubicle are in working order
(lamp test).

244
14. Reeling units, option

Cable reeling unit

C B

1250 0061 61

A Gear with motor

B Collector
Figure 14.1. Cable reeling unit

Hose reeling unit

1250 0134 84

A Gear with motor

Figure 14.2. Hose reeling unit

General
The reeling unit is controlled by a hydraulic motor. Unwinding
from the reel while travelling takes place by allowing the clutch on
the reel gear to slip. The unwinding control should be left in neu-
tral. Winding is done with the help of a hydraulic motor. The slip
clutch must be adjusted so that it is able to wind up the cable/hose
hydraulically but can still slip when the cable is being unwound
during travel.

245
Reeling unit gear

C A

1250 0061 62
D

A Oil level glass

B Set key for adjusting reel torque.
C Set screw for adjusting drive chain (not direct drive)
D 4 bolts, attachment for reeling unit gear.
Figure 14.3. Reeling unit gear

1. Check the oil level through the level glass (A) regularly. Top up
when necessary. See maintenance schedule Diesel engine
hours.

Adjusting reeling unit drive chain

1. Undo the four bolts (D) holding the gear.

C A

1250 0061 62
D

Figure 14.4. Reeling unit gear

2. Adjust the chain using the set screw (C). The chain slack should
be 10-15 mm.

3. Tighten the four bolts (D).

246
Adjusting the reeling unit slip clutch
The slip clutch should slip when winding in the electric cable or
water hose. The torque, which is conveyed by oil in the gear,
should be measured in operation while the clutch is slipping and is
only to be adjusted hard enough to lift and wind the cable or hose
without any slack.

For fault-free operation and retained torque, the oil in the gear
must be changed regularly.

The setting is done with small adjustments to the spring package,

1/6 of a turn at a time, after which the operation is tested and
adjusted again if necessary.

The following torque is recommended.

Cable reeling unit: Torque in operation on drum periphery to be

adjusted so that it corresponds to 25-30 kg (max 40-50 kg).

Hose reeling unit: Torque in operation on drum periphery to be

adjusted so that it corresponds to 10-15 kg (max 15-20 kg).

N.B.
The gear and chain can be damaged while winding out the cable
or hose if the clutch is set too hard. Always turn off the hydrau-
lics when not using the reeling units.

1. Screw out the set key (B).

C A

1250 0061 62
D

Figure 14.5. Reeling unit gear

2. Insert the set key upside down into the gear housing.

3. Rotate the drum slowly until the set key falls into locked posi-
tion.

4. The torque will increase as the drum is turned half a turn clock-
wise and decrease if turned half a turn anticlockwise.

247
 5. Remove the set key.

6. Check the torque. Repeat the procedure if further adjustment is

required.

Collector, cable reeling unit

Collector F460/1 and K4122/1

A
1250 0020 33

A Collector
Figure 14.6. Changing collector

Checking the collector

WARNING
DANGER! High voltage.

Risk of serious injury.

Before intervening in the system, make sure

that it is DEAD.

Intervention in the electrical system is

restricted to qualified electricians only.
1250 0022 23

The location of the collector depends on the type of rig. On some

rigs, the collector is located inside the cable reeling unit protected
by a cover plate that must be removed during inspection. On other
rigs, the collector is located in a protective box mounted on the
outside of the reeling unit.

248
 After about a week's use, the nuts on all the cable terminals on a
new or reconditioned collector must be retightened. The collector
slip rings must be retightened according to the torque table.

1. Make sure the collector housing and collector rings are dry,
clean and free from oil, copper deposits and other impurities.

2. Use a vacuum cleaner, clean cloth and a brush for cleaning.

NEVER USE WATER OR COMPRESSED AIR.

3. Replace damaged components with new ones.

4. Make sure the protective cable stocking is fitted properly.

Settings
See maintenance instructions Hydraulic system: Settings for set-
ting the speed of the reeling units.

Limit switch, option

Description
The task of the limit switch is to:

• warn when there are only three turns left on the drum of the
cable reeling unit.
• activate the parking brake when there is one turn left on the
drum of the cable reeling unit.

Adjusting
Adjust the limit switch contactors if the cable on the reel is
changed or if their settings are inadvertently changed.

249
 1. Remove the limit switch cover (1).

Figure 14.7. Limit switches

2. Slacken the lock screw (A).

A B C

E
1250 0113 97

Figure 14.8. Lock screw, set screw and contactors

3. Run out the cable until there are three turns left on the drum of
the cable reeling unit.

250
4. Adjust screw (C) until contactor (D) activates warning lamp
(H209) on the control panel.

Figure 14.9. Control panel

5. Run out the cable until there is one turn on the drum.

6. Adjust screw (B) until contactor (E) activates the parking brake.
Parking brake activation is indicated by lamp (H208) on the
control panel.

7. Tighten locking screw (A).

8. Refit the limit switch cover (1).

251
15. Exhaust filtering, option

Safety

WARNING
Make sure the engine is switched off during all
maintenance work.
Hot engine parts can cause personal injury.
Take care when draining hot oils/fluids, risk of
.burn injuries.
1250 0022 15

Scrubber

General

B
C
1250 0037 65

A Level cock
B Cock, water connection
C Draincocks
Figure 15.1. Exhaust filtering

Ensure the water level in the scrubber is sufficient by frequently

filling up with water.

252
Filling up with water
1. Make sure stopcock (1) is closed and stopcock (3) is open.

3
1
2 4

1250 0020 60 5
Figure 15.2. Water inlet

2. Connect a water supply to (4).

If the rig has a hose reel, connect the water to reel, as this in
turn is connected to connection (4).
3. Open cock (A).

B
C
1250 0037 65

Figure 15.3. Scrubber

4. Open cock (B) until water runs from cock (A).

5. Close cock (B) and then cock (A).

253
 6. The water line must be depressurised before it can be discon-
nected. Therefore, open cock (1) and close cock (3).

3
1
2 4

1250 0020 60 5
Figure 15.4. Water inlet

7. Disconnect the water from (4).

If the rig has a hose reel, disconnect the water from this.
8. Close cock (1).

Freeze prevention measures

Draining
1. Open water cock (C) and empty the system.

B
C
1250 0037 65

Figure 15.5. Draining the scrubber

2. Close water cock (C).

254
Particle filter

General
4
5

3
1250 0083 56

1 Particle filter
2 Flashing unit
3 Fan
4 Pressure switch (exhaust back pressure)
5 Indicator lamp (exhaust back pressure)
Figure 15.6. Particle filter and flashing unit

The particle filter (1) is mounted on the rig exhaust system where it
cleans solid particles (soot) from the exhaust gases. The particle
filter also acts as an silencer.

A pressure switch (4) is mounted on the rig exhaust system senses

the exhaust back pressure. When the exhaust back pressure is too
high, an indicator lamp (5) will light on the control panel to remind
the operator that the particle filter needs flashing.

After about 8 hours of operation, or as soon as the indicator lamp

(5) lights up, the filter must be flashed using the flashing unit (2).

A supply of air is required for the flashing. Normally, the flashing

unit is connected to compressed air supply. If this is not available,
the flashing unit can be equipped with a fan (3) instead.

255
Technical data

Efficiency, particle filter

Particle reduction (soot) 96 %
Silencing >15 dB

Weight, particle filter

Particle filter, model K 18 39 kg
Particle filter, model S 18 39 kg

Flashing the filter

Safety

Introduction
The particle filter should be flashed after about 8 hours of opera-
tion or as soon as the indicator lamp on the control panel lights up
continuously.

The flashing unit takes more or less time depending on the filter
fitted on the rig. Particle filter model K has a flashing time of about
8 hours. Particle filter model S has a flashing time of around 1
hour.

Flashing the filter, model K

The flashing unit for particle filter model K has two indicator
lamps (H1 and H2). The lamp (H1) comes on as soon as the flash-
ing starts and indicates that air is flowing to the filter. Lamp (H2)
comes on when flashing is complete (after approx. 6 hours). After
flashing, air will continue to flow in order to cool down the filter,
which will take about 2 hours. Lamp (H1) will go out when cool-
ing is complete.

256
 P1

P2
QL1

H1

H2

1250 0083 58

P1 Ammeter for flashing unit

P2 Ammeter for flashing unit
H1 Indicator lamp
H2 Indicator lamp
QL1 Knob for flashing unit on/off
Figure 15.7. Flashing unit for filter model K

1. Couple together the particle filter and flashing unit electric and
air connections.

2. Start flashing by turning knob (QL1) to position 1.

3. Check the flashing unit ammeter (P1 and P2) to see whether all
the flashing elements are drawing current.

4. Turn knob (QL1) back to position 0 once the flashing and cool-
ing has been completed and lamp (H1) has gone out

5. Disconnect the flashing unit from the rig.

Flashing filter, model S

The flashing unit for particle filter model S has a digital timer
(KT1) that shows the remaining time for flashing in minutes.
Flashing takes about 40 minutes. Once flashing is completed, the
indicator lamp (H1) on the flashing unit will come on.

Once flashing is complete, air will still be supplied to the filter in

order to cool it down. The timer will now start to count down the
remaining cooling time. Cooling the filter will take about 20 min-
utes.

257
 1250 0083 57

P1-P3 Ammeter for flashing unit

H1 Indicator lamp, flashing complete
QL1 Knob for flashing unit on/off
KT1 Digital timer
Figure 15.8. Flashing unit for filter, model S

1. Couple together the particle filter and flashing unit electric and
air connections.

2. Start flashing by turning knob (QL1) to position 1.

3. Check the flashing unit ammeter (P1 - P3) to see whether all the
flashing elements are drawing current.

4. Turn knob (QL1) back to position 0 once the flashing and cool-
ing has been completed

5. Disconnect the flashing unit from the rig.

Extra filter cleaning

1. Flash the filter as usual.

2. Allow the filter to cool for 3-4 hours.

3. Undo the clamps and dismantle the filter section (middle sec-
tion).

4. Place the filter section vertically and flush with water from the
outlet side so that the filter is cleaned from fuel and lubricant
residue.

Do not use high-pressure jets.

5. Let the filter drip dry.

6. Reassemble the filter with new gaskets.

258
Checking the indicator lamp
Check that the indicator lamp on the operator panel at regular
intervals. The following measures should turn on the lamp.

• Short the pin on the pressure sensor and make sure the indicator
lamp comes on.
• Block the exhaust pipe and make sure the indicator lamp comes
on. Clean soot from the connecting pipe if the lamp does not
come on.

Catalytic converter

General
The catalytic converter is effective for cleaning only once the
engine has warmed up.

Changing the catalytic converter

1. Loosen the clamps around the catalytic converter.

2. Change the catalytic converter.

259
16. Fire fighting equipment, option

Fire fighting systems

Description
The rig is equipped with an Ansul 101 or Forrex fire fighting sys-
tem to extinguish any engine fires.

The system consists of:

• a triggering system
• an N 2 cartridge
• extinguishing medium
• nozzles over the engine and hydraulic transmission
The chemical agent in Ansul 101 is FORAY (based on monoam-
monium phosphate) while Forrex contains a water-based agent.
These extinguishants are effective on class A, B and C fires.

There are also various types of fire fighting systems, manual and
automatic.

Ansul
• Manual system
Consists of only one fire fighting system. In case of fire the fire
fighting system must be activated manually.
• Automatic system (Checkfire).
Consists of a system with a sensor that automatically activates
the fire fighting system in case of fire. It can also switch off the
engine, cut off the supply of petrol and lock the brakes if an
alarm situation arises.

Forrex
• Manual system - M.
Consists of only one fire fighting system. In case of fire the fire
fighting system must be activated manually.
• Automatic system -EAA
Comprises an extinguisher system and a fire alarm.
Activates the fire fighting system automatically when the fire
alarm starts. Stops the engine, cuts off the fuel and turns off the
battery switch at the same time (option).

260
 Automatic operation can be disengaged from the central unit
whenever necessary.

Locations

1 Tank with actuating device

2 Activators
3 Nozzles
Figure 16.1. Location of extinguishing installation for M2/L2/L1

Manual triggering
1. Pulling out the pin (A) and pressing button (B) activates the fire
fighting system and the contents are spread through the nozzles
over the engine and transmission.

