Maintenance Manual
Maintenance Manual
Maintenance
Manual
SOLO 5 C / P / F
INTRODUCTION
SOLO 5 C / P / F
SOLO 5 C / P / F
CONTENTS
SOLO 5 C / P / F
5. MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2. For the new rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3. Carrier TC 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.4. Deutz engine BF4M 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.5. Cable reel TCR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.6. Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.7. Compressor CT10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.8. Rock drills HLX 5 LT, HL 710 S, HL 800 ST . . . . . . . . . . . . . . . . . . . . . . . 70
5.9. Feed LF 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.10. Boom ZR 20 / 32 P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.11. Air circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.12. Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.13. Rod changer RC 700 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.14. Retaining centraliser (PITO) 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.15. Commencing production use with a new rig . . . . . . . . . . . . . . . . . . . . . 90
5.16. Recommended lubrication of the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.17. Operation and maintenance of the diesel engine . . . . . . . . . . . . . . . . 90
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
1.3. Components
Drilling module
3
2 1. Rock drill
SOLO 5 P 5
4 2. Feed
3. Boom
1 4. Rod changer (optional)
5. Front frame
3 2
SOLO 5 C 5
4
2
5 4
SOLO 5 F
3
1
5 2
4
SOLO 5 F
3
4 3
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
2. Feed LF 700
1. Retaining centralis-
er (PITO) 7
2. Feed beam
3 3. Feed cylinder
4. Carriage
4
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
3
3. Transmission oil receiver
3 1. Sight glass
2. Breather filter and
1 fill plug
2 3. Level switch
4. Checking / cleaning
4 door
5. Drain plug
5
4. Transmission oil cooler
1. Hydraulic motor
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
5. Transmission pump
1. Transmission oil fil-
ter
6. Axles
1. Planetary gear
3
2. Brake cylinders
3. Brakes
1
1
7. Fuel tank
1. Filling cap
3
2. Level switch
2
3. Breather filter
8. Battery
1. Battery (x2)
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
2 1
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
7
15. Compressor
12 5 8 11 1. Air filter
7
2. Compressor
3. Filling unit cap
4. Oil separator filter
5. Electric motor
4 6. Oil level sight glass
7. Oil separator
8. Intake valve
3 9. Oil cooler
10. Oil filter
6 11. Oil separator
cyclone
15
12. Contamination
indicator for air filter
1
13. Pressure gauge
14. Temperature gauge
9 13 14 2 10
15. Drainage
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
3 4
22. High pressure washing unit (in models C and P)
(optional)
1. High pressure water
2 pump
2. Reel
3. High pressure
washer
4. Control valve
4 1
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
1 2 4
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
Drilling components
6 1,3,5
SOLO 5 C 4 4
1,3,5
6
SOLO 5 F 4
1,2,5 4
6
SOLO 5 F 3,5
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
4
5
6
1 3 2
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
1
4. Boom valves
1. Boom control block
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
SOLO 5 C / P / F
INTRODUCTION TO THE RIG
6. Pressure filter
1. Filter cartridge
2. Indicator
2
SOLO 5 C / P / F
SAFETY INSTRUCTIONS
2. SAFETY INSTRUCTIONS
2.1. The rig’s warning signs
The warning signs attached to the rig are described in the relevant section.
! DANGER
DANGER DANGER
Immediate danger caused by the rig’s
actuator.Risk of serious injury or death if
appropriate caution is not exercised.
Hazardous voltage.
These instructions prohibit use of the equipment before reading the manuals or
receiving training in its use.
Do not use the rig before you have participated in machine-- specific
operation and maintenance training. Read the operating and
maintenance instructions before using or servicing the equipment. The
CAUTION operator must be familiar with the operation, maintenance, and safety
instructions for the equipment as well as with mine safety regulations.
