Atlas Copco SMARTROC D65 TIER 4 FINAL Maintenance Manual
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Atlas Copco SMARTROC D65 TIER 4 FINAL Maintenance Manual

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

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Summary of Contents for Atlas Copco SMARTROC D65 TIER 4 FINAL

  • Page 1 SMARTROC D65 TIER 4 FINAL Maintenance Translation of the original instructions 2015-12-17 | No: 713991051.3 en...

  • Page 3: Reference

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

  • Page 5: Table Of Contents

    SmartROC D65 Tier 4 Final Table of Contents Table of Contents 1 Reference.......................  3 2 General.........................  11 General............................ 11 2.1.1 Safety .............................  11 2.1.2 Target group and objective.....................  11 2.1.3 Contact details........................ 11 2.1.4 Signs for outsourced components .................. 16 2.1.5 Dismantling and assembly......................
  • Page 6 SmartROC D65 Tier 4 Final Table of Contents 4.5.3 Pin configurations X8 - X9 ......................  48 4.5.4 LED functions .........................  48 5 RCS drilling system ....................  49 Drill system.......................... 49 5.1.1 RCS ............................ 49 5.1.2 Logging in .......................... 51 Overview of menus ........................ 52 5.2.1...
  • Page 7 SmartROC D65 Tier 4 Final Table of Contents Climbing chain ........................ 143 7.3.1 Lubricating the sprocket wheel and checking the climbing chain cover.......  143 Bearing unit and checking the chain guide................. 144 7.4.1 Replacing the bearing unit (chain feed)................ 144 Protective plates ........................ 145 Checking for wear on the sprockets .................. 145...
  • Page 8 SmartROC D65 Tier 4 Final Table of Contents 12.3.4 Checking the oil level...................... 175 12.3.5 Changing oil and oil filter ......................  176 12.3.6 Changing to new type of oil .................... 177 12.3.7 Cleaning the oil cooler ...................... 179 12.3.8 Test pressurising the safety valve .................. 179 12.3.9 Checking the pressure sensor B456 ..................
  • Page 9 SmartROC D65 Tier 4 Final Table of Contents 14.4.1 Daily checks and maintenance.....................  216 14.4.2 Annual maintenance...................... 216 14.4.3 Electric Welding, Steam Cleaning and High Pressure Cleaning ..........  216 14.5 Service Winch......................... 216 14.5.1 Cleaning .......................... 216 14.5.2 Transmission ........................ 217 14.5.3 Disengagement device ......................
  • Page 10 SmartROC D65 Tier 4 Final Table of Contents...

  • Page 11: General

    The maintenance instructions are intended for mechanics and personnel in maintenance and service. The user should have undergone Atlas Copco's training courses for the equip- ment concerned. The objective of these maintenance instructions is to detect and rectify faults at an early stage so that breakdowns, costly secondary damage and accidents can be prevented.
  • Page 12 SmartROC D65 Tier 4 Final 2 General Country Address Phone and fax number Fax: + 43 - (0)1 - 76 01 24 16 Bolivia P.O. Box 290 Santa Cruz de la Phone: + 591 - (0)2 - 211 20 00...
  • Page 13 SmartROC D65 Tier 4 Final 2 General Country Address Phone and fax number Cergy Pontoise Cedex Germany Postfach 10 02 25 D-46002 Es- Phone: + 49 - (0)201 - 217 70 Fax: + 49 - (0)201 - 21 77 360...
  • Page 14 SmartROC D65 Tier 4 Final 2 General Country Address Phone and fax number Korea 3rd Floor, Seowon Build- Phone: + 82 - (0)2 - 21 89 40 00 ing1515-4 Fax: + 82 - (0)2 - 522 82 39 Seocho 3-dong, Seocho-ku...
  • Page 15 Fax: + 260 - (0)2 - 12 31 38 77 Zimbabwe P.O. Box CY 935 Causeway Phone: + 263 - (0)4 - 62 17 63/64/65 Fax: + 263 - (0)4 - 62 17 94 Table 1: Addresses, telephone numbers and fax numbers to Atlas Copco companies...

  • Page 16: Signs For Outsourced Components

    Type designations and serial numbers are specified in a separate docu- ment, MI (Machine Identification). Spare parts can always be ordered through Atlas Copco. 2.1.5 Dismantling and assembly...

  • Page 17: Scaling

    Emissions cleaning unit 2.1.8 Tightening torque in bolted joints. All joints are tightened to the torque required by Atlas Copco Standard K 4369 unless oth- erwise specifically stated. In such cases, this will be specified in the maintenance instruc- tions of the module in question.

  • Page 18: Work On Painted Surfaces

    Applies to drill rigs equipped with one of the following engines: CAT C13, Tier 4 CAT C15, Tier 4 NOTE: It is important to consult Atlas Copco for approval of welding and choice of electrodes. Connections that must be disconnected prior to welding...

  • Page 19: Welding Can Bus

    SG 2 AWS: A/SFA 5.18: ER 70 S-6 Table 4: MIG electrodes If in any doubt, contact Atlas Copco for advice. 2.1.11 Welding CAN BUS Preparations before welding Disconnect the supply voltage to all modules, both + and -, as follows: Cable KC50A is removed from the right-hand rear pillar outside the cabin.

  • Page 20: Diagnostics

    SmartROC D65 Tier 4 Final 2 General Cable D530X1 is removed from D530/X1 Cable D511X25 is removed from D511/X25 Cable D102X25 is removed from D102/X25 Cable D510X25 is removed from D510/X25 Cable D101X25 is removed from D101/X25 Cable D103X25 is removed from D103/X25 Cable D512X25 is removed from D512/X25 Contact P61 is removed from J61 "Customer connection"...
  • Page 21 SmartROC D65 Tier 4 Final 2 General Explosive gas is formed in the battery during charging. A short circuit, naked flame or spark in the vicinity of the battery could cause a serious explosion. Ensure good ventilation. Al- ways turn off the charge current before disconnecting the clips. If the density has not risen noticeably despite a number of hours of recharging, the battery is probable expended.

  • Page 22: Starting With An Auxiliary Battery

    SmartROC D65 Tier 4 Final 2 General Remove the jumper lead between the negative terminal on battery G1A and the posit- ive terminal on battery G1B. Connect the positive battery charger cable to the positive terminal on G1A. Connect the batter charger's negative lead to the negative terminal on G1A.

  • Page 23: Steel Ropes

    SmartROC D65 Tier 4 Final 2 General First connect the positive terminal of the auxiliary battery to the positive terminal of the chassis battery (2). Then connect the negative terminal of the auxiliary battery (1) to ground on the chassis (not to the chassis battery's negative terminal).
  • Page 24 SmartROC D65 Tier 4 Final 2 General Occurrence of wire breaks due to operating time. Wire breaks occur first after a certain operating time depending on operating conditions and subsequently occur more frequently. If this is the case, the number of wire breaks in relation to the operating time should be de- termined and documented.
  • Page 25 SmartROC D65 Tier 4 Final 2 General Over a length of Over a length of 201 - 220 221 - 240 d = Cable diameter = Filler wire is not considered load-bearing. In cables with several layers of strands, only the outer, visible layer is considered.
  • Page 26 SmartROC D65 Tier 4 Final 2 General Strand displacement Waviness Cracking Kinks Flattening Local cable diameter decrease Local cable diameter increase Basket formation Wire displacement Individual wires or wire groups stick out like hairpins on the side facing away from the drum.
  • Page 27 SmartROC D65 Tier 4 Final 2 General Waviness Cracks Cracks are deformations through outer, violent influences. Cables with cracks must be scrapped. Cracks Kinks A kink is a deformation caused by the cable forming an eye that is contracted with out the cable being able to rotate around its own axle.
  • Page 28 SmartROC D65 Tier 4 Final 2 General Flattening Local cable diameter decrease Local decrease in cable diameter is often connected to core break. The area near the end attachments must be inspected especially carefully as it can be diffi- cult to detect cable diameter decrease at these spots.