2. If the system has been used, it is important that the nozzles are
changed and the pipes cleaned.

261
 B

1250 0020 63

Figure 16.2. Activators

Maintenance of fire fighting system

Safety measures
Be sure to avoid the accumulation of flammable items in the
machine such as leftover oil and fuel that could intensify the fire or
help spread it to places which otherwise do not in themselves con-
stitute a fire hazard.

Most important of all for avoiding fires in the machine are:

Periodic inspection and preventive service at those points where

fire can most easily break out - engine bay, electrical system,
turbo, manifolds and brake system.

Regular cleaning of all areas where flammable materials like oil,

grease, hydraulic fluids and other waste can accumulate.

Modification of the machine

If the machine is modified, an authorized fitter must check over the
fire-extinguishing system when the modification has been com-
pleted.

262
Service
It is essential that the fire fighting system is inspected at least once
a year by an authorized service company. Contact Atlas Copco's
sales company in your country for information regarding author-
ized service companies.

Steps to take after a fire or activation of the fire-fighting system

Do not start the machine until it has been cleaned and serviced.
Water can be used to remove chemicals. Neither should you start
the machine until the cause of the fire has been found and elimi-
nated. Recharge the fire-fighting system before you start to use the
machine again. You needed it once, you may need it again.

263
17. Service platform

HL 210-300 MB, HL 210-300 MBC

1250 0070 42

Figure 17.1. Service platform

Technical data

HL 210 MB/MBC

Maximum loads
for platform without protective roof400kg
for platform with protective roof 350kg

Working radius, swing angle and lifting range

Largest working radius 10250mm
Smallest working radius 6250mm
Swing angle 45°
Lifting range Up 60°
Down 35°

Weights
Weight for platform without protec-
tive roof 1625kg
Weight for platform with protective
roof 1675kg

Other
Working pressure 200bar

264
HL 230 MB/MBC

Maximum loads
for platform without protective roof400kg
for platform with protective roof 350kg

Working radius, swing angle and lifting range

Largest working radius 11300mm
Smallest working radius 6300mm
Swing angle 45°
Lifting range Up 60°
Down 35°

Weights
Weight for platform without protec-
tive roof 1800kg
Weight for platform with protective
roof 1850kg

Other
Working pressure 200bar

HL 300 MB/MBC

Maximum loads
for platform without protective roof450kg
for platform with protective roof 400kg

Working radius, swing angle and lifting range

Largest working radius 14150mm
Smallest working radius 6250mm
Swing angle 45°
Lifting range Up 60°
Down 35°

Weights
Weight for platform without protec-
tive roof 2865kg
Weight for platform with protective
roof 2915kg

265
 Other
Working pressure 200bar

Safety

CAUTION
Hazardous hydraulic oil pressure.

Risk of personal injury.

Operation of hydraulic oil system can involve great danger.

.Make sure the system is made pressure-free first.
1250 0022 19

Slinging
To avoid damage and accidents, it is essential that great care be
taken when slinging and lifting the service platform.

Distance to centre of gravity when slinging

Note
The following applies for slinging and lifting:
• A new service platform is delivered in transport position. If
this is not the case, make sure that the telescope is com-
pletely contracted and that the service platform is in the
horizontal position.
• Make sure to lift directly above the centre of gravity.
• Lift slowly and carefully. Make sure the slings do not slip or
become damaged and that the service platform does not
start to swing.

266
 g

1250 00 70 44

Figure 17.2. Distance to centre of gravity in relation to attachment

plate (telescope contracted)

Table 17.1. Distance to centre of gravity in relation to attachment

plate.
Distance to centre of HL 210 HL 230 HL 300
gravity (g) MB/MBC MB/MBC MB/MBC
Telescope contracted 2995 mm 3040 mm 2330 mm

Supporting the service platform

Note
In connection with all forms of service and maintenance work the
service platform must be supported on stands.

1250 0070 43

Figure 17.3. Supporting the service platform

Tools
The following tools will be required when carrying out mainte-
nance on the service platform and are available on special order:

267
 1. Hexagon hole spanners 3, 4, 5, 6 and 10 mm.

2. Hexagon spanners, width across flats 10, 13, 17, 19, 24, 36 and
36 mm.

3. Screw tap, M8.

4. Drills 6 and 8 mm.

5. Screwdriver.

6. Hook spanner, SKF HN7, HN8, HN13 and HN15.

7. Adjustable pin spanner, Belzen no. 4310.

Adjusting play in telescope tube guide

1. Undo bolts 1.

2. Screw in or out set screws 2 until the opening between the guide
heel and telescope tube is approximately 0.5 mm.

3. Tighten bolts 1.

1 2
0,5 mm

1250 0070 45

Figure 17.4. Adjusting play in telescope tube guide

Bleeding the hydraulic system

Note
Air in the hydraulic system can be detected if one or more hydrau-
lic cylinders give or operate jerkily.
The hydraulic system must be bled if air enters the system.

1. Check the oil level in the hydraulic oil tank before bleeding.

268
 2. Operate the cylinders several times between their end positions.
(This will force the aerated oil back to the hydraulic tank where
the air can be separated.)

Rear boom link

Checking clearances
1. Lower the service platform to the ground to relieve the boom
link.

2. Draw a line (C) with a marker pen on the boom bracket (A) and
the boom link (B). See illustration below.

C
A

B
1250 0004 09

Figure 17.5. Marking on boom bracket and rear boom link

3. Raise the service platform form the ground and measure the dis-
tance between the lines on the boom bracket and the boom link.

If the play exceeds 2.5 mm, the shaft must be disassembled

and the bushings replaced.

Lubricating before start

When starting a newly delivered, newly reconditioned or seldom
used service platform, it is essential that the lubrication is effective
from the beginning. See maintenance interval Operating hours.

Function check
1. Check the service platform for transport damage.

269
 2. Make sure no threaded joints or hoses have been shaken loose.

3. Make sure there are no oil leaks while performing all operative
movements.

4. Check that the entire service boom movement pattern can be

performed (all the hydraulic cylinders should be operated to
their end positions) without any hoses getting jammed or
pinched.

Long-term storage
If the service platform is not to be used for a long period, the fol-
lowing measures must be taken:

1. Clean the boom by spraying it with de-greasing agent. Then

flush with warm water and blow dry with compressed air.

2. Lubricate according to the lubrication schedule, see mainte-

nance intervals Operating hours.

3. Apply anti-rust oil on unpainted surfaces such as piston rods,

sliding surfaces, etc.

4. Keep the service platform in a dry place.

Transport
The following applies if the service platform is to be removed to
facilitate transport:

1. Remove the axle holding the hydraulic cylinder for the service
platform from the boom side.

2. Bind the loose cylinder at the service platform to prevent it

from being damaged.
3. Detach one of the cylinder ends for parallel holding. Lash the
loose cylinder end to the boom body.

270
4. Detach hydraulic hoses LK3, LK4 and LT1from the service
platform's valve block and attach them to a closed circuit to the
tank.

LK3

LK4

1250 0094 48
LT1
Figure 17.6. Connecting hydraulic hoses

Connecting the hoses together prevents pressure build-up in the

parallel cylinder circuit.
5. The remaining hoses of the service platform are detached and
plugged.

6. Remove the axle holding the service platform.

7. Dismantled shafts and bushes from cylinder lugs must be pro-

tected against corrosion with anti-corrosion agent and suitably
wrapped.

8. When the service platform is refitted and the hydraulic hoses

reattached, it is important to bleed the hydraulic system.

271
18. Swellex pump

HSP A51 Mk IB, option

3 4
2

6
7
1250 0089 85 8
1 Pressure switch
2 Pressure control valve
3 Axial plunger pump
4 Hydraulic motor
5 Control box, start and stop of Swellex pump
6 Electrical box
7 Pressure sensor (hidden)
8 Water filter
Figure 18.1. Swellex pump

The Swellex pump HSP A51 Mk IB is an axial plunger pump

designed exclusively for use with Atlas Copco's Swellex bolts.

The pump can be started by pressing the green button (A) whereby
the hydraulic motor will run at a constant speed. If the installation
arm is not activated, the pressure will rise to the preset value and
the pump will start to idle after 6 seconds. Once the installation
arm is activated, the pump will immediately start to pump water.
When the pressure has finally attained the set value, the pressure
switch will indicate the fact and the electric motor will be turned
off and come to rest after 6 seconds. The preset pressure is main-
tained in the installation arm until it is activated. The pump will
restart once the installation arm is activated and can be turned off
by pressing button (B).

272
 A
B

1250 0056 76

A Green button, start Swellex pump

B Red button, stop Swellex pump
Figure 18.2. Control box, start and stop of Swellex pump

Note
If the temperature is expected to drop below 0°C, the water system
must be drained to prevent the build up of ice. See section Freeze
prevention measures .

Swellex arm
A

B
C
1250 0056 43

D
A Pressure gauge
B Chuck
C Three-way valve
D Trigger
Figure 18.3. Swellex arm

273
Safety

WARNING
Extremely high water pressure from the pump.

Risk of injury.

Rectify any leakage in high-pressure lines and

couplings without delay.

Before carrying out any work on the pump,

turn off the main switch for the power supply.
Before starting work on the pump, check that
the hydraulic system is depressurized.
Before starting work on the pump, check that
the water system is not under pressure. Do this
by pressing the release button on the Swellex arm.
1250 0035 31

Technical data

HSP A51 Mk IB

Water pressure, water consumption and water temperature

Water pressure, in 2-8bar
Max. water pressure, out 320bar
Water consumption 10litres/min
Max. temperature, water 70°C

Hydraulic motor
Pressure 190-230bar
Unladen flow 20litres/min
Displacement 15cc/rev
Voltage 24V, stabilised
Max. voltage 28V DC
Max. current consumption 1A

Axial plunger pump

Type Speck A51/10

274
 Rated flow 10litres/minute
Max. pressure 320bar
Oil capacity 0.27litres

Water filter
Max. water pressure, in 8bar

Weight
Installation arm with valve and
chuck 6.5kg
Chuck only 1.0kg
Hoses 2.0kg
Pump unit 48kg

Size
Pump unit (length x width x height)660x300x300mm

EC - Declaration of conformity
CE marked Yes

Other
Vibration in installation arm Unmeasurable
Sound level at operator's ear Below 80dB (A)

275
Connecting the Swellex pump

5
4
3
2
1

1250 0089 86

1 Swellex arm connection

2 Water inlet connection
3 Inlet pressure connection, oil
4 Drain connection, oil
5 Return connection, oil
Figure 18.4. Swellex pump connections

Table 18.1. Connections, description

Pos. Connection Hose designation Coupling
1 Swellex arm SWW2 9/16” jic coupling
2 Water inlet SWW1 3/4” jic coupling
3 Pressure inlet, oil SWP 7/8” jic coupling
4 Drain, oil SWD 7/8” jic coupling
5 Return, oil SWT 3/4” jic coupling

276
Component parts

Pressure switch

General
Pressure switch (D) is set on delivery for a swelling pressure up
to 300 bar, which is used for Standard and Super Swellex bolts.

For a lower swelling pressure, pressure switch SP2 should be

changed. See section Swelling bolts to other pressures. Other
pressure switch values must be set according to basic setting.

1250 0089 87

Figure 18.5. Pressure switch (D)

Basic setting

Note
Change the SP2 value to set another swelling pressure for Swellex
bolts. See section Swelling bolts to other pressures.

Table 18.2. Basic setting of pressure switch on delivery

Setting Parameter Value Explanation
Cut-in point SP1 56 Specifies the pressure at which switch one is ac-
tive. The upper LED lights up on the display.
Cut-out point rP1 52 Specifies the pressure at which switch one ceases
to be active.
Cut-in point delay dS1 0 Specifies for how long the measured pressure is to
exceed SP1 before switch one is made active.