E 2006 SANDVIK TAMROCK CORP., Tampere Plant
P.O. Box 100
FIN--33311 TAMPERE, Finland
Tel.: +358 205 44 121
FAX: +358 205 44 120
B 01497 - 5 en 0606 / TL 29 (90)
SOLO 5 C / P / F
SAFETY INSTRUCTIONS
2.5. General
It is recommended to keep a record of the use of spare parts and wear parts. This way
the need for preventive maintenance can be predicted more easily, resulting in improved
rig usability, efficiency, and safety.
Neglecting caution can also make the maintenance work dangerous for the service
personnel. Each and every maintenance person working with the rig must recognise the
possible risks and use safe working methods. Before starting any maintenance or repair
work, read the manufacturer’s instructions carefully. Be sure to follow them exactly.
The person responsible for maintenance and repair work must be clearly specified.
-- Never start a task for which you have not received training or been given proper
authorisation.
-- Inform the operator of the rig of the start of maintenance and repair work.
-- Before starting the work, ensure that all unnecessary items are removed from the
vicinity of the site and that the area is safe to work in.
-- Ensure that the rig cannot be accidentally started if maintenance or repair work is
to be carried out on it.
D Turn the main switch off.
D Remove the ignition key.
D Place a DANGER – DO NOT START warning sign on the main switch. The sign
may only be removed by a person who is fully aware of the current status of the
work.
-- Clean and wash the rig regularly, and always before starting maintenance or repair
work.
-- Before washing the rig using water, a high--pressure cleaner, a steam cleaner, or
another method, protect the components that are susceptible to damage or
exposed to water. Pay special attention to the protection of electric motors, boxes,
and cabinets.
-- If necessary, use appropriate steps or working platforms for the site.
-- Never use the components of the rig as steps. If the work is carried out at a great
height, or in an otherwise dangerous place, install rails as necessary to prevent
falling.
-- Keep all stairs, rails, anti--slip devices, steps, etc. clean of oil, grease, snow, ice,
unnecessary items, and dirt to prevent accidents caused by slipping.
-- Use only undamaged, high--quality tools that are appropriate for the work in
question.
-- Before starting the work, ensure that the rig is on a level surface and that the wheels
of both axles are wedged to prevent movement.
SOLO 5 C / P / F
SAFETY INSTRUCTIONS
-- Observe the operation and condition of the exhaust pipe and exhaust cleaner in
particular. Ensure sufficient ventilation.
-- Overheating of the diesel engine indicates a fault. Stop the engine and fix the
problem causing the overheating in order to prevent damage to the engine. Ensure
that air can flow freely through the engine’s radiator. If necessary, clean the radiator
and remove any obstructions.
-- Stop the engine and allow it and the coolant to cool down before you check the
coolant level. If an overheated engine has to be stopped, allow the coolant to cool
down before checking the coolant level. If this is not possible, try to prevent burns
by using protective gloves and other protective clothing when opening the radiator
cap. Stand as far to the side as possible, turn your face away, and carefully open
the cap a little. Before finally opening and removing the cap, wait until no more
pressure or coolant is being discharged from the cooling system.
-- When moving heavy parts and equipment, use only appropriate hoists and lifting
methods. Follow the hoist manufacturer’s instructions.
SOLO 5 C / P / F
SAFETY INSTRUCTIONS
SOLO 5 C / P / F
SAFETY INSTRUCTIONS
-- Ensure that the new hose connectors and the hose types and lengths correspond
to the types originally used by the manufacturer. When replacing hoses and
connectors, use original Tamrock parts or equivalent types recommended by the
manufacturer. Also ensure that the hoses and connectors are rated for the
pressure level they will be subjected to.
-- Modifications to the rig require written permission from the manufacturer.
-- Check the operation of the earth leakage control system weekly by pressing the
test button. If the control does not switch the power off, the control system must be
repaired before any device connected to it is started.
-- When working with high voltage systems, remember that the capacitors in various
components can be charged even though the system is disconnected from the
mains. Discharge a capacitor by grounding it.