  • Page 29: Air Conditioning

    SmartROC D65 Tier 4 Final 2 General 2.4 Air conditioning 2.4.1 Safety WARNING Serious injury Refrigerant under pressure Risk of serious personal injury Service of refrigerant must always be carried out by authorised personnel NOTE: Do not use the system with too little refrigerant, leakage or any other fault until it is rectified.

  • Page 30: Diagnostics

    SmartROC D65 Tier 4 Final 2 General Changing the main filter: Undo the screws around the cover (C). Open the cover and lift out the filter. Fit the new filter in place and screw back the cover. Changing the prefilter: Undo the screws on the louvre cover (D).
  • Page 31 SmartROC D65 Tier 4 Final 2 General Abnormal system noise is often connected to incorrectly assembled 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.
  • Page 32 SmartROC D65 Tier 4 Final 2 General...

  • Page 33: Transport Instructions

    SmartROC D65 Tier 4 Final 3 Transport instructions 3 Transport instructions 3.1 Hoisting 3.1.1 Single-section boom version WARNING Serious injury Hanging load May cause serious personal injury and damage to property Do not approach a hanging load Only use lifting equipment and lifting straps with adequate lifting capacity...

  • Page 34: Transport

    SmartROC D65 Tier 4 Final 3 Transport instructions Left control panel Make sure that none of the hoses, controls or any other components can fasten or sustain damage when the hoisting slings are tensioned and under load. Place the hoisting slings under both crawler tracks at points A and B as shown in the il- lustration Hoisting.

  • Page 35: Before Loading The Drill Rig Onto The Transport Vehicle

    SmartROC D65 Tier 4 Final 3 Transport instructions 3.2.1 Before loading the drill rig onto the transport vehicle Run the rotation unit/rock drill to its lowest position. Use the boom and feed controls alternately to bring the feed down into the transport posi- tion and firmly down on its jack (A).

  • Page 36: Towing

    SmartROC D65 Tier 4 Final 3 Transport instructions 3.3 Towing WARNING Serious injury Danger of moving parts May cause serious personal injury and damage to property Position a wedge under both of the track frames, before disengaging the traction gears...
  • Page 37 SmartROC D65 Tier 4 Final 3 Transport instructions Before the machine can be towed, the centre shaft (C) on both track frames must be disen- gaged. Condition p The track frames must be clean and completely free of dirt and mud before the cover plate (B) for the traction gears is removed.
  • Page 38 SmartROC D65 Tier 4 Final 3 Transport instructions...

  • Page 39: Hardware Rcs

    SmartROC D65 Tier 4 Final 4 Hardware RCS 4 Hardware RCS 4.1 Display, application and CCI module Display/Application/CCI module 4.1.1 Connections Contact Function Power supply module CAN network 2 X3, X4 CAN network 1 Address plug COM2 USB/COM1 Video Ethernet...

  • Page 40: Pin Configurations

    SmartROC D65 Tier 4 Final 4 Hardware RCS 4.1.2 Pin configurations Contact Type Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Four-pin +24V supply +24V supply M12, male voltage voltage contact X2, X3, X4 Five-pin NC (Not CAN +24V...

  • Page 41: Resolver Module

    SmartROC D65 Tier 4 Final 4 Hardware RCS 4.2 Resolver module Resolver module 4.2.1 Connections Contact Function Power supply module X3, X4 CAN network Address plug X6-X9 Resolver inputs Encoder input X11, X12 Analogue inputs Table 6: Functions of connections 4.2.2 Pin configurations...

  • Page 42: Led Functions

    SmartROC D65 Tier 4 Final 4 Hardware RCS Contact Type Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 X3, X4 Five-pin M12, NC (Not CAN GND CAN Hi CAN Lo male contact Connec- +24V (X3) or female...

  • Page 43: I/O Module

    SmartROC D65 Tier 4 Final 4 Hardware RCS 4.3 I/O module I/O module 4.3.1 Connections Contact Function X1, X19 CAN in (X1), CAN out (X19) X2, X3, X4, X20, X21, X22 Analogue inputs X5, X23 DI/DO NPN Encoder X7, X8, X9, X10, X14, X15, X16, X24...

  • Page 44: Pin Configurations

    SmartROC D65 Tier 4 Final 4 Hardware RCS Contact Function Power supply module Table 7: Functions of connections 4.3.2 Pin configurations Contact Type Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 X1, X19 Five-pin Screen CAN +24V CAN GND...
  • Page 45 SmartROC D65 Tier 4 Final 4 Hardware RCS When there is no CAN communication or if the I/O module is starting up the LED will flash five times per second. 5V supply for CAN control. 24V supply for valves and sensors.

  • Page 46: Operator Panel

    SmartROC D65 Tier 4 Final 4 Hardware RCS 4.4 Operator panel 4.4.1 Connections Operator panel Contact Function Supply voltage CAN network end plug CAN network (to display D501) Address plug D569 Aim Device Emergency stop (NOT CAN network) Table 8: Functions of connections...

  • Page 47: Decoder, Operator Panel

    SmartROC D65 Tier 4 Final 4 Hardware RCS 4.5 Decoder, operator panel Decoder, operator panel 4.5.1 Connections Contact Function Supply voltage Can network Can network Address plug RS232 X8, X9 Input/output contacts Table 9: Functions of connections 4.5.2 Pin configurations X1 - X6...

  • Page 48: Led Functions

    SmartROC D65 Tier 4 Final 4 Hardware RCS Contact Type Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Each address ID is connected to GND (ground). The address plug can be connected to four different addresses. Five-pin RXD 1...

  • Page 49: Rcs Drilling System

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5 RCS drilling system 5.1 Drill system 5.1.1 RCS RCS (Rig Control System) is a system that controls and monitors drilling functions as well as various drill rig functions. The RCS system is based on CAN technology (CAN = Con- troller Area Network).
  • Page 50 SmartROC D65 Tier 4 Final 5 RCS drilling system Rig Layout Feeder Layout...

  • Page 51: Logging In

    5.1.2 Logging in NOTE: The service menus in these instructions are intended for service personnel that have completed Atlas Copco's training for the drilling system. Incorrect handling can lead to the system becoming inoperative. A user code that only service personnel should have access to is required in order to ac- cess the service menus.

  • Page 52: Overview Of Menus

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.2 Overview of menus 5.2.1 Menu structure Direct selection menu Direct selection menu F2.1 Direct selection menu F2.2 Direct selection menu Direct selection menu Performance log Direct selection menu Direct selection menu...
  • Page 53 SmartROC D65 Tier 4 Final 5 RCS drilling system Logging Logging Trace Log Logging Signal Log Logging Auxiliary Temperature Logging Positioning Positioning Sensors Positioning Sensors Calibration Positioning Actuations Positioning Parameters Positioning Parameters Valve parameters Positioning Parameters Auto parameters Drilling Sensors...