277
Setting Parameter Value Explanation
Cut-out point delay dr1 0 Specifies for how long the measured pressure
must be below rP1 before switch one is made inac-
tive.
Output switch func- OU1 Hno Specifies whether switch one is to be normally
tion open, Hno, or normally closed, Hnc.
Cut-in point SP2 300 The SP2 value governs the pressure at which
the pump is to shut off.
Specifies the pressure at which switch two is ac-
tive. The lower LED lights up on the display.
Cut-out point rP2 52 Specifies the pressure at which switch two ceases
to be active.
Cut-in point delay dS2 6.0 Specifies for how long the measured pressure
must exceed SP2 before switch two is made ac-
tive.
Cut-out point delay dr2 0 Specifies for how long the measured pressure
must be below rP2 before switch two is made inac-
tive.
Output switch func- OU2 Hno Specifies whether switch two is to be normally
tion open, Hno, or normally closed, Hnc.
Sampling interval dAP 60 Time between pressure readings.

Note
If any of the values are changed by mistake, see the section
Change pressure switch settings to reset the values using the table
above.

Check pressure switch settings

1. Press the Mode/Enter button repeatedly until the desired param-
eter is shown on the display (1).

2. Press the Set button briefly. The parameter value is shown on

the display (2) for five seconds.

Mode/Enter Set Mode/Enter Set

[bar] [bar]

1 2
1250 0056 74

Figure 18.6. Pressure switch display

278
Change pressure switch settings
The following steps are an example of how to change the pressure
switch setting for parameter SP2. Parameter SP2 governs the pres-
sure to which the bolt is swelled.

1. Press the Mode/Enter and Set buttons together for ten seconds.

Step one must be carried out to indicate that the settings are to
be changed, not just viewed.
2. Then press the Mode/Enter button repeatedly until the parame-
ter SP2 is shown on the display (1).

3. Change the value by pressing the Set button until the desired
value is shown on the display (2).

4. Confirm the change of value by pressing the Mode/Enter button

once.

5. Press the Mode/Enter and Set buttons together for ten seconds.

Step five must be carried out to indicate that the pressure switch
is to be locked to avoid changing any other values.

Mode/Enter Set Mode/Enter Set

[bar] [bar]

1 2
1250 0056 74

Figure 18.7. Pressure switch display

Note
In order to swell a bolt to a pressure other than the preset one, the
pressure switch and the pressure control valve both be adjusted.
See section Swelling bolts to other pressures, for more information
on how to proceed.

Error messages
On certain occasions, the pressure switch can indicate causes of
faults on the Swellex pump that affect the function of the pressure
switch.

279
 Table 18.3. Error messages
Error messages Explanation
OL, Overload Pressure Pressure too high
SC1 flashing, Short-circuit Short circuit on output switch 1
SC2 flashing, Short-circuit Short circuit on output switch 2

Pressure control valve

General
Pressure control valve (C) is mounted directly on the pump unit. If
the pump attains a pressure higher than the pressure set for the
pressure control valve, the valve will open and lead the water back
to the pump's water inlet.

1250 0056 77

Figure 18.8. Pressure control valve (C)

Setting the pressure control valve

The pressure control valve can be adjusted using the lock nut (3)
on the end of the blue spring. Undoing the lock nut will reduce the
pressure and tightening it will increase the pressure. Max setting
for pressure control valve, see section Technical data.

280
 3

1250 0062 39

Figure 18.9. Pressure control valve lock nut (3)

Table 18.4. Examples of pressure settings

Exam- Desired swelling Pressure control valve set-
ple pressure, bolt ting
1 300 bar 308-316 bar
2 240 bar 248-256 bar

Note
In order to swell a bolt to a pressure other than the preset one, the
pressure switch and the pressure control valve both be adjusted.
See section Swelling bolts to other pressures, for more information
on how to proceed.

Pressure reducing valve

The pressure control valve is used to govern the water pressure to
the water filter (H). The water pressure reading on the pressure
gauge (E) must not be excessive as this will damage the water fil-
ter.

Adjusting the pressure reducing valve

1. Screw in the adjusting screw on the pressure reducing valve
(G).

2. Check that the reading on pressure gauge (E) does not exceed
the maximum water pressure for the water filter, see section
Technical data.

281
 E

F
G
1250 0089 90
H
E Pressure gauge
F Button for bleeding the system
G Adjuster screw for pressure reducing valve
H Water filter
Figure 18.10. Part of Swellex pump

282
Water filter

General

F
G
1250 0089 90
H
E Pressure gauge
F Button for bleeding the system
G Adjuster screw for pressure reducing valve
H Water filter
Figure 18.11. Part of Swellex pump

The Swellex pump pressure sensor automatically limits the max

water pressure to the water filter to protect it.

To avoid air in the system, it should be bled every time the water
filter is checked or changed.

Note
The water filter will be damaged if the limit for the pressure of sup-
ply water to the pump is exceeded. See section Technical data. If
damaged, the water filter must be changed.

Changing water filter and bleeding the system

1. Make sure the water supply to the pump is turned off.

2. Unscrew the filter housing.

3. Remove the filter housing from the pump unit case.

4. Change filter if necessary.

5. Then screw the filter housing back on.

283
 6. Connect the water supply to the pump.

7. Start the pump.

8. Press button (F) on the top of the filter housing to bleed the sys-
tem.

Swellex arm

Changing chuck seals

The chuck seals must be changed if the chuck leaks while install-
ing bolts. This can be done on site. Other chuck repairs must be
carried out in a workshop.

1. Undo nut (1).

Figure 18.12. Chuck

2. Remove the seals (2) and spacer ring (3).

3. Clean all parts thoroughly. Change the seals, spacer ring (3) and
any damaged parts.

4. Lubricate the plunger 4 with waterproof grease.

5. Fit the chuck with the new seals.

6. Tighten the nut (1).

Water pump

Checking the seals

1. Remove the first valve housing, see section Checking the
valves.

284
 2. Remove the leakage return ring (J), seal housing (M) and seals
(K) from plunger (D).

Figure 18.13. Seals

3. Thoroughly clean the valve housing and the drainage hole in the
leakage return ring (J). Check the surface of the plunger for
damage.

4. Replace any worn parts

5. Change the seals by removing spacer ring (N) and carefully

extracting the seals (O) with a hook.

6. Refit in reverse order.

Checking the valves

1. Clean thoroughly before detaching the valves.

285
 2. Remove the 5 plugs (F).

Figure 18.14. Valves

3. Remove the pressure valve (E).

4. Inspect components and change worn parts.

5. Undo the 5 nuts (B).

6. Remove the suction flange (C) and valve housing (D).

7. Remove the valve retainer (G) from the back of the valve hous-
ing.

8. Remove the suction valve (H).

9. Inspect components and change worn parts.

10.Refit in reverse order.

11.Tighten nuts (B) to 47 Nm.

286
Repairing the water pump
1. Drain the oil by opening the oil drain plug (G).

Figure 18.15. Water pump

2. Undo the 4 bolts (L) from the motor flange, which secures the
pump to the electrical motor.

3. Remove the pump housing (E) from the connection flange (A)
by undo the 8 bolts (L) in diagonal pairs, so that the spring force
does not unevenly load the gearbox.

4. Remove the plungers (D), complete with seal housing (M) and
seals (K), and leakage return ring (J).

5. Inspect for worn parts such as plungers, bearings and seals.

Change if necessary.

6. Refit in reverse order.

7. Firstly, fit the pump housing (E) loosely to the connection

flange (A) using 2 M8x50 bolts (L). Make sure that the gearbox
is not placed skew. Then tighten the bolts (L) in sequence.
8. Fit the plungers (D) and all seals.

9. Fit the valve housing assembly. Tighten nuts (B) to 47 Nm.

10.Before fitting the pump to the electric motor, make sure all dirt
has been removed and there are no sharp edges.

11.Press in the pump along the hydraulic motor shaft in one move-
ment. Secure the pump to flange (A) with bolts.

287
Swelling bolts to other pressures

Change of pressure
The steps below describe how to swell a bolt to a pressure lower
than 240 bar, used for Midi Swellex bolts.

1. Temporarily adjust the SP2 value of the pressure switch to 350

bar, see section Pressure switch.

2. Start the pump.

3. Check the pressure on the switch display.

4. Adjust the pressure control valve lock nut until the value on the
pressure switch display is 252 (+/-4). See section Pressure con-
trol valve.

The pump will now be circulating the same water and can there-
fore quickly overheat, which is noticed by noise. Therefore,
drain the water regularly when adjusting the pressure control
valve lock nut by pressing in the handle on the Swellex arm.
5. Stop the pump.

6. Adjust the SP2 value of the pressure switch to 240 bar.

7. Check that the pressure switch dS2 value is set to 6 seconds.

See section Pressure switch.

Checking a change of pressure

1. Start the pump.

2. Bleed the system by pressing the handle on the Swellex arm.

3. After releasing the handle, the pressure switch display should

increment until it shows 252 (+/-4) and then maintain that pres-
sure for 6 seconds before the pump is automatically turned off.

4. If the pressure deviates from the specified value, it must be

adjusted using the pressure control valve lock nut. See section
Pressure control valve. Repeat steps 1-4 until the specified
value is shown on the pressure switch display.

Note
Check that the pressure is maintained once the pump has stopped.
A rapid decease in pressure indicates that there is a leak on the
pressure side. The pump will then start automatically once the

288
 pressure has dropped to 52 bar. This leads to unnecessary pump
wear, even when the pump is not used for bolting. Any leaks must
therefore be located and rectified.

Changing oil

Recommended oils
Use a polyalkylene glycol-based synthetic oil, e.g. Statoil Avia
Avilub VSG68. Other oils that may be used are:

• Klüber Lubrication Syntheso HT68

• Elf Oil Syntherma P55
Use SAE 80 gearbox oil as an alternative if the above oils are not
available.

Changing oil
1. Check that the oil does not contain water. If the oil contains
water there could be an internal leak. Any leaks must be located
and rectified before the oil is changed.

2. The oil is drained by opening the drain plug (L) positioned on

the opposite side from oil filler plug (J).

I
J
K
1250 0062 40 L

I Axial plunger pump

J Oil filler plug
K Oil level glass
L Oil drain plug
Figure 18.16. Swellex pump axial plunger pump

3. Thoroughly clean around the oil filler plug (J) before opening it.

4. Inspect the oil carefully to see that it is clean and the correct
grade.

289
 5. Check that the right oil level is reached by checking level glass
(K). With the pump turned off, the oil level should be in the
centre of the glass. Close plug (J) properly.

Test running
1. Make sure the equipment is not damaged.

2. Connect hydraulics and water:

a. to the pump, see section Connecting the Swellex pump.

b. to the rig, see operator's instructions Electrical system:

Connecting to mains.

3. Check the pressure of water supplied to the Swellex pump. See

section Technical data.

4. Check the integrity of the seals in chuck (B) and that the seals
are clean. If the seals leak it will not be possible to provide the
necessary pressure. For changing the seals, see section Chang-
ing chuck seals.

B
C
1250 0056 43

D
A Pressure gauge
B Chuck
C Three-way valve
D Trigger
Figure 18.17. Swellex arm

5. Make sure all the high-pressure water hose connections are

tightened securely and that none of the hoses are damaged. A
leaking system can give a low installation pressure.

290
6. Check that the water filter is clean. If necessary change filter
(H).

F
G
1250 0089 90
H
E Pressure gauge
F Button for bleeding the system
G Adjuster screw for pressure reducing valve
H Water filter
Figure 18.18. Swellex pump water filter

7. Check the oil level (K) for axial plunger pump (I). If necessary
top up with oil (J).

291
 When taking a new pump into service, the first oil change must
be carried out after 50 operating hours.

I
J
1250 0056 78
K
L

I Axial plunger pump

J Oil filler plug
K Oil level glass
L Oil drain plug
Figure 18.19. Swellex pump axial plunger pump

8. Connect a 9-12 mm (1/4”-1/2”) needle valve to the high-pres-

sure pump outlet. Water can be led off through a hose mounted
on the needle valve.

9. Open the needle valve.

10.Turn on the water and start the pump:

292
a. with the green button (A).

A
B

1250 0056 76

A Green button, start Swellex pump

B Red button, stop Swellex pump
Figure 18.20. Control box, start and stop of Swellex pump

b. with the green button (1), applies to RCS.

1
2

4
3

1250 0036 70

1 Green button, start Swellex pump

2 Red button, stop Swellex pump
3 Activating and deactivating button for pump 1, left pump
4 Emergency stop
5 Service platform, control lever with button
Figure 18.21. Control box on service platform for RCS

293
 c. with the green button (1), applies to DCS.