-- Electrical modifications to the rig require written permission from TAMROCK’s
electrical design department, ensuring the correct operation of the modified
device.
SOLO 5 C / P / F
SAFETY INSTRUCTIONS
2.12. Welding
Before welding, determine the material to be welded and appropriate welding methods
and consumables. If necessary, contact TAMROCK Service.
-- Never repair steering devices by welding.
-- Leave welding to a professional welder.
-- Disconnect both battery terminals before welding since the welding voltage can
damage electrical equipment.
-- Use a protective mask when welding.
-- Provide adequate ventilation.
-- Provide adequate fire--extinguishing equipment.
-- Attach the grounding cable as close to the welding location as possible.
SOLO 5 C / P / F
REGULAR MAINTENANCE
3. REGULAR MAINTENANCE
The continued operation of the rig is ensured by regular maintenance carried out correctly
at the proper intervals. The purpose of regular maintenance is to check the rig at regular
intervals, ensuring a high uptime for the rig. This prevents high repair costs and lost
productivity. Neglecting maintenance leads to high extra costs.
It is important to carry out daily maintenance routines carefully. All possible faults must be
repaired immediately or reported to the person in charge. Daily maintenance includes
general lubrication, inspections, and adjustments. Each new operator must be
familiarised with the daily maintenance routines.
Intervals listed for regular maintenance are usually based on diesel engine hours
or percussion hours.
SOLO 5 C / P / F
REGULAR MAINTENANCE
D Tightness of the diesel engine bolts and the intake and exhaust manifold bolts.
D Check the suction hoses and their connections.
D Tighten the pump--mounting bolts.
D Check the torque of the rock--drill bolts.
D Tighten all loose connectors and bolts.
D Check the tightness of wheel bolts and tighten if necessary.
D Check the operation of the warning and shutdown systems.
D Check the compressor’s operating temperature.
D Check the compressor’s air filter.
D Check the tightness of the slide ring unit’s wire connections.
D Check the alignment of the slide ring unit’s slide brushes.
D Check the traction of the cable reel motor.
D Check the functioning of the cable reel’s reel--limiting switches.
D Replace the return filters according to the service indicators.
The delivery inspection checklist for the Deutz engine must be completed
at this time!
CAUTION
SOLO 5 C / P / F
MAINTENANCE TABLES
4. MAINTENANCE TABLES
4.1. General
PERCUSSION HOURS
AT THIS INTERVAL (hours)
EVERY
GENERAL SHIFT 50 250 500 1,000 1,500 2,000 3,000
SOLO 5 C / P / F
MAINTENANCE TABLES
PERCUSSION HOURS
AFTER THE FIRST
FOR A NEW RIG 1 to 20 hours 50 hours 100 hours
COMPRESSOR HOURS
AFTER THE FIRST
FOR A NEW RIG 1 to 20 hours 50 hours 100 hours
SOLO 5 C / P / F
MAINTENANCE TABLES
SOLO 5 C / P / F
MAINTENANCE TABLES
SOLO 5 C / P / F
MAINTENANCE TABLES
4.4. Cabin
SOLO 5 C / P / F
MAINTENANCE TABLES
COMPRESSOR HOURS
AT THIS INTERVAL (hours)
EVER
COMPRESSOR CT 10 Y 50 250 500 1,000 1,500 2,000 3,000
SHIFT
SOLO 5 C / P / F
MAINTENANCE TABLES
PERCUSSION HOURS
AT THIS INTERVAL (hours)
ROCK DRILL HLX 5 LT
EVERY
SHIFT 50 250 500 1,000 1,500 2,000 3,000
SOLO 5 C / P / F
MAINTENANCE TABLES
PERCUSSION HOURS
AT THIS INTERVAL (hours)
ROCK DRILL HL 710 S / HL 800 ST
EVERY
SHIFT 50 250 500 1,000 1,500 2,000 3,000
SOLO 5 C / P / F
MAINTENANCE TABLES
PERCUSSION HOURS
AT THIS INTERVAL (hours)
EVERY