  • Page 54: Settings

    SmartROC D65 Tier 4 Final 5 RCS drilling system Sensors Wagon Frame Calibration Actuations Actuations Power Pack Actuations Wagon Frame Actuations Cooling fan Parameters Parameters Tramming Sensors Sensors Calibration Actuations Left Digital Lever Actuations Right Digital Lever Actuations Bit Breaker...

  • Page 55: Parameters

    SmartROC D65 Tier 4 Final 5 RCS drilling system Symbol Explanation Drill bit. This symbol is next to various parameters and indicates that they are drill bit specific. The symbol can also be found together with a list of options from which the desired type of drill bit can be selected.

  • Page 56: Actuations

    Select the Actuate desired value box. Press Enter and hold it depressed. The desired value is actuated as long as Enter is kept depressed. NOTE: The actuation menus should only be used by personnel from Atlas Copco or other trained personnel.

  • Page 57: Direct Selection Menus

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.4 Direct selection menus 5.4.1 Direct selection menu F1. Direct selection menu F1. Symbol description for direct selection menu F1 NOTE: GPS is covered separately in the chapter entitled Options The following is an explanation of the symbols shown in direct selection menu F1.
  • Page 58 SmartROC D65 Tier 4 Final 5 RCS drilling system Symbol Name Explanation Resetting hole length Zeroes the measured hole length. Length measurement should be reset with the drill bit against the ground before begin- ning to drill a new hole.

  • Page 59: Direct Selection Menu F2

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.4.2 Direct selection menu F2. Direct selection menu F2. Settings 1 Quick Settings In F2 a choice can be made between Settings 1 (see illustration above) and Settings 2 (see next illustration).
  • Page 60 SmartROC D65 Tier 4 Final 5 RCS drilling system Ignore chair switch: Normally you have to sit in the seat to operate the positioning levers. If the box is checked, you can leave the seat for 10 seconds and still carry out positioning.
  • Page 61 SmartROC D65 Tier 4 Final 5 RCS drilling system Direct selection menu F2 Settings 2 Laser Plane: Selection of laser plane function. Dist. Laser Sens. to Drill Bit Dist. to Ref. Laser Plan:Used when there are several laser planes present. The ref- erence plane is always the uppermost laser plane.

  • Page 62: Direct Selection Menu F3

    SmartROC D65 Tier 4 Final 5 RCS drilling system Use Drillplan: Used if import of drill plan from ROC Manager is executed. 5.4.3 Direct selection menu F3. Direct selection menu F3. Symbol description for direct selection menu F3 Symbol Name...

  • Page 63: Direct Selection Menu F4

    SmartROC D65 Tier 4 Final 5 RCS drilling system Symbol Name Explanation Save Save to USB memory stick for printing on PC. Grinding interval Resettable counter for grinding interval. View performance log: 5.4.4 Direct selection menu F4. Direct selection menu F4.

  • Page 64: Direct Selection Menu F5

    SmartROC D65 Tier 4 Final 5 RCS drilling system The end of the needle reaching the centre of the graphic image means the feeder position is at the desired value. This setting can also be made using "Automatic feeder positioning" (Extra equipment).
  • Page 65 SmartROC D65 Tier 4 Final 5 RCS drilling system Symbol Name Explanation Coolant temperature Displays temperature of coolant Hydraulic Oil Temp Displays the temperature of the hydraulic oil Compressor temperature Reads and displays the current compressor temperature. If the compressor attains a high air temperature (120 ºC), the diesel...

  • Page 66: System

    SmartROC D65 Tier 4 Final 5 RCS drilling system Symbol Name Explanation Fuel pressure Displays the operating fuel pres- sure to the injectors Forced regeneration Start forced regeneration Block regeneration Block automatic regeneration Max. time left before regenera- Shows maximum time remaining...

  • Page 67: System - Modules

    SmartROC D65 Tier 4 Final 5 RCS drilling system Engine Status Service Interval Configure 5.5.2 System - Modules Four different views can be selected: Status View System Layout Rig Layout Feeder Layout Status View The status of all the modules can be checked in this menu:...
  • Page 68 SmartROC D65 Tier 4 Final 5 RCS drilling system D102 I/O module D103 I/O module Select the module using the arrow keys and open it with Enter to see the message that the system has written for the module. (These figures are not shown.)
  • Page 69 SmartROC D65 Tier 4 Final 5 RCS drilling system Rig Layout Feeder Layout...

  • Page 70: System - Levers

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.5.3 System - Levers Levers. The lever function can be checked in this menu by moving the lever in its X axis (rotation left/right) and Y axis (feed forward/back). If the lever is working, you should see its actu- ation value, 0 - 127 units.
  • Page 71 SmartROC D65 Tier 4 Final 5 RCS drilling system System - levers - calibration Calibration Calibration status: Indicates whether the levers have been calibrated Calibration mode: With calibration mode activated, none of the functions will be ac- tuated, and it will only be the lever movements that will be shown as a reading on the display.

  • Page 72: System - Monitors

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.5.4 System - Monitors Guards. The status of the various guards (On/Off) can be read from the Guards menu. The mod- ule, marking and connector each sensor has on the module is also specified here. This means it is easier to locate the source of the fault so that it can be rectified more quickly.

  • Page 73: System - Administration

    The information is saved on a USB memory stick. NOTE: Only use USB memory sticks from Atlas Copco. Save parameters: Parameters are saved on a USB memory stick. Load parameters: Parameters are retrieved from a USB memory stick.

  • Page 74: Loading New Software

    SmartROC D65 Tier 4 Final 5 RCS drilling system Saving and loading parameters USB Socket Save parameters is used when all settings have been made and you want to save a back- up copy on a USB memory stick. Load parameters is used when you want to read parameters into the RCS system from a USB memory stick.
  • Page 75 SmartROC D65 Tier 4 Final 5 RCS drilling system Control panel for operator's cabin. Insert the USB memory stick with the new software into the USB socket. USB Socket Start the RCS system. NOTE: The system now reads the new software and displays the "Load ready!"...
  • Page 76 See the section Saving and loading parameters. NOTE: Only use USB memory sticks from Atlas Copco. Date and time The date and time may have to be set on a new rig or if new software has been loaded.

  • Page 77: System - Engine Status

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.5.7 System - Engine status Engine Status The status of all the sensors associated with the engine can be checked in the Engine Status menu. In conjunction with each fault, a diagnostic code will appear on the scroll list on the left.

  • Page 78: System - Service Interval

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.5.8 System - Service Interval Service Interval Time To Service Service Interval Service Done Distance to grinding Grinding interval Grinding Done...

  • Page 79: System - Configuration

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.5.9 System - Configuration Configure In the Configuration menu you can see how the rig is equipped. Configuration file: An approved configuration file means that the rig's software is con- sistent with the equipment on the rig.

  • Page 80: System - Rig Options

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.5.10 System - Rig Options Rig Options This menu shows which Rig Options are active on the rig Certain rig options can be activated or deactivated by checking the box to the right and pressing Enter.