1
2

1250 0060 20

1 Green button, start Swellex pump

2 Red button, stop Swellex pump
Figure 18.22. Control box in service platform for DCS

294
11.Check the maximum water pressure in water filter (H) shown
on pressure gauge (E). See section Technical data.

F
G
1250 0089 90
H
E Pressure gauge
F Button for bleeding the system
G Adjuster screw for pressure reducing valve
H Water filter
Figure 18.23. Swellex pump water filter and pressure gauge

12.Close the needle valve slowly keeping an eye on the pressure

gauge needle (A) for the Swellex arm.
13.Note the pressure of the Swellex handle (D) when the pump
pressure control valve opens and the water is reconnected to the
inlet.

B
C
1250 0056 43

D
A Pressure gauge
B Chuck
C Three-way valve
D Trigger
Figure 18.24. Swellex arm

295
 14.Check that the necessary pressure is maintained when the pres-
sure control valve opens. See section Technical data.

Long-term storage
• Protect the pump with rust inhibitor.
• Always drain the pump prior to storage and store it in a frost-
free place. See section Freeze prevention measures.

Note
Starting a frozen pump can cause extensive damage.

Freeze prevention measures

Draining the Swellex pump

If the ambient air temperature around the pump is below 0°C
(32°F), the water system must be drained to prevent freezing.

296
1. Detach hose (SWW1) that is connected to the water inlet (2).

5
4
3
2
1

1250 0089 86

1 Swellex arm connection

2 Water inlet connection
3 Inlet pressure connection, oil
4 Drain connection, oil
5 Return connection, oil
Figure 18.25. Swellex pump connections

2. Connect pure compressed air to the water inlet (2).

The air pressure must not exceed the maximum pressure (water
pressure in) that the pump can handle, see section Technical
data.
3. Start the pump by pressing in the Swellex trigger (D) and blow
the water out of the chuck (B) for max 60 seconds.

B
C
1250 0056 43

D
Figure 18.26. Swellex arm

4. Unscrew the water filter and keep it safe from frost.

297
 5. Mark the pump so that it is not started without filter.

Extra freeze prevention measures

1. Drain the pump but leave the filter insert in place.

2. Fill the pump water inlet with a mixture of water and anti-freeze
(with respect to temperature and anti-freeze mixture recommen-
dations).

3. Connect air to the water inlet.

4. Blow glycol through the pump.

5. Unscrew the water filter and keep it safe from frost.

6. Mark the pump so that it is not started without filter.

Electrical system
The electrical system comprises an electrical box, a cable to the
hydraulic valve Y531, pressure monitor B192 and pressure sensor
B251.

The control unit in the HSP A51 Mk IB is called AP1 and is situ-
ated in the electrical box. AP1 contains a circuit board that controls
what is to happen and what is allowed to happen. The following
table contains information on what the terminals are used for and
the expected test values.

Table 18.5. Explanations and values for terminals in AP1.

Ter
mi- Expected
nal Explanation reading Other
1 Supply, pushbuttons 24 V DC
2 Supply, LED -24 V DC
3 Supply, LED +24 V DC
4 Supply, thermo-con- 24 V DC
tact
5 Signal 24 V DC Thermo-contact OK at 24V
DC
6 Contactor 24 V AC
7 Contactor 0V
8 Input supply 0 V AC/DC
9 Input supply 24 V AC/DC
10 Signal 24 V DC The inlet water pressure is
correct at 24V DC, 2-8 bar
11 Supply, flow switch +24 V DC

298
 Ter
mi- Expected
nal Explanation reading Other
12 Supply, flow switch -24 V DC
13 Signal 24 V DC Switch two on pressure
switch = 300 bar at 24V DC
14 Signal 24 V DC Switch one on pressure
switch = 52 bar at 24V DC
15 Supply, pressure -24 V DC
switch
16 Supply, pressure +24 V DC
switch
17 Signal, stop button 24 V DC
18 Signal, start button 24 V DC

1250 0094 22

Figure 18.27. Wiring diagram, Swellex pump

Fault finding

General
Fault finding is based on a logical sequence of actions to locate
faults and thereby rectify them as quickly as possible.

299
 • Start by determining what is functioning normally and what is
malfunctioning so that fault finding can be confined to a certain
system or a certain function.
• Then refer to the table below for help in fault tracing the pump.

Fault finding help

Table 18.6. Fault finding.

FAULT CAUSE ACTION
Pump does not No water or incorrect pressure. Connect the water and make sure there is an
start even flow of water from the chuck before starting
the pump.
Check the pressure of the supply water.
The pump stops Air in the system. Bleed the system and allow an even flow of wa-
shortly after start ter from the chuck.
Drop in pressure Fouled or worn valves. Leaking Clean and change defective parts.
seals. Fouled or leaking pressure
control valve.
Pressure too low Incorrectly adjusted pressure Adjust or change the pressure switch setting.
switch. Change water filter.
Water filter blocked.
Pressure drops, Cavitation. Clean the water filter. If the water temperature
noisy pump exceeds 70°C, provide cooling.
Uneven pressure Lack of water, pump sucks in air. Check the supply of water and integrity of the in-
Dirty valves. let line. Clean the valves.
Water leak Worn seals. Change seals. Check plunger surface.
Oil leak between Leaking seals. Change seals.
pump and gear
housing
Oil leak between Retaining screws loose. Leaking Tighten the screws. Change the seals.
gear housing and O-rings/seals.
motor
Increased noise Worn thrust ball bearing. Dismantle the gear housing, inspect all compo-
without drop in nents and change if necessary. Check the oil lev-
pressure el.

Note
A fault after a brief period of use may indicate
overloading or incorrect interval for changing
gear housing oil.
Water in gear hous- High air humidity, condensation in Shorten oil change interval from 500 hours to a
ing gear housing suitable period.
Pump does not turn Faulty pressure switch. Voltage fluctuation too great.
off Hose ruptured or other leakage.

300
19. Rod handling equipment, option

RAS

B
1250 0104 92

A
A Rear RAS arm
B Front RAS arm
C Hydraulic drill-steel support, BSH 110
Figure 19.1. Rod handling equipment, RAS

The Rod Adding System (RAS) is a system for handling drill rods
for extension drilling. The equipment comprises two arms with
gripper claws mounted on the feed beam, and a hydraulic front
drill steel support.

The RAS arms can each be positioned, by a motor, to one of two

positions: parked position and drilling centre. The gripper claws
can assume one of three positions: closed, guide position and open.
The guide position means that the gripper claws hold the drill rod
gently allowing the rod to rotate.

The drill steel support can either be open or closed. These posi-
tions are adapted to the diameter of the drill rod (closed position)
and the diameter of the rod joint (open position).

The auto-RAS option enables the automatic joining and removal of

drill rods.

301
Settings

Sensors

Position sensors menu

Figure 19.2. Position sensors menu

The position sensor (B307) detects the position of the rock drill on
the feeder. This information is used by the RCS system for exten-
sion drilling and hole depth measurement. The Position sensors
menu is used to calibrate the sensor (B307), as described in main-
tenance instructions, Directional control.

302
Other sensors menu

Figure 19.3. Other sensors menu

The RAS arms have a total of six sensors to keep track of the posi-
tion of the arms. B109 and B110 monitor parked position, B107
and B108 drilling centre and B111a and B111b whether the RAS
arms hold a drill rod. If one or both of the RAS arms are aligned
with the drilling centre, drilling is not possible.

The status of the sensors (On/Off) can be seen in the Other sen-
sors menu. This can be useful for faultfinding. The module and
module connector to which the various sensors are connected, as
well as the designation of the sensors, is also specified.

Adjusting the RAS arm position sensors

1. Open the covers over the two position sensors for rear RAS
arm.

2. Position the RAS arms at drilling centre.

3. Adjust the arm on the sensor (B107) so that it bears against the
stop.

4. Move the RAS arms to the parked position.

5. Adjust the arm on the sensor (B109) so that it bears against the
stop.

6. From the Other sensors menu, check that the sensors display
the correct value for both positions.

7. Fit the covers over the sensors.

303
 8. Adjust B108 and B110 on the front RAS arm in the same way.

Adjusting the gripper claw sensors

1. Undo the nuts on the sensors (B111a and B111b) and adjust the
vertical position of the sensors so that a signal is emitted when
there is a drill rod in the gripper claws.

2. Check that the sensor value in the Other sensors menu is cor-
rect.

Actuations

Actuations menu

Figure 19.4. Actuations menu

This menu displays which function or functions that are currently

actuated. Using this menu you can, for example, actuate the RAS
arms to check their function during fault diagnosis. The ability to
actuate a certain function can also be useful if you need to actuate
manually the RAS arms, for example.

1. Mark the desired function and press ENTER.

2. Enter the desired actuation value (mA) with the arrow keys and
press ENTER.

3. Mark the “Actuate desired value” button. Press and hold

ENTER. The function is actuated as long as the ENTER button
is held depressed.

304
 4. The “Actuated value” column displays the actuated value in
mA.

Parameters

Parameters menu

Figure 19.5. Parameters menu

From the Parameters menu you can set and adjust values for
threading and unthreading. The parameters apply to both auto-
matic and manual extension drilling with RAS.

Time before thread cutting

Time delay. The time from the activation of threading with the drill
lever to the start of threading. Normally this parameter should be
set to 100 - 600 ms.

In-feed pressure
The highest permitted feed pressure used during threading. The
value is set in mA and the pressure can be checked on the feed
pressure gauge (operator menu Drilling ) when the rock drill is in
its front end position on the feeder.

This parameter should not be set too high. Normal setting: 40 - 60

bar.

305
In-feed speed
The speed at which the rock drill moves during threading. The
speed must be adjusted so that it matches the thread pitch of the
drill rod.

Note
Make sure that the “In-rotation speed” and “Out-rotation speed”
parameters are correctly set before setting the feed speeds.

In-rotation speed
The speed of the adapter during threading. Measure the speed with
a tachometer and adjust it to 140 - 160 rpm.

Out-feed pressure
The highest permitted feed pressure used during unthreading. The
value is set in mA and the pressure can be checked on the feed
pressure gauge (operator menu Drilling ) when the rock drill is in
its rear end position on the feeder.

This parameter should not be set too high. Normal setting: 40 - 70

bar.

Out-feed speed
The speed at which the rock drill moves during unthreading. The
speed must be adjusted so that it matches the thread pitch of the
drill rod.

Note
Make sure that the “In-rotation speed” and “Out-rotation speed”
parameters are correctly set before setting the feed speeds.

Out-rotation speed
The speed of the adapter during unthreading. Measure the speed
with a tachometer and adjust it to 150 - 170 rpm.

Percussion time
The time that percussion is activated when the threaded joints are
undone and the rock drill is in its front end position on the feeder.

306
Slow feed speed
The speed of the rock drill during rearward movement, before it
reaches cradle position 3 (rod joint in drill steel support). See the
section on cradle position.

Auto-RAS menu

Figure 19.6. Auto-RAS menu

The Auto-RAS menu contains a number of parameters for setting

and adjusting automatic rod adding.

Time for open/close drill support

The time taken for the drill steel support to open or close fully.
This time must be specified since there are no sensors to indicate
this.

Time for open/close gripper claws

The time taken for the gripper claws to open or close fully. This
time must be specified since there are no sensors to indicate this.

Max times
To prevent wear and damage to the equipment, there are maximum
time setting for various stages of rod adding: “Max time for thread-
ing”, “Max time for movement of RAS arms” and “Max time for
feed movement”. If the set maximum times are reached, automa-
tion is halted.

307
Pressure for detection of tightened thread
The rotation pressure that the system uses to check that a joint
between the shank adapter and rod is tightened.

No. of unthreading retries....

When removing drill rods (after drilling a hole), the front joint
must be unthreaded first. If, instead, the rear joint is unthreaded,
the system detects this. You can order the system to make a fresh
attempt to unthread the front joint. The attempt can include or
exclude percussion.

First, X attempts (0 and upward) are made without percussion and

then Y attempts (0 and upward) attempts with percussion.