FEED LF 700 SHIFT 50 200 500 1,000 1,500
SOLO 5 C / P / F
MAINTENANCE TABLES
4.6.4. Boom ZR 20 / ZR 32 P
PERCUSSION HOURS
AT THIS INTERVAL (hours)
BOOM ZR 20 / ZR 32 P EVERY SHIFT 50 200 500 1,000
SOLO 5 C / P / F
MAINTENANCE TABLES
PERCUSSION HOURS
AT THIS INTERVAL (hours)
BOOM ZR 20 / ZR 32 P EVERY SHIFT 50 200 500 1,000
SOLO 5 C / P / F
MAINTENANCE TABLES
PERCUSSION HOURS
AT THIS INTERVAL (hours)
EVERY
AIR CIRCUIT SHIFT 50 250 500 1,000 1,500 2,000 3,000
Water separator(s)
Shank lubrication receiver and air
cleaner IP5**
Condition of the shank lubrication
device **
Visually check the shank lubrication
oil level **
Pressure switch
Air valves
Cleaning the inside of the shank
lubrication receiver **
** Refer to separate instructions KVL--10
4.6.6. Water circuit
PERCUSSION HOURS
AT THIS INTERVAL (hours)
EVERY
WATER CIRCUIT SHIFT 50 250 500 1,000 1,500 2,000 3,000
SOLO 5 C / P / F
MAINTENANCE TABLES
PERCUSSION HOURS
AT THIS INTERVAL (hours)
EVER
Y 1,000 1,500
POWER PACK HPP 755 SHIFT 1--20 50 200 500 2,000 3,000
SOLO 5 C / P / F
MAINTENANCE TABLES
PERCUSSION HOURS
AT THIS INTERVAL (hours)
EVERY
ROD CHANGER RC 700 SHIFT 50 200 500 1,000 1,500 2,000 3,000
PERCUSSION HOURS
AT THIS INTERVAL (hours)
EVERY
Retaining centraliser (PITO) 7 SHIFT 50 200 500 1,000 1,500 2,000 3,000
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
5. MAINTENANCE PROCEDURES
Regular maintenance procedures
Refer to the following separate maintenance instructions:
-- carrier maintenance and lubrication instructions
-- feed instructions
-- boom instructions
-- rock drill instructions
-- diesel engine instructions
-- power pack: electric motor instructions
-- air circuit: compressor instructions
-- air circuit: KVL--10 instructions.
5.1. General
EVERY 500 HOURS
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
** Before checking the oil level in the hydraulic receiver, ensure that all
piston rods are inside the cylinders and the boom is in the transport
position.
CAUTION
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
5.3. Carrier TC 5
d Standard
a
c
b
Alternative
b
abcd
2. Lubricate:
a. Oscillation axle nipples
b. Frame joint
c. Steering cylinder joints
d. Thrust bearing of the joint shaft
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
3
4 5
Service brake
The indicator light is on if front or rear brake pressure is below 145 bar.
1. Service brake warning light
2. Service brake pedal
Service brake
The indicator light is on if front or rear brake pressure is below 110 bar.
1. Service brake warning light
2. Service brake pedal
5. Brake pressure under 15 bar indicator light
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
2
1 1 Refer to the carrier maintenance
and lubrication instructions.
Change the engine oil.
1. Motor oil filling cap
2. Drain plug
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
1 4 3
Refer to the carrier maintenance
and lubrication instructions.
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
1. Fuel filters
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
2
Check the tightness of the chain
(2).
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
5.6. Cabin
1
Clean the air filter
1
Replace the air filter
1. Hinges
1
Check the operation of the
heating and air conditioning
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
EVERY 50 HOURS
Check the hour-- meter reading.
HL 710 S / HL 800 ST
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
HLX 5 LT
Check the pressure accumulator
bolts (4).