  • Page 81: Logging

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.6 Logging 5.6.1 Logging Menu Logging Event Log Save Trace Log Signal Log Aux. Temp.
  • Page 82 SmartROC D65 Tier 4 Final 5 RCS drilling system Logging - Event Log Event Log Save Event Log by inserting a USB memory stick into the USB socket on the right-hand pillar behind the display and select the button at the bottom of the display using the arrow...
  • Page 83 SmartROC D65 Tier 4 Final 5 RCS drilling system Logging - Save Save Statistics: Save statistics from the rig. Can be saved as text or spreadsheet depend- ing on what it is going to be used for. Blast log: Used when the log from the round is to be exported to ROC Manager.
  • Page 84 SmartROC D65 Tier 4 Final 5 RCS drilling system Logging - MWD MWD Logging: Off or On. Sample distance: The interval with which MWD is saved.
  • Page 85 SmartROC D65 Tier 4 Final 5 RCS drilling system Logging - Trace Log Trace Log Only used after contact with staff from Atlas Copco.
  • Page 86 SmartROC D65 Tier 4 Final 5 RCS drilling system Logging - Signal Log Signal Log...
  • Page 87 SmartROC D65 Tier 4 Final 5 RCS drilling system Logging - Auxiliary Temperature Logging Aux. Temp. Threshold Resolution...

  • Page 88: Positioning

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.7 Positioning 5.7.1 Positioning menu Positioning. Sensors Actuations Parameters...
  • Page 89 SmartROC D65 Tier 4 Final 5 RCS drilling system Positioning - sensor Positioning - sensor. Adjustable sensors are: Feed swing Feed dump Boom swing Aim device...
  • Page 90 SmartROC D65 Tier 4 Final 5 RCS drilling system Positioning - Sensor - Calibration Calibration Sensors Feed swing Feed dump Boom swing Aim device Raw val Value Calibrate Offset Coefficient The sensors for the angle instrument can be reset in the Calibration menu.
  • Page 91 SmartROC D65 Tier 4 Final 5 RCS drilling system Positioning - Actuations Actuations. Boom lift Boom swing Feed dump Feed swing Feed extend...
  • Page 92 SmartROC D65 Tier 4 Final 5 RCS drilling system Positioning - Parameters Parameters Valve Parameters The parameters used when the positioning cylinders are operated manually. Auto Parameters The parameters used when the Semi-automatic boom positioning (optional equipment) is used.
  • Page 93 SmartROC D65 Tier 4 Final 5 RCS drilling system Positioning - Parameters - Valve Parameters Valve Parameters Boom lift Boom swing Feed dump Feed swing Feed extend Cylinder in Lowest valve current Highest valve current Cylinder out Lowest valve current...
  • Page 94 SmartROC D65 Tier 4 Final 5 RCS drilling system Positioning - Parameters - Auto Parameters Auto Parameters Feed dump Feed swing Cylinder in Lowest valve current Highest valve current Cylinder out Lowest valve current Highest valve current Calibration aid Actuated value...

  • Page 95: Drilling

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.8 Drilling 5.8.1 Menu Drilling Drilling Sensors Actuations Parameters...
  • Page 96 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Sensor Sensors Rotation pressure Percussion Feed pressure Pump pressure HECL Oil level HECL Laser Sensor Water Level, WM-Tank Drilling - Sensor Calibration Calibration of the sensors involved in the drilling process can be carried out in the Calibra-...
  • Page 97 SmartROC D65 Tier 4 Final 5 RCS drilling system Ensure that the system is depressurised. Select the Set to zero by the relevant pressure sensor. Press Enter to Set to zero the sensor. The pressure sensor is then reset and automat-...
  • Page 98 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Actuations Actuations Feed speed Rapid feed Feed pressure Rotation Speed Rotation pressure threading Air flow, reduced Air flow, full Lubrication Thread greasing spray (air valve) Thread greasing spray (grease valve)
  • Page 99 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - parameters Parameters Feed speed Feed pressure Rotation Lubrication Timers Drill bit Others...
  • Page 100 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Feed Speed Feed speed Min current, drill feed Max current, drill feed Min current, rapid feed Max current, rapid feed Min speed braking, forward Min speed braking, backward...
  • Page 101 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Feed Pressure Feed pressure Feed pressure, collaring Feed pressure, drilling Max feed pressure, drilling Min feed pressure, drilling Pressure increase rock contact...
  • Page 102 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Feed Pressure - Calibration Calibration Calibration of feed pressure: Operate the cradle down to mechanical stop. Select Start calibration. The system will now automatically read the different pressures for the different currents and enter them into the system.
  • Page 103 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Rotation Rotation Rotation speed, drilling Rotation pressure, jamming Pressure decrease, free...
  • Page 104 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Rotation - Calibration Calibration Clamp the adapter in the break table and start the calibration.
  • Page 105 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Lubrication Oil Lubrication Frequency lubrication, HECL-pump Min HECL Pressure Time Before HECL Guarding Timeout HECL Pressure Thread Greasing Spray, Pulse Duration Thread Greasing Spray, Start Delay Thread Greasing Spray, Stop Delay...
  • Page 106 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Times Timers Min collaring time Air flushing time Half rod flushing, time Extra flushing, time...
  • Page 107 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Drill Bit Drill bit Feed pressure, drilling Max speed, automatic collaring Speed drilling, forward Speed drilling, backward Rotation speed, drilling Pressure increase, jamming...
  • Page 108 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - Parameters - Miscellaneous Others Min air pressure Air pressure, drill out Initial collar length M4 offset...
  • Page 109 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - DCT Parameters Actuations...
  • Page 110 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - DCT - Parameters Parameters Time clean pulse Pause time Number of after clean pulses...
  • Page 111 SmartROC D65 Tier 4 Final 5 RCS drilling system Drilling - DCT - Actuations Actuations DCT Fan DCT Flap Filter clean A Filter clean B Filter clean C Filter clean D...

  • Page 112: Rig

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.9 Rig 5.9.1 Rig menu Rig menu. Sensors Actuations Parameters...
  • Page 113 SmartROC D65 Tier 4 Final 5 RCS drilling system Rig - sensor Rig - sensor Power Pack Wagon Frame...
  • Page 114 SmartROC D65 Tier 4 Final 5 RCS drilling system Rig - sensor - drive unit Start Key Ignition: Start Key Start: Fuel Meter: Shows the volume in litres in the fuel tank.
  • Page 115 SmartROC D65 Tier 4 Final 5 RCS drilling system Calibrate by selecting and setting the box to zero. Rig - sensor - chassis frame Rig - sensor - chassis frame. Hydraulic Oil Temp: Shows the temperature of the hydraulic oil.
  • Page 116 SmartROC D65 Tier 4 Final 5 RCS drilling system Calibrate by selecting and setting the boxes to zero. Rig - actuations Actuations.
  • Page 117 SmartROC D65 Tier 4 Final 5 RCS drilling system Power Pack Wagon Frame Cooling Fan Rig - actuations - drive unit ECM Enabled Start Engine On Enable diesel filler pump Load Compressor Loading Valve, High Pressure Hydraulic oil heat Reverse Warning...
  • Page 118 SmartROC D65 Tier 4 Final 5 RCS drilling system Rig - actuations - chassis frame Tramming high speed Hydraulic Jack In Hydraulic Jack Out Track oscillation lock Left Track Oscillation Fwd Left Track Oscillation Bwd Right Track Oscillation Fwd Right Track Oscillation Bwd...
  • Page 119 SmartROC D65 Tier 4 Final 5 RCS drilling system Rig - actuations - cooling fan Cooling fan engine Cooling fan hyd. oil/compr.
  • Page 120 SmartROC D65 Tier 4 Final 5 RCS drilling system Rig - parameters Parameters. Tramming...
  • Page 121 SmartROC D65 Tier 4 Final 5 RCS drilling system Rig - parameters - tramming Left Track Forward Lowest valve current Highest valve current Right Track Forward Lowest valve current Highest valve current Left Track Reverse Lowest valve current Highest valve current...