The sequence for new attempts is as follows:

• Threading of rear joint

• Gripper arms and drill steel support opened
• RAS arms to parked position
• (Percussion)
• RAS arms to drill centre
• Gripper arms and drill steel support closed
• Tightening of rear joint
• Adjustment of sleeve position in drill steel support, if necessary
• New attempt to unthread the front joint

Percussion pressure and time for unthreading

“Percussion pressure for unthreading” refers to the percussion
pressure during a fresh removal attempt with percussion as
described above.

“Time percussion at unthreading” is the time during which percus-

sion is activated during a fresh removal attempt with percussion as
described above.

Cradle positions

Introduction
A precondition for both manual and automatic extension drilling is
that the RCS system detects that the rock drill cradle is in the cor-
rect position on the feeder during the various stages of rod adding
and removal. There are five cradle positions defined for this pur-
pose.

308
 Cradle positions 1 - 4 are for rod removal after a hole has been
drilled, while cradle position 5 is for drilling.

2
1250 0104 88

Figure 19.7. Cradle positions

Table 19.1. Cradle positions

Cradle posi-
tion Signal to RCS system Order from RCS system
5 Rock drill moving forward towards drill steel Open the drill steel support!
support.
4 Rock drill moving backward and the rod-rod Reduce the feed speed!
joint is almost by the drill steel support.
3 Rod-rod joint in the drill steel support. Stop the rock drill!
and for auto-RAS also:
Close the drill steel support and unthread
the rod-rod joint!
2 Rod-rod joint undone. Stop the rock drill!
and for auto-RAS also:
Unthread the shank adapter-rod joint!
1 Shank adapter-rod joint undone. Stop the rock drill!
and for auto-RAS also:
Move RAS arms to parked position!

In addition to these five cradle positions, there is a further position

of significance to the jointing sequence: the front end position on
the feeder, which unlike the other five positions is a fixed position
that cannot be adjusted.

When the rock drill reaches the front end position, drilling is halted
and the rock drill stops in this position and undoes the threaded
joints. The drill steel support is then closed.

309
Cradle positions menu

Figure 19.8. Cradle positions menu

Setting the cradle position

To set the cradle positions correctly, the position sensor (B307)
must be correctly calibrated. See maintenance instructions, Direc-
tional control.

The Cradle positions menu has a button for setting each cradle
position. By marking one of the buttons (1-5) and pressing
ENTER, the system detects the position of the rock drill on the
feeder and saves this as the cradle position in question (1-5).

The easiest way to set the cradle positions is to run the rock drill to
the correct position on the feeder and record the position with one
of the buttons (1-5). If a cradle position only requires minor adjust-
ment, the value can be increased or decreased with the arrow keys.

310
Setting the pressure regulators

Valve block

MAT3

CT4

MAT2
CT3

CT2

MAT1
1250 0104 89

MAT Test outlet

CT Pressure regulators
Figure 19.9. Valve block

Operator panel

A B
37 37

12

D
12

C 11
11
1250 0104 90

D
C

A Sit-down panel
B Stand-up panel
C RAS lever of operating RAS arms and gripper claws
D Drilling lever
11 Open drill-steel support
12 Close drill-steel support
37 Activate extension drilling
Figure 19.10. Operator panel

311
Pressure regulator for drill steel support BSH 110
1. Start the hydraulic pump.

2. Connect a pressure gauge to the test outlet (MAT1).

3. Activate the drill steel support with button (11) or (12) on the
operator panel and adjust the pressure of the pressure regulator
(CT2) to 200 bar.

Pressure regulator for RAS arms

1. Start the hydraulic pump.

2. Activate extension drilling with button (37) on the operator

panel.

3. Connect a pressure gauge to the test outlet (MAT2).

4. Operate the RAS arms with the RAS lever on the operator panel
and adjust the pressure of the pressure regulator (CT3) to 100
bar.

Pressure regulator for gripper claws

1. Start the hydraulic pump.

2. Activate extension drilling with button (37) on the operator

panel.

3. Place a rod in the gripper claws and close the claws.

4. Connect a pressure gauge to the test outlet (MAT3).

5. Activate the gripper claws with the thumb switch on the RAS
lever and adjust the pressure of the pressure regulator (CT4).

Adjust the pressure to roughly 1/3 of the positioning pressure so

that the drill rod can rotate freely in the gripper claws without
the claws opening.

Mechanical adjustments

Drill centre for RAS arms

For threading and unthreading to work without burring the threads,
the drill centre position of the RAS arms must be correct. The RAS
arms must be adjusted both vertically and laterally.

1. Place a drill rod in the gripper claws of the RAS arms and close
the gripper claws.

2. Move the RAS arms to drill centre using the RAS lever.

312
 3. Adjust the vertical position of the RAS arms with the set screws
(A).

4. Adjust the horizontal position of the RAS arms by slackening

the four bolts (B) slightly and then moving the arms so that the
drill rod assumes the correct position.

5. Tighten the bolts (B).

6. Check the adjustments by threading and unthreading the drill

rod on the rock drill's shank adapter. Readjust if necessary.

Parked position for RAS arms

For the rock drill to clear the RAS arms during drilling, the parked
position must be correct.

1. Place a drill rod in the gripper claws of the RAS arms and close
the gripper claws.

2. Move the RAS arms to the parked position with the RAS lever.

3. Undo the bolts (C) on the clutch for the RAS arm motor.

4. Adjust the position of the arms.

5. Lock the arms in this position by tightening the bolts (C). ???

6. Check that the rock drill clears the arms by running it forward
and backward past the RAS arms.

After adjustment
After adjusting the drill centre and parked position of the RAS
arms, check that the sensors display the correct values for each
position in the Other sensors menu. If not, the RAS arm position
sensors must be adjusted, see Adjusting the RAS arm position sen-
sors.

313
20. Directional control, option

ABC R (Advanced Boom Control Regular)

B307
B300 B301 B309 B302

B306 B310 B305 B303

1250 0058 78

B300 Angle sensors, boom swing

B301 Angle sensors, boom lift
B302 Angle sensors, rotation
B303 Angle sensors, lookout cylinder
B305 Length sensor, feed extension
B306 Length sensor, boom telescope
B307 Length sensor, drilling machine
B309 Angle sensors, feed swing
B310 Angle sensors, feed lift
Figure 20.1. Sensors, location

B312/B313

1250 0060 25

B312 Inclination sensor, longitudinal inclination (Y)

B313 Inclination sensor, lateral inclination (X)
Figure 20.2. Inclination sensor, location

314
 B311

1250 0060 26 XL3 WL3

B311 Angle sensor, console lift
Figure 20.3. Sensors, location

Sensor calibration

Introduction
The following section describes how to calibrate all sensors, basic
calibration. As a rule it will only be necessary to calibrate them in
the following cases:

• When changing a sensor

• When changing the cable to the feed telescope or boom tele-
scope
After changing a sensor or cable for the feed telescope or boom
telescope , you should first operate the function forward and back-
ward to its end positions a few times. Calibration is then performed
only on the sensor that has been changed (or whose wire has been
changed)

After changing a sensor for feed lookout or eagle lift, it is suffi-

cient to calibrate the sensor that has been changed.

After changing a sensor for boom swing, boom lift, feed swing
or feed lift , the boom must be calibrated in a calibration laser.

After changing a sensor for rig inclination, the changed sensor

should be calibrated in X and Y-axes.

Conditions
The following tools are required to calibrate the sensors for con-
tour control:

315
 • Digital spirit level.
• Tape measure.
• Stand and wire for setting rig laser.
The sensors are to be calibrated in the order given below. Before
calibration is started, the rig must be levelled and the boom config-
urations loaded. This is done in the service menu Parameters for
contour control. Press the "Read rig config" button and wait until
the "ready" message is shown on the screen.

Figure 20.4. ABC R (Advanced Boom Control Regular)

On completion of calibration the parameters should be saved to

cards. See maintenance instructions Control system.

316
Inclination sensor
1. Go to the "Contour control/Calibration/Other calibration"
menu.

Figure 20.5. Other calibration

2. Raise the rig on its outriggers and level it laterally. Check with a
spirit level on the boom bracket. Precision +/- 0.05 degrees.

3. Reset the inclination sensor sideways by activating the "reset

button" for inclination X (sideways).
4. Raise the rig on its outriggers and level it in forward/rear direc-
tion. Check with a spirit level on the boom bracket. Precision +/
- 0.05 degrees.

5. Reset the inclination sensor for forward/backward by activating

the "reset button" for inclination Y.

6. Incline the rig about 5 degrees to the right. Check the result with
a spirit level at the same position as for resetting inclination X.

7. Change the coefficient for Inclination X (sideways) so that the

angle on the display screen is the same as that read on the spirit
level and has a plus sign. Accuracy +/-0.1 degrees.

8. Level the rig again.

9. Incline the rig about 5 degrees forward. Check the inclination

with a spirit level in the same way as for resetting inclination Y.

10.Change the coefficient for Inclination Y (longitudinal) so that

the angle on the display screen is the same as that read on the
spirit level and has a plus sign. Accuracy +/- 0.1 degrees.

317
 11.Level the rig. Inclination X and Y should be 0.0 degrees on the
display screen.

Console lift, type "Wide Eagle"

1. Level the rig. Inclination X and Y should be 0.0 degrees in the
menu.

2. Go to the Contour control/Calibration/Other calibration menu.

Figure 20.6. Other calibration

3. Position the console lift arm vertically using a spirit level. Pre-
cision +/- 0.05 degrees.

4. Reset the sensor by activating the "reset button".

5. Set the coefficient (+1 or -1) so that clockwise rotation of the
arm viewed from behind gives a positive angle.

Console lift, type "Standard Eagle"

1. Level the rig. Inclination X and Y should be 0.0 degrees in the
menu.

318
2. Go to the Contour control/Calibration/Other calibration menu.

Figure 20.7. Other calibration

3. Position the console lift arm horizontally using a spirit level.

Precision +/- 0.05 degrees.

4. Reset the sensor by activating the "reset button".

5. Set the coefficient (+1 or -1) so that clockwise rotation of the

arm viewed from behind gives a positive angle.

319
Boom telescope
1. Go to the Contour control/Calibration/Other calibration menu.

Figure 20.8. Other calibration

2. Run the boom telescope all the way in.

3. Reset the boom telescope by activating the "reset button".

4. Run the boom telescope all the way out.

5. Measure the distance between the boom telescope end posi-

tions.

6. Change the coefficient for the boom telescope so that the length
is the same as the one measured between the end positions and
positive. Precision +/- 0.5 cm.

7. Move the telescope back to about the middle and measure how
far out the telescope is. Compare this measurement with that
indicated on the display screen. Accuracy +/- 1.5 cm.

320
Feed telescope
1. Go to the Contour control/Calibration/Other calibration menu.

Figure 20.9. Other calibration

2. Run the feed telescope all the way back.

3. Reset the feed telescope by activating the "reset button".

4. Run the feed telescope all the way to the front.

5. Measure the distance between the feed telescope end positions.

6. Change the coefficient for the feed telescope so that the length
is the same as the one measured between the end positions and
positive. Precision +/- 0.5 cm.

7. Move the telescope back to about the middle and measure how
far out the telescope is. Compare this measurement with that
indicated on the display screen. Accuracy +/- 1.5 cm.

Drilling machine position

The drilling machine position is reset automatically in the rear end
position if certain conditions are met. There is also an adjustment
of the zero position in front end position. Certain conditions must
also be met here.

After restarting the system, the sensor must always be reset in

order to obtain auto drilling.

321
 The first reset after restarting the system has the condition that the
reverse feed pressure must be higher than Minimum feed pres-
sure at resetting for at least the period Minimum time against
stop position first resetting and the drilling machine cradle must
be stationary.

The conditions for continuous resetting in rear end position is that

the reverse feed pressure must be higher than Minimum feed
pressure at resetting for at least the period Minimum time
against stop position continuous resetting , the drilling machine
cradle must be stationary and the drilling machine cradle must be
within the range +/- Near resetting position .

The conditions for adjusting zero position in front end position is

that the drilling machine cradle must be stationary and the signal
for drilling machine return must be active.