1. Lubricate the threads with petro-
leum jelly.
2. Pre--tighten all 4 bolts to 100
Nm (10 kpm). The tightening se-
3 1 quence is 1--2--3--4.
3. The final tightening torque is 200
6 7 Nm (20 kpm). The tightening se-
quence is 1--2--3--4.
4. Pre--tighten bolts 5, 6, and 7 to
5 100 Nm (10 kpm). The final tighte-
ning torque is 200 Nm (20 kpm).
The tightening sequence is free.
HL 710 S / HL 800 ST
Check the pressure accumulator
200 Nm (100 Nm) bolts (4).
3 1. Lubricate the threads and nut
2
contact surfaces.
2. Pre--tighten all 4 bolts to 100
Nm (10 kpm). The tightening se-
quence is 1--2--3--4.
3. The final tightening torque is 200
4 Nm (20 kpm). The tightening se-
1 quence is 1--2--3--4.
HL 710 S / HL 800 ST
Check the rotary actuator bolts
150 Nm (100 Nm) 1. Lubricate the bolts.
3 2 2. Pre--tighten all 4 bolts to 100
Nm (10 kpm). The tightening se-
quence is 1--2--3--4.
3. The final tightening torque is 150
1 Nm (15 kpm). The tightening se-
4
quence is 1--2--3--4.
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
HL 710 S
High--pressure accumulator 80 bar
Low--pressure accumulator 4 bar
HL 800 ST
High--pressure accumulator 80 bar
Low--pressure accumulator 4 bar
HL 710 S / HL 800 ST
Check the condition of the
max. 1 mm max. 1 mm shank, chuck, and coupling
1
1. Shank
Replace the shank if the bevel of
the percussion surface has worn >
2 mm, the bevel surface of the dri-
A
ve teeth has worn 1 mm, or ano-
ther wear limit is exceeded.
2 A. Work measure 2 mm, reject
measure 1 mm.
2. Chuck
The chuck inside the rotation bus-
hing must be replaced if it has worn
over 1 mm (picture) from its original
3 level or the chuck has cracks in it.
Remove the chuck with a hydraulic
press and the tools included in the
special toolkit.
3. Coupling
Pull the coupling out from the rota-
tion bushing. Check it and replace
if the edges of the inner teeth are
worn to a pointed shape.
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
2
2 3 3
1
HL 710 S / HL 800 ST
Check the shank bearings and
2 seals
1. Shank bearing
2. U--seals
3. O--rings
HL 710 S / HL 800 ST
Check the chuck and rotation
bushing
1. Rotation bushing assembly
Check the wear of the teeth and
1 the bearing surfaces. Replace the
rotation bushing if the collar (pictu-
re) has worn down.
2. Chuck The chuck inside the ro-
tation bushing must be replaced if it
2 has worn over 1 mm (picture) from
its original level or the chuck has
cracks in it. Remove the chuck with
a hydraulic press and the tools in-
cluded in the special toolkit.
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
EVERY 50 HOURS
Fastening
screws 3
pcs/side
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
clearance = 0
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
Fastening
screws 3
pcs/side
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
5.10. Boom ZR 20 / 32 P
EVERY 50 HOURS
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
1
B1 A1
Adjusting
screws
3 pcs/side
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
Checking the
gear ring
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
EVERY 50 HOURS
Check the pressure switch.
S421
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
EVERY 50 HOURS
Check the hydraulic circuit ope-
rating pressures.
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
EVERY 50 HOURS
2 1
3
Replace the hydraulic cylinder
seals.
1. Jaw cylinders
2 2. Turn lever cylinders
3 3. Turn arm cylinders
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
EVERY 50 HOURS
SOLO 5 C / P / F
MAINTENANCE PROCEDURES
1
Replace the pins and bushes.
1. Bushes
2. Pins
2
1
1
SOLO 5 C / P / F
MAINTENANCE PROCEDURES