  • Page 122: Rhs

    SmartROC D65 Tier 4 Final 5 RCS drilling system 5.10 RHS 5.10.1 RHS menu Sensors Actuations Parameters Cradle positions Auto RHS Parameters...
  • Page 123 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Sensor Sensors The status of all the sensors involved in rod handling can be checked from this menu. The sensor module location, connector and marking are shown to facilitate fault finding where appropriate.
  • Page 124 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Sensor - Calibration Calibration Sensors Cradle position (pulses) Cradle position (length) Value Set to zero Offset Coefficient Activate learn mode calibr. sensor Distance to upper calibration sensor Distance to lower calibration sensor Operate the cradle to mechanical stop.
  • Page 125 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Actuations Actuations - Left Digital Lever Actuate desired value Function Grippers in Guide Position Grippers open Magazine outlet open Rotate Gripper Towards Drill Centre Rotate Gripper Towards Magazine Arm to drill centre...
  • Page 126 SmartROC D65 Tier 4 Final 5 RCS drilling system Actuations - Right Digital Lever Actuate desired value Function Lower Drill Support Closed Lower Drill Support Open Upper Drill Support Closed Upper Drill Support Open Suction Hood Up Suction Hood Down...
  • Page 127 SmartROC D65 Tier 4 Final 5 RCS drilling system Actuations - Break table Actuate desired value Function Breaking cylinder, CW Breaking cylinder, CCW Break out jaws, lower open Break out jaws, lower closed Break out jaws, upper open Break out jaws, upper closed...
  • Page 128 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Parameters Parameters - RHS Drill Rod / Drill Tube Parameters - Threading Feed speed, threading...
  • Page 129 SmartROC D65 Tier 4 Final 5 RCS drilling system Feed speed, unthreading Feed pressure forward, RHS Feed pressure backward, RHS Feed pressure, threading Feed pressure, unthreading Rotation speed, threading Rotation speed, unthreading Parameters - Length Sensor Pulses per revolution Wheel diameter...
  • Page 130 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Cradle positions Cradle positions Current position Set Current Position Break distance Position tolerance M1: Cradle in the lower position (should be about 3 cm above mechanical stop) (ap- plicable when automatic rod handling is activated on the right-hand control panel).
  • Page 131 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Auto RHS parameters Auto RHS Parameters Feed speed Rotation Timers Others (Not used)
  • Page 132 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Auto RHS parameters - Feed speed Feed speed Feed Speed, Asyncronous Threading/Unthreading...
  • Page 133 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Auto RHS parameters - Rotation Rotation Max. Rotation Pressure Threading, Adapter-Rod (Y155) Max. Rotation Pressure Threading, Rod-Rod (Y155) Threshold Value For Threading Completed, Adapter-Rod Threshold Value For Threading Completed, Rod-Rod...
  • Page 134 SmartROC D65 Tier 4 Final 5 RCS drilling system RHS - Auto RHS parameters - Times Timers Rotation Time For Loosening Adapter-Rod Joint...

  • Page 135: Hydraulic Systems

    Always collect used oil, oil spillage, waste with oil content and lubrication grease residue and spillage. Treat in accordance with local regulations in force. Use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products wherever possible. Contact your local Atlas Copco office for further information 6.2 General...

  • Page 136: Repairing Hydraulic Components

    Atlas Copco personnel. Components to be sent to the manufacturer's local agent for repair. Component repairs are carried out by Atlas Copco. Overhauling instructions are avail- able for the most important and most complicated hydraulic components. 6.4 Replacement of hydraulic hoses The high system pressure with safety valves set to 280 bar, together with the vibration and other mechanical strain, puts high demands on the hydraulic hoses.

  • Page 137: Hydraulic Workshops

    SmartROC D65 Tier 4 Final 6 Hydraulic systems 6.5 Hydraulic workshops Workshops used for the repair of hydraulic components must: Be separate from activities which generate dust and particles, such as welding, grind- ing, the transportation of vehicles, etc. Have their own suitable washing equipment which is required for repairing the com- ponents.

  • Page 138: Breather Filter

    SmartROC D65 Tier 4 Final 6 Hydraulic systems Changing the return oil filter The filter inserts can be dismantled by removing the cover and lifting them up. Clean on and around the filter cap and unscrew the nuts (A). Changing filter Lift off the cap (B) and replace the O-ring (C) if it is damaged.
  • Page 139 SmartROC D65 Tier 4 Final 6 Hydraulic systems 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.
  • Page 140 SmartROC D65 Tier 4 Final 6 Hydraulic systems...

  • Page 141: Feeder

    SmartROC D65 Tier 4 Final 7 Feeder 7 Feeder 7.1 Feeder chain tension Correct feeder chain tension Feed beam Gear Chain It is important to ensure that the feeder chain has the correct tension. A poorly tensioned chain leads to increased wear on both the chain and associated components.

  • Page 142: Feeder Chain Tension

    SmartROC D65 Tier 4 Final 7 Feeder 7.1.1 Feeder chain tension tension, feeder chain Tighten or loosen the feeder chain with the bolts (1). If it is necessary to change the tension of the feeder chain, lubricate the bolts (1) via the grease nipples (2) before starting to adjust.

  • Page 143: Climbing Chain

    SmartROC D65 Tier 4 Final 7 Feeder 7.3 Climbing chain 7.3.1 Lubricating the sprocket wheel and checking the climbing chain cover. Climbing chain, sprocket wheel and climbing chain cover The climbing chain's gear (2) is lubricated by means of filling 2 to 3 pump strokes of grease in the grease nipple (3) on the gear's shaft.

  • Page 144: Bearing Unit And Checking The Chain Guide

    SmartROC D65 Tier 4 Final 7 Feeder 7.4 Bearing unit and checking the chain guide Bearing unit (2) and chain guide (1) 7.4.1 Replacing the bearing unit (chain feed) After 5000 engine hours the bearing unit (2) should be replaced with a new unit.

  • Page 145: Protective Plates

    SmartROC D65 Tier 4 Final 7 Feeder 7.5 Protective plates Chain feed, protective plates The feed beam is equipped with black protective plastic plates (1). These are designed to stop the chain and beam causing damage to each other. They must be replaced when they become worn.

  • Page 146: Sealing Disc

    SmartROC D65 Tier 4 Final 7 Feeder 7.7 Sealing disc Sealing disc (1) Cuttings accumulate over time behind the sealing disc (1). There is risk that the cuttings may damage the chain and gears. Bend the cutting disc down in order to clean out dirt col- lected behind it.