The following applies to software version 1.7 or earlier:

1. To obtain adjustment of zero position for the length sensor in
front end position, the first drilling machine must be run all the
way back, reset and then run continuously with the drilling
lever to the front end position, where it hits the drilling machine
return. The length of the feeder will then have been measured
and adjustments for the length sensor can be made in front end
position as well.

The following applies to software version 1.8 or later:

1. For adjustment of zero position for the length sensor in front
end position, the Length front position value must be greater
than 0.

2. To calibrate Length front position , the drilling machine must

first be run all the way back and the sensor reset.

3. Check Calibration and then run the drilling machine to the

front end position where it hits the drilling machine return. The
length of the feeder will then have been measured and is entered
as Length front position . The check for calibration will be
removed automatically.

322
1. Go to the Contour control/Positional sensors menu.

Figure 20.10. Position sensors

2. Set the coefficient to 300.

3. Set Near resetting position to 10.0 cm.

4. Set Minimum time against stop position first resetting to

2000 ms.

5. Set Minimum time against stop position continuous reset-

ting to 500 ms.

6. Set Minimum feed pressure at resetting to 150 bar.

7. Set Minimum time against stop position for hole depth reset
to 1000 ms.

8. Run the drilling machine all the way back and calibrate the sen-
sor. Check that it is reset.

9. Then run the drilling machine far forward on the feeder, but not
so it hits the limit switch, and measure the length it has been
moved. Now change the coefficient in the menu so that the
length agrees with that measured and is positive. Precision +/- 1
cm.

10.Run the drilling machine all the way back and calibrate the sen-
sor. Check that it is reset.

11.Then calibrate Length front position as described above.

Different methods for software version 1.7 or earlier and 1.8 or

later.

323
Feed rotation
1. Go to the Contour control/Calibration/Other calibration menu.

Figure 20.11. Other calibration

2. Level the rig. Inclination X and Y should be 0.0 degrees in the

menu.

3. Turn the feed rotation so the lookout axis is horizontal to the

drilling machine above the feeder. Measure with a spirit level
on the feed beam for example. Precision +/- 0.05 degrees.

ON/OFF HOLD

1250 0058 75

Figure 20.12. Lookout axis horizontal.

4. Reset the sensor for feed rotation by activating the "reset but-
ton".

324
 5. Set the coefficient (+1 or -1) so that the clockwise rotation
viewed from behind gives a positive angle on the feed rota-
tion.

Feed lookout
1. Go to the Contour control/Calibration/Other calibration menu.

Figure 20.13. Other calibration

2. Turn the feed rotation to 0 +/- 2 degrees.

3. Level the rotation axis. Precision +/- 0.05 degrees.

ON/OFF
HOLD

1250 0058 77

Figure 20.14. Rotation axis horizontal

4. Run the drilling machine all the way to the rear of the feeder.

5. Run the feed telescope all the way back.

6. Run in the lookout cylinder completely.

7. Measure the inclination of the feeder with a spirit level.

325
 8. Enter the value into the box to adjust the deviation of the look-
out axis. If the feeder is pointing upward, the value should be
negative and if it is pointing downward it should be positive.

9. Preset the sensor for feed lookout by activating the " Preset ”
button.

10.Set the coefficient (+1 or -1) so that it gives a negative angle

when the lookout cylinder is extended.

Boom extender
1. Go to the Contour control/Calibration/Other calibration menu.

Figure 20.15. Other calibration

2. If the boom is equipped with a boom extender, the boom

extender box must be checked. Otherwise, it should be left
empty.

3. Repeat step 2 for all booms.

326
Feed holder
1. Go to the Contour control/Calibration/Other calibration menu.

Figure 20.16. Other calibration

2. Check that Feed holder default is selected for all booms.

3. Check this measurement to make sure it is correct. If the feed

holder does not agree, select Feed holder custom and enter
the new length. The length is the distance from the back edge of
the protective plate on the feeder to the centre of the lookout
axis when the feed telescope is in its rear position.

327
Setting coefficient for swing and lift angles.
1. Go to the Contour control/Sensors menu

Figure 20.17. Sensors

2. Set the coefficient (+1 or -1) for boom swing so that the angle
increases (gets more positive) when the boom is moved to the
left.

3. Set the coefficient (+1 or -1) for boom lift so that the angle
increases (gets more positive) when the boom is lowered.
4. Set the coefficient (+1 or -1) for feed swing so that the angle
increases (gets more positive) when the feeder is angled to the
left. (Run only with front tripod).

5. Set the coefficient (+1 or -1) for feed lift so that the angle
increases (gets more positive) when the feeder is angled down.
(Run only with front tripod).

328
Setting rig laser

+/-5mm
90°
A

5m

+/-5mm

X X
B
1250 0058 74

Figure 20.18. Setting the laser

The laser on the rig must be aligned so the beam is parallel with the
rig axis as illustrated above. A stand (B) and a measured wire (A)
with eyelets are needed for this method.

1. Go to the "Contour control/Calibration/Other calibration"

menu.

Figure 20.19. Other calibration

2. Level the rig. Inclination X and Y should be 0.0 degrees in the

menu.

329
 3. Fasten the ends of the wire to the front retaining bolts for the
resolver sensor in the boom swing joint and the eye in the mid-
dle of the wire to stand B.

4. Position the stand so that the wire is taut. The wire must be long
enough for the stand to be approx. 5 m from the laser.

5. Raise or lower the stand until the mark for the laser dot is level
with the laser "output". Precision +/- 5 mm.

6. Turn on the laser.

7. Direct the laser so that it lights on the mark on the stand. Preci-
sion +/- 5 mm.

8. Measure the distances from the front retaining bolts for the
resolver sensor in the boom swing joint to the laser "output" and
make sure they are the same. Precision +/- 5mm.

Calibrating Boom swing, boom lift, feed swing and feed lift
1. Go to the Contour control/Calibration/Laser calibration menu

Figure 20.20. Laser calibration

2. Mount the sight plates on the feeder. One sight plate as far back
as possible and the other as far forward as possible. The dis-
tance between the sight plates should be at least 3 metres.

3. Run in the boom telescope and feed telescope completely (0

cm).

4. Run the drilling machine all the way to the rear of the feeder (0
cm).

330
 5. Run in the lookout cylinder completely.

6. Turn on the laser.

7. Operate the boom and feeder so that the calibration laser lights
through the centre of both sight plates. Feed rotation can be in
any position.

8. To obtain as good a calibration as possible, the laser beam must

be within a radius of 1 cm from the centre of the sight plates.

9. Activate the “calibrate all sensors” button. The system automat-

ically calculates the correct values for the sensors.

10.Turn off the laser.

Replacement of components

Replacement of angle sensors

1. Clean the area where the sensor is built into the boom joint.

2. Undo the four hexagon socket screws (A) on the existing sen-
sor.

1250 0042 93

Figure 20.21. Angle sensors

3. Disconnect the cable from the cable connector (B).

331
 4. Remove the sensor and bellows coupling. The bellows coupling
consists of two parts. One part (1) is mounted on the sensor by
means of a hexagon socket screw. The other part (2) is mounted
in the boom joint by means of a hexagon socket screw in the
bottom of the coupling.

1250 0059 28

Figure 20.22. Bellows coupling

5. Fit part 2 of the new bellows coupling into the boom joint and
tighten the hexagon socket screw in the bottom. Check that the
correct mounting dimension is obtained, see following illustra-
tion.

B A
1
14 mm

1250 0059 64

Figure 20.23. Mounting dimensions, angle sensors

6. Fit part 1 of the bellows coupling onto the new sensor.

7. Fit the sensor in place in the boom joint. Make sure the splines
of the bellows coupling (on the part mounted on the sensor) are
in the correct groove on the part mounted in the boom joint. Fit
the sensor so that its connector is pointing in the correct direc-
tion with regard to the run of the cable.

332
 8. Press down the sensor while tightening the four hexagon socket
screws (A).

9. Connect the cable to the cable connector (B).

10.Calibrate the sensor, see the section Sensor calibration.

Replacement of length sensor

Boom telescope/Feed extension

Note
All cylinders must be contracted when fitting the length sensors so
that the measuring distance is a short as possible.

1 Sensors
2 Wire control (BUT 35 only)
Figure 20.24. Length sensor, boom telescope

333
 1

1250 0058 80

1 Sensors
2 Wire control
Figure 20.25. Length sensor, feed extension

1. Turn the sensor (1) so that the wire runs out from above.

2. Coil the wire 10+4=14 turns on the drum. Fasten it with the
screw.

3. Pull out a length corresponding to 4 turns (approx. 1.2 m).

4. Fasten the wire as above.

Check that the wire is coiled in one layer only when the boom is
operated.

334
Feeder

1
4
3

1250 0060 24
5 2
1 Sensors
2 Wire pulley
3 Rear wire attachment
4 Front wire attachment
5 Spring
Figure 20.26. Length sensor, feeder

1. Make sure the sensor (1) is filled with grease before screwing it
to the beam. Note that the lubricating nipple lubricates the seal
only.

2. Lay the wire one turn around the wire pulley. Note the direction
of the coil (2), the spring side of the wire must be closest to the
beam.

3. Adjust the wire length so the spring is 100 mm (Spring is 70mm

unloaded).

4. Run the feed cylinder in/out and check that the wire does not
stick anywhere.

5. Note that the wire attachment (3) is in two parts when assem-
bling.

335
Fault finding

Angle sensors
By measuring the winding resistances of the sensor, it is possible
to determine whether the sensor and the cable between resolver
module and sensor are in working order. First, disconnect the cable
from the contact on the resolver module. Take readings across the
cable pins as follows:

• Across pins 1 and 2. The resistance should be approx. 36 ohms.

• Across pins 3 and 4. The resistance should be approx. 105
ohms.
• Across pins 5 and 6. The resistance should be approx. 105
ohms.

5 6 1

4 2
3

1250 0060 28

Figure 20.27. Sensor connection

If any of the measurements should indicate a value that deviates

greatly, the same measurement should be made on the sensor pins.
Detach the cable from the sensor contact and measure across the
pins as above. If the same fault is obtained as when measuring on
the cable, the sensor should be changed. Otherwise, it can be
assumed that the fault is in the cable.

Should fault finding show that both cable and sensor are intact and
free from faults, the fault probably lies in the resolver module.

Inclination sensor
Check that the sensor is supplied with current. Disconnect the
cable from the sensor and take a reading on the cable.

• If the sensor is supplied with current it may be assumed to be

defective.

336
 • If there is no supply of current, the fault could be in the cable.
Take the same reading on the I/O module connector to check
that the I/O module is supplying current.
If the I/O module is supplying current, the fault is probably in
the cable.

B
A
123

654

1 5
6
2 4
3
123
C 1250 0060 29
654

A Inclination sensor connection

B I/O module connection
C I/O module connection
Figure 20.28. Sensor cable connections

Table 20.1. Inclination sensor cable connections

Contact A
Contact C (pin) Contact B (pin) (pin) Signal
- 2 1 Earth
- 3 2 5V supply
- - 3 -
- - 4 -
1 - 5 Signal X-axis
- 1 6 Signal Y-axis

Length sensor
Check that the sensor is supplied with current. Disconnect the
cable from the sensor and take a reading on the cable.

• If the sensor is supplied with current it may be assumed to be

defective.
• Check the sensor by measuring the resistance across earth (pin
2) and the power supply (pin 3). The resistance should be 5.5
kohm.

337
 5 6 1

4 2
3

1250 0060 31

Figure 20.29. Sensor connection

• If there is no supply of current, the fault could be in the cable.

Take the same reading on the resolver module contact to check
that the resolver module is supplying current.
If current is supplied by the resolver module, the fault is proba-
bly in the cable.

A B

4 1 1 5
5 6
2 4
3 2 3
1250 0060 30

A Resolver module connection

B Sensor connection
Figure 20.30. Sensor cable connections

Table 20.2. Sensor cable connection

Contact A (pin) Contact B (pin) Signal
3 1 Signal
1 2 Earth
2 3 5 V supply

Length sensor, drilling machine

Check that the sensor is supplied with current. Disconnect the
cable from the sensor and take a reading on the cable.

• If the sensor is supplied with current it may be assumed to be

defective.
• If there is no supply of current, the fault could be in the cable.
Take the same reading on the resolver module contact to check
that the resolver module is supplying current.