  • Page 147: Replacement Of Slide Bars

    SmartROC D65 Tier 4 Final 7 Feeder Prise off the slide pieces (C) from the holder using a screwdriver and remove the keys (D). Slide a new slide piece into the holder track and fit the new keys. Makes sure that the holders are refitted to the cradle correctly and that they are adjus- ted so that the total lateral play is 2-3 mm.

  • Page 148: Lubricating The Feeder

    SmartROC D65 Tier 4 Final 7 Feeder 7.10 Lubricating the feeder The feeder requires lubrication at certain intervals. A number of red grease nipples (A) are located in different positions on the feeder. (B). In order to reduce the wear of hoses over the drum the hoses (C) must be lubricated with...

  • Page 149: Track Frames

    SmartROC D65 Tier 4 Final 8 Track frames 8 Track frames 8.1 Stretching the crawler tracks NOTE: The clearance (A, see illustration: Crawler track) between the straightedge and the crawler track should be between 20 and 30 mm (0.8 and 1.2").

  • Page 150: Check Torques

    SmartROC D65 Tier 4 Final 8 Track frames 8.2 Check torques Tightening torques for track frames Size Torque in Nm Quantity/track Comments frames T45, C50, D50, D55, T50SF, C65SF T50LF, D60, D65, C65LF 9/16" UNF 260 ± 10 T45, C50, D50,...

  • Page 151: Check For Wear

    SmartROC D65 Tier 4 Final 8 Track frames Size Torque in Nm Quantity/track Comments frames 370 ± 20 T50LF, D60, D65, C65LF Table 13: Tightening torques for track frames 8.3 Check for wear 8.3.1 Procedures Components on the track frames that show wear of 100% must be replaced by new components.

  • Page 152: Check For Wear On The Front Wheel

    SmartROC D65 Tier 4 Final 8 Track frames Limberoller T45, C50, D55, T50SF, C65SF Limberoller T50LF, D60, D65, C65LF Wear 100% limber- oller 100.0 98,5 96,7 94,6 92,0 10,2 11.5 8.3.4 Check for wear on the front wheel Check the wear by measuring the distance between the top and bottom of the front wheel.

  • Page 153: Check For Wear On The Track Shoe

    SmartROC D65 Tier 4 Final 8 Track frames Wear New front 100% wheel 17.5 19.1 20.9 23.0 25.5 8.3.5 Check for wear on the track shoe Check the wear on the track shoe by measuring the distance (A) between the top and bot- tom of the track shoe.

  • Page 154: Check For Wear On The Chain

    SmartROC D65 Tier 4 Final 8 Track frames 8.3.7 Check for wear on the chain Check the wear on the chain by measuring the distance between the centre point in the first pin to the centre point in the fifth pin.

  • Page 155: Dust Collector (Dct)

    SmartROC D65 Tier 4 Final 9 Dust collector (DCT) 9 Dust collector (DCT) 9.1 Filter test, dust collector (DCT) Measurement points for dust collector filter For checking filters in dust collector. Unscrew plugs (a) and apply a differential pressure gauge to the two holes.

  • Page 156: Adjust The Suction Capacity

    SmartROC D65 Tier 4 Final 9 Dust collector (DCT) 9.2 Adjust the suction capacity Valve plate The DCT's fan wheel is driven by P3. Sometimes it is necessary to adjust the DCT's suction capacity. This is performed by ad- justing the pressure for pump 3 on the valve block. The valve block is fitted on the DCT.
  • Page 157 SmartROC D65 Tier 4 Final 9 Dust collector (DCT) Dust collector...
  • Page 158 SmartROC D65 Tier 4 Final 9 Dust collector (DCT)

  • Page 159: Radiator

    SmartROC D65 Tier 4 Final 10 Radiator 10 Radiator 10.1 Environmental issues when handling coolant NOTICE Environmental effect Think of the environment! Chemicals, e.g. flushing additives, other additives and coolants, can be environmentally hazardous. Treat in accordance with local regulations in force for both handling and waste dis- posal.
  • Page 160 SmartROC D65 Tier 4 Final 10 Radiator Radiator and expansion tank...

  • Page 161: Diesel Engine

    Always collect oil residue, oil spillage, waste with oil content, and lubrication grease residue and spillage. Treat in accordance with local regulations in force. Use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products wherever possible. Contact your local Atlas Copco office for further information.

  • Page 162: Maintenance Of Components

    SmartROC D65 Tier 4 Final 11 Diesel engine NOTE: See the chapter Oils and fuel for oil grade. Check that the oil level is between the upper and lower marks on the dipstick (1). Diesel engine Dipstick Filling up Top up (2) if the oil level is below or level with the lower mark on the oil dipstick (see the table "Recommended oils and lubricants").

  • Page 163: Air Filter For Engine And Compressor, Maintenance

    SmartROC D65 Tier 4 Final 11 Diesel engine The discharge from the first stage of the cleaning flows through a single evacuation valve. This should preferably be checked once each shift. The filter housing also contains a safety cartridge which must be replaced every third time the filter cartridge is replaced.

  • Page 164: Fuel System

    SmartROC D65 Tier 4 Final 11 Diesel engine NOTE: NOTE! If the safety cartridge has also been removed for changing, the filter housing air outlet must be completely covered with adhesive tape before cleaning the filter housing. Check that the evacuation valve (4) is not damaged. Change it if necessary.
  • Page 165 SmartROC D65 Tier 4 Final 11 Diesel engine Primary and secondary filters Primary and secondary filters Drainage Drain the water from the primary filter container daily by closing the fuel cock (B) and opening the drain cock (E). Replacing the primary filter Remove the filter bowl (D) and clean with pure diesel fuel.

  • Page 166: Environmental Issues When Handling Fuel

    SmartROC D65 Tier 4 Final 11 Diesel engine 11.4.4 Environmental issues when handling fuel NOTICE Environmental effect Think of the environment! Fuel spill is a hazard to the environment and a fire hazard. Always collect fuel residue and spillage. Treat in accordance with local regulations in force.

  • Page 167: Draining The Fuel Tank

    SmartROC D65 Tier 4 Final 11 Diesel engine Fuel tank brackets Check that the front fuel tank retaining bolts (A) are tightened to the correct torque of 73 Nm every 500 engine hours. All fuel tank retaining bolts (A + B) and mountings must be checked before performing any maintenance under the rig.
  • Page 168 SmartROC D65 Tier 4 Final 11 Diesel engine Ease up on the belt tension by turning the tensioning wheel (A). Belt tension NOTE: See the chapter Technical data for the correct engine al- ternative. Secure the tensioner wheel in the position where the belt is slack using a pin (A).

  • Page 169: For Further Instructions, See Separate Instructions For The Diesel Engine

    SmartROC D65 Tier 4 Final 11 Diesel engine The belt is tensioned automatically when the lock-out assembly is removed from the tensioning wheel. Refit the belt cover. 11.4.8 For further instructions, see separate instructions for the diesel engine.
  • Page 170 SmartROC D65 Tier 4 Final 11 Diesel engine...

  • Page 171: Compressor And Air System

    The oil can reach temperatures of 130°C during operation. When replacing air hoses, use only Atlas Copco original hoses, or consult Atlas Copco. In the event of a suspected leakage you must absolutely not use your hands to de- tect/search for the leakage.
  • Page 172 SmartROC D65 Tier 4 Final 12 Compressor and air system Diagram, compressor system Loading valve Y210B Loading valve Y210A Control valve, high percussion pressure Control valve, low percussion pressure Intake valve Air filter Filter indicator Drain valve Compressor, low pressure stage...
  • Page 173 SmartROC D65 Tier 4 Final 12 Compressor and air system Thermostat Radiator Pressure relief valve (extra equipment) Pressure tank sensor, B456 Water separator filter Safety valve Minimum pressure valve Air receiver Restriction Compressor parts Control valve, high percussion pressure Control valve, low percussion pressure...

  • Page 174: Maintenance

    SmartROC D65 Tier 4 Final 12 Compressor and air system Safety valve Minimum pressure valve Air receiver Restriction Oil separator element Water separator filter 12.3 Maintenance Right and left-hand draining points Engine radiator Hydraulic oil cooler Compressor cooler Compressor element...

  • Page 175: Draining The Water Separator Filter

    SmartROC D65 Tier 4 Final 12 Compressor and air system 12.3.2 Draining the water separator filter The water must be drained on a daily basis, preferably before the work shift. Drain by opening the cock under the water separator filter.

  • Page 176: Changing Oil And Oil Filter

    SmartROC D65 Tier 4 Final 12 Compressor and air system Make sure the rig is standing level. Switch off the rig and allow the oil level to settle for at least 5 minutes. Check the compressor oil level. The indicator on the gauge (1) must be in the green zone.

  • Page 177: Changing To New Type Of Oil

    SmartROC D65 Tier 4 Final 12 Compressor and air system Fill the air receiver until the oil level reaches the filler pipe. The indicator on the gauge (1) must be in the upper section of the green zone. Make sure that no dirt falls down into the system.
  • Page 178 Open the cover plate on the air receiver and remove the oil separator element. Check the inside of the oil reservoir. If sediments are detected, the parts (A-E) must be thoroughly cleaned before the process is completed. Contact Atlas Copco's ser- vice department.

  • Page 179: Cleaning The Oil Cooler

    SmartROC D65 Tier 4 Final 12 Compressor and air system Fill the oil reservoir with the minimum amount of oil permissible and run the com- pressor unloaded in light mode for 30 minutes. Drain the system thoroughly when the oil is hot so that as little oil as possible is left in the system, especially in inaccessible areas.

  • Page 180: Checking The Pressure Sensor B456

    SmartROC D65 Tier 4 Final 12 Compressor and air system 12.3.9 Checking the pressure sensor B456 Pressure tank's top side Valve plate Pressure sensor B456 Check that the tank pressure shown on the display corresponds with the tank pressure shown on the pressure gauge at the regulators. The difference must be no greater than 0.1 bar.

  • Page 181: Setting The Percussion Pressure

    SmartROC D65 Tier 4 Final 12 Compressor and air system Loading valve (solenoid valve) Y210B Flushing air valve Y115 Flushing air valve Y116 When the compressor is unloaded the loading valves Y210A and Y210B are 0-activated (open). When the compressor is loaded (button (5) on the right-hand control panel) the solenoid valve Y210A will be activated (closed) and lead the air over the low pressure reg- ulator (4) provided that the pressure is above 4 bar.
  • Page 182 SmartROC D65 Tier 4 Final 12 Compressor and air system...

  • Page 183: Oil And Fuel

    SmartROC D65 Tier 4 Final 13 Oil and fuel 13 Oil and fuel 13.1 Environmental issues when handling fuel NOTICE Environmental effect Think of the environment! Fuel spillage is environmentally hazardous and a health risk. Always collect fuel residue and spillage. Treat in accordance with local regulations in force.

  • Page 184: Def (Diesel Exhaust Fluid)

    SmartROC D65 Tier 4 Final 13 Oil and fuel NB! Use Ultra Low Sulphur Diesel (ULSD). It must not have more than 15ppm Diesel Fluid Sulphur. 13.3 DEF (Diesel Exhaust Fluid) DEF fluid must meet the requirements specified in ISO 22241-1. Read the CAT manual for more information about DEF.

  • Page 185: Environmental Considerations When Handling Oil

    Always collect oil residue, oil spillage, waste with oil content, and lubrication grease residue and spillage. Treat in accordance with local regulations in force. Always use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products wherever possible. Contact your local Atlas Copco office for further information.

  • Page 186: Oil Sampling

    SmartROC D65 Tier 4 Final 13 Oil and fuel Switch off the rig and allow the oil level to settle for at least 5 minutes. Check the compressor oil level. The indicator on the gauge (1) must be in the green zone.

  • Page 187: Lubrication

    SmartROC D65 Tier 4 Final 13 Oil and fuel Hydraulic oil reservoir 13.8 Lubrication The lubricating oil tank (1) is fitted on the hydraulic oil tank (2). The lubricating oil level can be read in the sight glass (4). In the event of a low level there is also a warning on the display for engine and directional instruments.

  • Page 188: For Engine Oil And Fuel, See Chapter "Diesel Engine

    SmartROC D65 Tier 4 Final 13 Oil and fuel NOTE: Always use a funnel with strainer when refilling. NOTE: If the lubricating system is fully drained of oil then the system must be bled. See the maintenance instructions for the drill system.

  • Page 189: Draining Def (Diesel Exhaust Fluid)

    SmartROC D65 Tier 4 Final 13 Oil and fuel 13.10.1 Draining DEF (Diesel Exhaust Fluid) DEF tank drain plug (2) Drain the DEF fluid by unscrewing the DEF tank (1) drain plug (2). 13.11 Recommended oils and lubricants 13.11.1 Engine oil Ambient temperature °C...

  • Page 190: Lubricating Oil Tank (Ecl) (Ecg) (Hecl)

    13.11.3 Lubricating oil tank (ECL) (ECG) (HECL) Atlas Copco recommends the use of Atlas Copco COP OIL which has been specially de- veloped for our hydraulic rock drills and DTH hammers. COP OIL is an environmentally friendly, degradable oil which can be used in ambient tem- peratures between -25 °C and +50 °C.

  • Page 191: Traction Gears, Carrier Rollers

    ISO/TR 3498. 13.11.7 Oil recommendations for two-stage compressor Atlas Copco recommends only using Atlas Copco PAROIL for the two-stage compressors. Use of another oil is at customer's own risk The type of PAROIL should correspond to the table below. If the ambient temperature per- mits, then PAROIL S XTREME should be used in the first instance.
  • Page 192 SmartROC D65 Tier 4 Final 13 Oil and fuel...

  • Page 193: Options

    SmartROC D65 Tier 4 Final 14 Options 14 Options 14.1 GPS 14.1.1 General The GPS system consists of two antennas and one receiver. The antennas are fitted at a distance of 0.5 metres apart. There must not be any permanent fixture between the anten- nas and the horizon, apart from the drill rig's feeder.
  • Page 194 SmartROC D65 Tier 4 Final 14 Options CAN BUS cable CAN BUS cable PWR: Green lamp that indicates that the supply voltage is OK. GPS lock : Yellow lamp that indicates that the satellite reception is OK. HDG : Green lamp that indicates that the drill rig's direction data has been sent onward to the CAN BUS.

  • Page 195: Service Equipment

    SmartROC D65 Tier 4 Final 14 Options 14.2 Service equipment 14.2.1 Service tool bag RCS Service bag CAN tester Resolver tester Multimeter Encoder tester CAN Open cable I/O tester Signal cable Test cables Test box Connectors Torque tools Torque tools...