338
 If current is supplied by the resolver module, the fault is proba-
bly in the cable.

5 6 1

4 2
3

1250 0060 32

Figure 20.31. Sensor connection

A B

5 1 1 5
6 6
4 2 2 4
3 3
1250 0060 33

Figure 20.32. Sensor cable connections

Table 20.3. Sensor cable connection

Contact A (pin) Contact B (pin) Signal
1 1 5V supply
2 2 5V supply
3 3 Signal A
4 4 Earth
5 5 Signal B
6 6 Earth

339
21. Automatic, option

Settings

Service menus
There are Auto settings on the service menu for:

• Anchoring
• Positioning
The following menus exist for the control of area guards and actu-
ation of warning lamps for Auto:

• Sensors
• Actuations

Anchoring

Figure 21.1. Anchoring

• Max sliding after rock contact (0.0-30.0): Specifies how far

the feeder spike is permitted to slide lengthwise along the rock
surface after rock contact has been detected.
• Number of anchoring attempts (0-3): Specifies how many
anchorage attempts should be made if the feeder spike slides
more than the value specified above.

340
 • Collaring at rock contact: Determines whether drilling is
permitted on rock contact if the feeder spike has slid more than
the specified value.
• Velocity before rock contact: Specifies the desired feed speed
before the feeder spike makes rock contact.
• Velocity after rock contact: Specifies the desired feed speed
after the feeder spike has made rock contact.
• Velocity reduction for detection of rock contact: Specifies
the percentage reduction in feed speed for rock contact to be
detected.
• Velocity reduction for detection of solid rock contact: Spec-
ifies the percentage reduction in feed speed for solid rock con-
tact to be detected and drilling permitted.
• Velocity reduction detection time: Specifies the time period
during which the feed speed must have been reduced for rock
contact or solid rock contact to be detected.

Positioning

Figure 21.2. Positioning

• Feeder return within radius R1: Specifies how far the feeder
beam will be retracted from the rock if the distance to the next
hole lies within the specified radius, R1.
• Inner radius R1: Specifies the distance to the next hole for
the feeder beam to be retracted as above.
• Feeder return between radius R1 and R2: Specifies how far
the feeder beam will be retracted from the rock if the distance to
the next hole lies between radii R1 and R2.

341
 • Outer radius R2: Specifies the maximum distance to the next
hole for the feeder beam to be retracted as above. If the distance
is greater than R2, the feeder beam is retracted the sum of dis-
tances for R1 and between R1 and R2.
• Absolute feeder extension at positioning: Specifies how far
the feeder telescope must be extended for autopositioning to be
permitted.
• Distance between move steps: Specifies the distance between
each calculated move position.
• Blind zone radius: Specifies the radius around the boom body
to prevent the boom body and feeder from colliding.
• Safety distance for contour hole: Specifies the distance from
the theoretical contour hole to which the feeder lookout should
be adjusted before boom/feeder are moved to the correct posi-
tion.

Sensors

Figure 21.3. Sensors

On the left and right-hand sides of the boom bracket are area
guards that halt all automatic operations if a person passes them.
There is also a red warning light by each area guard that flashes
when an automatic function is activated.

Guard functions can be controlled from the Sensor menu. When a

person passes in front of a sensor, its status should change.

342
Actuations

Figure 21.4. Actuations

The warning lights can be controlled by first setting the "Desired

value" to 1 and activating the function manually by pressing Enter
when the marker is in the "Actuate desired value" box.

Calibrating boom speed

Parameters
The speed of the cylinders can be adjusted from the Boom/Param-
eters menu. The speed can be adjusted in relation to the reference
speed shown when the calibration aid is activated. Always start
with the minimum speed, and then adjust the maximum speed.
Position the boom so that it points straight forward, and perform
calibration in this direction. Position the knob so that the lookout
axis is vertical.

343
 Figure 21.5. Actuations

• Select the boom and cylinder to be calibrated.

• Activate the calibration aid.

Lowest valve current

1. Activate the function with the smallest possible lever move-
ment. The value is displayed in the Actuation field.

2. Adjust the current value so that the cylinder just starts to move.

Highest valve current

1. Operate the function moving the lever as far as possible.

2. Compare the speed of the cylinder in question with the refer-

ence speed, which is also shown in the menu.

3. Adjust the valve current so that the speeds correspond as closely

as possible.

Note
Repeat the procedure for all cylinders and in both directions.
Deactivate the calibration aid when all cylinders have been cali-
brated.

344
Checking boom movement
1. Operate the boom straight up and down with the lever. Check
that the boom body does actually move straight up and down. If
not, the maximum speed of one of the two rear cylinders must
be adjusted.

2. Operate the feeder straight up and down with the lever. Check
that the feeder does actually move straight up and down. If not,
the maximum speed of one of the two front cylinders must be
adjusted.

345
22. Air conditioning, option

Safety

WARNING
Refrigerant under pressure.

Risk of serious personal injury.

Service of refrigerant system should be

carried out by authorised staff.
1250 0042 41

Note
Do not use the system with too little refrigerant, leakage or any
other fault until it is rectified. Otherwise, there is risk of the com-
pressor breaking down.

Technical data
Refrigerant R134a
Amount of refrigerant 1,6 kg
Refrigerating capacity (35°C, Rh
50%) 8.5 kW
Heating capacity, from diesel engine
12 kW
Heating capacity, electric heater 3 kW
Air flow 1300 m 3 /h

346
Adjusting compressor V-belts
A B
D

1250 0006 86

Figure 22.1. Adjusting V-belts

• Unscrew the cover under the driver's seat in the operator cab.
• Undo the nut (A) and adjust the belts (D) by turning the ten-
sioner (B) towards or away from the motor (C).
• Tighten the nut (A) and refit the cover under the driver's seat.

Fresh air filter and recirculation filter

The fresh air filter (1) and the recirculation filters (2) are both kept
in place by a metal plate (3). The metal plate is held in place with
two screws (4).

347
 1

1250 0052 57

1 Fresh air filter

2 Recirculation filter
3 Metal plate
4 Screws
Figure 22.2. Fresh air filter and recirculation filter

The fresh air filter should be inspected regularly and cleaned as

necessary. How often the filter needs cleaning or changing depends
on the prevailing operating conditions. If the air conditioning effi-
ciency becomes impaired despite cleaning the filter regularly, it is
probably time to change the filter.

The recirculation filter cleans purer air than the fresh air filter and
therefore will not need cleaning as often. Regular inspections of
the recirculation filters are recommended, however.

Electric heater
1

2
1250 0063 62

Figure 22.3. Electric heater

348
 An output of 2 or 3kW can be selected using the knob (2). A suita-
ble setting is 3 kW.

The screw (3) can be used to check that the pump has not become
jammed, which can happen if the heater has not been used for
some time.

Fault finding
No heating
Check for air in the diesel engine cooling system. For bleeding the
system, see maintenance instruction Engine.

No cooling
Check the following points:

• Fuses, electric connections, compressor earth, electromagnets,

switches and pressure switches
• V-belt and compressor
• Expansion valve and temperature control valve
• Coolant hoses

Poor cooling
Check the following points:

• Fresh-air fan and V-belt tension

• That the air does not evade the evaporator in the unit
• That the evaporator and condenser are not clogged by rubbish
and the filter in the air intake is not dirty
• That the expansion valve capillary tube is firmly against the
evaporator outlet pipe
• That the thermostat does not cut out too early

Uneven cooling
Check the following points:

• That connections to switches, magnetic coupling or pressure

switch are not loose
• That the expansion valve is not clogged
• That the system is filled and the thermostat is not defective

349
Abnormal noise
Check the following points:

• That the V-belts for the compressor are properly tensioned and
that compressor retaining bolts are tight.
• That the system is filled sufficiently and not overfull
• That the expansion valve is in working order
• That the airflow across the evaporator is sufficient
• That the condenser is clean and the airflow is sufficient
Abnormal system noise is often connected to incorrectly assem-
bled components. If the compressor is noisy at a certain speed, for
instance, and the noise disappears when the speed increases or
decreases, there is probably nothing wrong with the compressor
itself.

Each individual vehicle has so-called critical frequencies where

vibration of different types can generate noise. The speed at which
these frequencies arise can differ from vehicle to vehicle. It is often
possible to eliminate such vibration by increasing or reducing the
belt tension. If the belt tension is to high, it will cause excessive
wear on compressor bearings, belts and belt pulleys. You should
therefore avoid tensioning the belts too much.

There is seldom any point in changing the compressor due to noise

when the belts "jump". Adjusting the belt tension or changing to
another belt length is better. Changing the length of the delivery
hose to the compressor can also reduce noise.

The difference between the pressure on the suction side and the
pressure side also affects the level of noise. A compressor with low
suction makes more noise than a compressor with high suction.
Likewise, a compressor with high high-pressure makes more noise
because it puts more load on bearings, etc.

350
23. Service equipment, option

Service tool bag RCS

B
A C

D F
E 1250 0066 84

A Resolver tester
B CAN tester
C Multimeter
D Encoder tester
E Test cables
F I/O tester
Figure 23.1. Service bag

The service bag is used for fault finding on rigs equipped with the
Atlas Copco Rig Control System (RCS).

351
Overview of RCS system
Ad 1 Ad 1
CAN 2 CAN 2
Ad 0 Ad 1
CAN 1

Ad 0 Ad 0

Ad 2 Ad 2
Ad 3
CAN 1

D501 D503
Ad 1 Ad 0 Ad 1 Ad 1

Ad 0 Ad 0
CAN 1

Ad 0 Ad 1
1250 0066 78

Figure 23.2. Example, RCS system, 2-brake rig

Table 23.1. Description, RCS

Type Description
I/O module D101, D102, D103, D201, D202, D203, D510, D511
Resolver module D120, D121, D220, D221
Application module D100, D200
Master module D506
Display module D501, D503
Fuse box D150, D550, D551, D552, D250
Operator panel D500, D502
Lever casing, service platform D520
Address plugs Ad0, Ad1, Ad2, Ad3
CAN 1 Can network 1
CAN 2 Can network 2

Checking the power supply and the CAN network

The power supply for the module, the CAN power supply and
CAN communication can be measured and checked using the
CAN tester.

• MAIN POWER lights if power is being supplied to the module.

352
• CAN POWER lights if power is being supplied to the CAN net-
work.
• CAN HI and CAN LO flash while communication is in progress
on the CAN network.

1250 0066 83

A Multimeter
B CAN tester
Figure 23.3. CAN tester

Table 23.2. Pin configuration, CAN inputs and outputs, I/O

modules
Pin Function
1 CAN LO
2 CAN HI
3 CAN +
4 CAN -

Table 23.3. Pin configuration, CAN inputs and outputs, other

modules
Pin Function
1 CAN -
2 CAN LO
3
4 CAN HI
5 CAN +

353
Measuring voltage/power
1. Mount the tester on the multimeter. Make certain the pins are
positioned correctly as indicated by the colour coding. The red
pin goes to V/Ohm on the multimeter. Set the multimeter range
to DC Volt.

2. Connect the tester's 4-pin connectors to the CAN network

requiring measurement:

• Decoder: contact X2 or X3.

• Display, application and master modules: contact X2, X3 or X4.
• I/O modules: contact X7 or X13.
• Resolver modules: contact X3 or X4.
3. Connect the tester's connector to the module's power supply:

• I/O modules: connector X25. 7-pin connector.

• Other modules: connector X1. 5-pin connectors.

The voltage should normally be as follows.

a. Power supply (MAIN POWER) 24-28V (green light glows).

b. CAN power supply (CAN POWER) 20-24V (shines green).

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

d. CAN communication (CAN LO), about 2.3 V (flashes

green).

Fault indication
• 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, then there is no commu-
nication even though power is being supplied to CAN.
• If any light is flashing red, then CAN communication is at the
wrong level or is inverted.

CAN cable test

N.B.
System is to be shut down.

354
 1. Mount the tester on the multimeter. Make certain that the pins
are in the right place as indicated by the colour coding. The red
pin is to be connected to V/Ohm on the multimeter. Set the mul-
timeter range to Ohm.

2. Connect the tester's 4-pin connectors to the CAN network

requiring measurement:

• Decoder: contact X2 or X3.

• Display, application and master modules: contact X2, X3 or X4.
• I/O modules: contact X7 or X13.
• Resolver modules: contact X3 or X4.

3. Select CABLE TEST on the CAN tester. The multimeter is to

read about 60 ohms.

Fault indication
• If the multimeter reads 120 Ohm, the end plug is missing or
there is a break in a cable.

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

Lever panel

Connections

X6 X1 X1
X3 X2
1250 0066 86

Figure 23.4. Operator panel (standing panel)

355
 Table 23.4. Functions of connections
Contacts Function
X1 Power supply
X2 CAN network (to display)
X3 Address plug
X6 Emergency stop (NOT CAN network)

Decoder

X4
X3
X2
1250 0066 90 D500:2 X1

A Lever
B Decoder
Figure 23.5. Lever/decoder (sitting panel)

Table 23.5. Functions of connections

Contacts Function
X1 Power supply
X2 Can network
X3 Can network
X4 Input/output contacts

356
Lever casing, service platform

X4 X3 X2 X1

1250 0066 88

Figure 23.6. Lever casing

Table 23.6. Functions of connections

Contacts Function
X1 Power supply / Can network
X2 From I/O module
X3 Address plug
X4 Extra input/output (not used)

Replacement of decoder or lever

1. If any lever or lever decoder is changed, the lever must be cali-
brated. See maintenance instructions Control system .

X4
X3
X2
1250 0066 90 D500:2 X1

A Lever
B Decoder
Figure 23.7. Example, Lever/decoder (sitting panel)

357
Display, application and master modules

Connections

X1
D1

X2
D2 D3

X3
D4 D5

X4
D6
X5

1250 0066 89

Figure 23.8. Module

Table 23.7. Functions of connections

Contacts Function
X1 Power supply module
X2 CAN network 2
X3, X4 CAN network 1
X5 Address plug

Table 23.8. Functions of light-emitting diodes

Light-emit-
ting diode
(LED) Function
D1 Power supply module
D2 Communication, CAN network 2. Lights if communica-
tion in CAN network malfunctions.
D3 Voltage to CAN network 2
D4 Communication, CAN network 1. Lights if communica-
tion in CAN network malfunctions.
D5 Voltage to CAN network 1
D6 Indicates module status. Diode normally flashes at 1
Hz. In the event of a fault on any of the CAN networks,
it flashes at 16 Hz. The network where the fault is locat-
ed is indicated by D2 or D4.

358
I/O module

Connections

X7 X13
X1 X19

X8 X25 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 85

Figure 23.9. I/O module

Table 23.9. Functions of connections

Contacts Function
X1, X3, X4, X5, X19, PWM outputs
X21, X23
X2, X20, X22 Digital outputs
X6, X8, X10, X14, X16, Analogue inputs
X17
X7, X13 Can network
X9 Address plug
X11, X15, X24 Digital inputs
X12, X18 Encoder inputs
X25 Power supply module

• An LED on the I/O module provides the following indications:

- When the system starts, it flashes twice each second.
- When CAN communication is in progress it will flash once
per second.
- When there is no CAN communication, it will flash 5 times
per second.

Check digital inputs X11, X15, X24.

There are two digital inputs designated A and B at each contact
Normally, the signal is 0V for an open contact and +24V for a
closed contact.

359
 Table 23.10. Pin configuration
Pin Function
1 Signal A
2 GND A
3 +24V supply voltage for A
4 +24V supply voltage for B
5 GND B
6 Signal B

Interrupted signal (open circuit)

1. Connect the I/O tester between the I/O module input and the
guard as illustrated.

[V]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 79

Figure 23.10. Connecting the I/O tester

2. Connect the multimeter between GND and whichever of signals

A and B is of interest.

3. Normally, the signal is to be 0V at an open contact and +24V at

a closed contact.

Fault indication
• If the multimeter always reads 0V, the signal is interrupted
(open circuit).

360
Short circuit or open circuit in the power supply
1. Connect the I/O tester between the I/O module input and the
guard as illustrated.

[V]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 80

Figure 23.11. Connecting the I/O tester

2. Connect the multimeter between GND and the power supply.

Normally, the power supply is to be +24V.

Fault indication
• If the multimeter reads 0V, there is a short circuit in the power
supply for the guard.
• If the multimeter reads +24V, there is an open circuit in the
power supply for the guard.

Checking digital outputs X2, X20, X22

There are two digital outputs designated A and B in each contact.

Table 23.11. Pin configuration

Pin Function
1 out -A
2 out -B
3 out +A
4 out +B

361
Output with open circuit
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[V]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 81

Figure 23.12. Connecting the I/O tester

2. Connect the 6-position connector on the I/O tester to an unoccu-

pied 6-position connector in the I/O module.

3. Connect the multimeter between GND and the +A or +B output

that is of interest.

4. Activate the function. Normally, the multimeter will read ~ 24V.

Fault indication
• If the valve is not activated, there is an open circuit in the cable
running to the valve or in the coil in the valve.

362
Output with open circuit in valve coil
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[A]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 82

Figure 23.13. Connecting the I/O tester

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

is of interest.

3. Activate the function. Normally, the multimeter is to read ~1A.

Fault indication
• If the multimeter reads 0.00A and the solenoid coil diode is
lighted, there is an open circuit in the coil in the valve.

363
Output with short circuit of (+) to the chassis or (-) in the cable
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[A]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 82

Figure 23.14. Connecting the I/O tester

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

is of interest.

3. Activate the function. Normally, the multimeter is to read ~1A.

Fault indication
• If the multimeter reads 0.00A and the solenoid coil diode is
NOT lighted, there is a short circuit in the cable.

Checking analogue inputs X6, X8, X10, X14, X16, X17.

Table 23.12. Pin configuration

Pin Function
1 Input, 0-5V
2 GND
3 +5V power supply out
4 +12V power supply out
5 Input, 0-6V
6 Input, 4-20 mA

364
Input with short or open signal circuit
1. Connect the 6-position connector on the I/O tester between the
input of interest on the I/O model and the sensor as illustrated.

[V]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 94

Figure 23.15. Connecting the I/O tester

2. Connect the multimeter between GND and the signal, pin 5.

3. Normally, the voltage is to be +1V in there is no pressure

present.

Fault indication
• If the multimeter reads 0.00V there is an open or short signal
circuit.

365
Input with short circuit in the power supply
1. Connect the 6-position connector on the I/O tester between the
input of interest on the I/O model and the sensor as illustrated.

[V]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 93

Figure 23.16. Connecting the I/O tester

2. Connect a multimeter between GND an the power supply, pin 4.

3. Normally, the power supply will be +12 V.

Fault indication
• If the multimeter reads 0.00V there is a short circuit in the
power supply.

Checking PWM outputs X1, X3, X4, X5, X19, X21, X23.
There are two PWM outputs designated A and B in each contact.

Table 23.13. Pin configuration

Pin Function
1 out -A
2 out -B
3 out +A
4 out +B

366
Output with short circuit of (-) or (+) to the chassis.

Measuring voltage/power
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[V]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 81

Figure 23.17. Connecting the I/O tester

2. Connect the 6-position connector on the I/O tester to an unoccu-

pied 6-position connector in the I/O module.

3. Connect the multimeter between GND and the +A or +B output

that is of interest.

4. Activate the function.

Fault indication
• If the multimeter reads about 26V (system voltage) there is a
short circuit between a (-) lead and the chassis.
• If the multimeter reads 0.00V there is a short circuit between a
(+) lead and the chassis.

367
Measuring current
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[A]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 82

Figure 23.18. Connecting the I/O tester

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

is of interest.

3. Activate the function.

Fault indication
• If the multimeter reads more than 1A regardless of the level of
activation, and the solenoid coil diode is lighted, there is a short
circuit between the (-) lead and the chassis.
• If the multimeter reads 0.00A and the solenoid coil diode is
NOT lighted, there is a short circuit between the (+) lead and
the chassis.

368
Output with short circuit between (+) and (-) in the cable.

Measuring voltage/power
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[V]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 81

Figure 23.19. Connecting the I/O tester

2. Connect the 6-position connector on the I/O tester to an unoccu-

pied 6-position connector in the I/O module.

3. Connect the multimeter between GND and the +A or +B output

that is of interest.

4. Activate the function.

Fault indication
• If the multimeter reads 0.00V and the solenoid coil light-emit-
ting diode is NOT lighted, there is a short circuit between the
(+) lead and the (-) lead.

369
Measuring current
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[A]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 82

Figure 23.20. Connecting the I/O tester

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

is of interest.

3. Activate the function.

Fault indication
• If the multimeter indicates the approximate degree of activation
and the solenoid coil diode is NOT lighted, there is a short cir-
cuit between the (+) lead and the (-) lead.

370
Output with open circuit

Measuring voltage/power
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[V]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 81

Figure 23.21. Connecting the I/O tester

2. Connect the 6-position connector on the I/O tester to an unoccu-

pied 6-position connector in the I/O module.

3. Connect the multimeter between GND and the +A or +B output

that is of interest.

4. Activate the function.

Fault indication
• If the multimeter reads about 26V (system voltage), there is an
open circuit in the cable.

371
Measuring current
1. Connect the 4-position connector on the I/O tester between the
output of interest on the I/O module and the valve as illustrated.

[A]

X7 X13
X1 X19

X8 X14
X2 X20
X9 X15
X3 X21
X10 X16
X4 X22
X11 X17
X5 X23
X12 X18
X6 X24

1250 0066 82

Figure 23.22. Connecting the I/O tester

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

is of interest.

3. Activate the function.

Fault indication
• If the multimeter reads 0.00A and the solenoid coil diode is
lighted there is an open circuit in the solenoid coil.

372
Resolver module

Connections

X6 X1

X7 X3
X4
X8
X5
X9 X11

X10 X12
1250 0066 87

Figure 23.23. Resolver module

Table 23.14. Functions of connections

Contacts Function
X1 Power supply module
X3, X4 Can network
X5 Address plug
X6-X9 Resolver inputs
X10 Encoder input
X11, X12 Analogue inputs

• There is an LED on the resolver module that provides the fol-

lowing indications:
- When the system starts, it flashes twice each second.
- When CAN communication is in progress it will flash once
per second.

Checking resolver inputs X6 - X9

Pin configuration:

Table 23.15. Pin configuration

Pin Function
1 Ref +
2 Ref -
3 Sine signal
4 Sine GND

373
 Pin Function
5 Cosine signal
6 Cosine GND

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

1250 0066 92

Figure 23.24. Resolver tester

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

• 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 the test sensor slowly and check that the
angle on the sensor menu changes.

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

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

Checking the encoder input (Pulse sensor input) X10

Table 23.16. Pin configuration

Pin Function
1 +15V
2 +15V
3 Signal A
4 GND
5 Signal B
6 GND

374
 1. Connect the encoder tester to the end of the relevant cable. Turn
the test sensor slowly and check that the length measurement
shown on the sensor menu changes.

1250 0066 91

Figure 23.25. Encoder tester

• If it changes, the sensor on the boom is faulty.

• If it does NOT change, the cable on the boom must be checked.
2. Connect the test sensor with test cable directly to the resolver
module input. Turn the test sensor slowly and check that the
length measurement shown on the sensor menu changes.

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

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

Checking analogue input channels X11 and X12

Table 23.17. Pin configuration for input channel X11

Pin Function
1 GND
2 + 4.5V power supply out
3 Signal in
4 (Not used)
5 (Not used)

Table 23.18. Pin configuration for input channel X12

Pin Function
1 GND
2 + 15V power supply out
3 Signal in
4 (Not used)
5 (Not used)

375
Replacing the module
1. Make certain the module has the correct address plug and that
the end plug (if any) is mounted in place.

2. When any of the application module, I/O or resolver module is

replaced, the program must be read into the system again.

3. Insert the program card into slot 2 and start the RCS system.

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

5. Turn off the system - remove the program card and start the sys-
tem again.

Make certain that electric power is present at the rig or that the
diesel engine is running before loading the program. Avoid
starting the diesel engine while the program is being loaded.
Never turn off the system while the program is being loaded.

376