  • Page 196: Checking The Power Supply And The Can Network

    SmartROC D65 Tier 4 Final 14 Options The service bag is used for fault finding on rigs equipped with Atlas Copco RCS (Rig Con- trol System). 14.2.2 Checking the power supply and the CAN network General The power supply for the module, the CAN power supply and CAN communication can be measured and checked using the CAN tester.
  • Page 197 SmartROC D65 Tier 4 Final 14 Options Function NC / not connected CAN + CAN - CAN HI CAN LO Table 20: Pin configuration, CAN inputs and outputs, other modules Mount the tester on the multimeter. Make certain the pins are positioned correctly as indic- ated by the colour coding.

  • Page 198: I/O Module

    SmartROC D65 Tier 4 Final 14 Options Mount the tester on the multimeter. Make sure the pins are positioned correctly ac- cording to the colour markings. Red pin to V/Ohm on the multimeter. Set the multi- meter measuring range to ohms.
  • Page 199 SmartROC D65 Tier 4 Final 14 Options Measuring voltage/power Connecting the I/O tester Connect the I/O tester between the I/O module input and the guard as illustrated. Measure the voltage according to the table. Checking the digital outputs There are two digital outputs designated A and B in each contact.
  • Page 200 SmartROC D65 Tier 4 Final 14 Options Connecting the I/O tester Connect the 5-position connector on the I/O tester to an unoccupied 5-position con- nector in the I/O module. Connect the multimeter between GND and the +A or +B output that is of interest.
  • Page 201 SmartROC D65 Tier 4 Final 14 Options Connect the multimeter in series with the +A or +B output that is of interest. Activate the function. Normally, the multimeter is to read ~1A. Fault indication If the multimeter reads 0.00A and the solenoid coil diode is lit, there is an open circuit in the coil in the valve.
  • Page 202 SmartROC D65 Tier 4 Final 14 Options Function out +B out -B out +A Out -A Table 24: Pin configuration Measuring current Connect the 5-position connector on the I/O tester between the output of interest on the I/O module and the valve as illustrated.

  • Page 203: Resolver Module

    SmartROC D65 Tier 4 Final 14 Options Function Table 25: Pin configuration 14.2.4 Resolver module Checking resolver inputs X6 - X9 Pin configuration: Function Ref + Ref - Sine signal Sine GND Cosine signal Cosine GND Table 26: Pin configuration Connect the resolver tester to the relevant cable. Turn the test sensor slowly and check that the angle shown on the sensor menu changes.
  • Page 204 SmartROC D65 Tier 4 Final 14 Options Function Signal B Table 27: Pin configuration 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.

  • Page 205: Replacing The Module

    SmartROC D65 Tier 4 Final 14 Options Test box Connect the multimeter to test box pins 2 and 3. Set the multimeter to DC voltage (=). It should read 4.5V on connector X11 and 15V on connector X12. If the multimeter reading is 0V there may be a fault in the signal cable or resolver module.

  • Page 206: Lubrication

    SmartROC D65 Tier 4 Final 14 Options There are also a number of lubrication points. A general inspection is recommended every week or every 50 engine hours. Before any component is unscrewed the system should be depressurised. Failure to do so would cause the O-rings to be sucked out from their grooves when the air escapes past them.
  • Page 207 SmartROC D65 Tier 4 Final 14 Options Lubrication points Outlet swivel Air swivel Shaft Rotary actuator The air swivel should be lubricated carefully. A maximum of a couple of presses with grease in each nipple is sufficient. Too much lubrication can pressurise the seals and lead to heat development which damages seals and bearings.

  • Page 208: Maintenance Of Components

    SmartROC D65 Tier 4 Final 14 Options 14.3.3 Maintenance of components Down-the-hole rock drill Good lubrication, clean air and regular maintenance are critical factors for the service life of the down-the-hole rock drill. The most common cause of breakdown is a defective inner tube. The inner tube tends to wear at the lower end first.
  • Page 209 SmartROC D65 Tier 4 Final 14 Options Air swivel Normal maintenance includes lubrication of seals and bearings via the 4 grease nipples (14) on the shell (1). This must be carried out daily or every 10 engine hours. A maximum of a couple of presses with grease in each nipple.
  • Page 210 SmartROC D65 Tier 4 Final 14 Options Outlet swivel (with Metzke Blowdown Valve) Metzke Blowdown Valve Seal Seal O-ring Seal Hex head screw Washer Short adapter housing Washer Socket head cap screw...
  • Page 211 SmartROC D65 Tier 4 Final 14 Options O-ring Spindle adapter Spindle DHR6RC Circlip Inner tube Outer tube O-ring Hex head screw Deflector 1 Deflector 2 Seal 5 on the outlet swivel requires regular lubrication. There is a grease nipple for this on the adapter housing (8).
  • Page 212 SmartROC D65 Tier 4 Final 14 Options Deflectors The first deflector (A) meets all the force from the sample flow, which can reach speeds of up to 200 m/s, and is therefore exposed to hard wear. The deflector has a heavy ceramic block (4) which is easy to replace by removing the bridge (1) and the cover plate (2).
  • Page 213 SmartROC D65 Tier 4 Final 14 Options Ensure that all screws are at least 8.8 in strength class and that all nuts have Nylock for the reassembly of these components. Discharge System The roller for the sample hose, fitted on the feeder, requires no maintenance as it is made of nylon.

  • Page 214: Blow Adapters

    14.3.4 Blow adapters Blowdown adapter Certain RC machines from Atlas Copco are equipped with a blowdown system from Met- zke. It is possible to screw blowdown system loosely on the drill string on RC rigs without one. The blowdown adapter directs the compressed air down through the inner tubes and in this way clears any blockages and forces return air to the outside of the drill pipes.

  • Page 215: Fault Finding In The Event Of Air Leakage

    SmartROC D65 Tier 4 Final 14 Options Check for any uneven wear on the inserts as this can indicate that the main air seals are leaking. It is essential the inner pipes included in components fitted in the system after the blow- down valve are in good condition.

  • Page 216: Fire Suppression System

    SmartROC D65 Tier 4 Final 14 Options The RC tubes are removed and replaced with normal drill pipes. The air swivel is re- moved and replaced with an adapter. The deflectors and sample hose can be re- moved. An adapter is fitted on the rotation head for the air supply to the drill string.

  • Page 217: Transmission

    SmartROC D65 Tier 4 Final 14 Options 14.5.2 Transmission Check the oil level regularly. Replace the oil every 8000 engine hours. Service winch, oil filling orifice Oil drain plug Oil filling orifice cover plate The winch gear holds 0.5 L oil. Drain out the old oil by removing the oil drain plug (1). Pour in new oil into the winch transmission via the oil filling orifice cover plate.

  • Page 218: Adjusting - Drum Brake

    SmartROC D65 Tier 4 Final 14 Options 14.5.4 Adjusting - Drum brake WARNING Serious injury Check regularly that the brake is correctly adjusted. When the drum is disengaged there is a risk that the cable may unreel uncontrollably. Increase braking force Undo the lock nut on the adjusting screw (3).
  • Page 219 14 Options...
  • Page 220 www.atlascopco.com...

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