Reg.

code ASB ROC 203PC 2000-05

CAUTION

Before each shift commences, carry out the Daily checks incl. Extra safety check as described in the Operating Instructions No. AIB 181 00 10 For rock drills see Maintenance Schedule

CAUTION

Repairs to the crawler shall only be carried out by experienced service personnel which is familiar with the rig design. Also, any welding work necessary may only be carried out by approved welders (authorized acc. to EN 287 part 1). After repair, the crawler is to be inspected and approved by qualified engineers before being put back into service.

NOTE l = Check points and maintenance measures m = Lubrication, oil change etc.

Service Schedule for Pneumatic Crawler Drills

ROC 203PC

No. ASB 181 00 10

ATLAS COPCO ROCK DRILLS AB REBRO l SWEDEN

Copyright 2005, 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.

PM No. 9853 1108 01

WAGON FRAME WITH TRACK FRAME

4 3 4

3 4 6 3 4

2 1 3 5

Sr. No.

Check Point

Check Procedure

Delivery check l l

Interval in hrs of operation 40 125 500 1500 l l l l l l l l

Instructions

1 2

Frame Tow Hook

Cracks, Damage Cracks, Damage & Function Fill with Grease Attachment, damage Cracks, Destortion @ Idler Guide Legibility, Attachment

Lubricate Pawl bearing with thin oil See Table, Page 12 Avoid Excessive Track Tightening -

3 4 5

Grease Nipple Lock Plates Track Frame

m l l l

m l

m l l

m l l

Warning Plates

BOOM SYSTEM

2 4

3 6 3 4

5 1 3 1 4

1 3 4 3

Sr. No.

Check Point

Check Procedure

Delivery check l

Interval in hrs of operation 40 125 500 1500 l l l l

Instructions

Boom, Boomhead Boom support Feed holder Grease Nipple Lock Plates Boomhead Warning Plates

Cracks, Damage

2 3 4 5 6

Cracks, Damage Fill with Grease Attachment, damage Attachment Legibility, Attachment

l m

l m l l l

l m l l l

l m l l l

See Table, Page 12 -

l l l

l l

TRACK FRAME WITH TRACTION UNIT

A
2 1

4 5 6 7 9 9 8

Sr. No.

Check Point

Check Procedure

Delivery check m l

Interval in hrs of operation 40 125 500 1500 m l m l m l m l

Instructions

1 2

Grease Nipple Track tensioning Cylinder

Fill with Grease Track tension

See Table, Page 12 Check as shown in illustration (A). Force in grease so that the clearances is between 25-50 mm Check that the track plates are in good condition Level should reach the plug. Rig should stand horizontal. See table, page 12 See table, page 12 First change after 125 hours Before tapping up with new oil, rinse out the gear with flushing oil

Crawler track

Wear

4 5 6 7 8

Front wheel Track rollers Drive wheel Traction unit Gear box

Attachment, leakage Attachment, leakage Attachment Leakage Oil level

l l l l m l l m

l l l l m

l l l l m

Gear box

Oil change

CHAIN FEED

5 1

7 4

Sr. No.

Check Point

Check Procedure

Delivery check l

Interval in hrs. of operation 40 125 500 1500 l l l l

Instructions

Feed beam

Damage, cracks, bending, scoring

Make sure the beam is not bent nor has deformed sliding surfaces Forward and return movements should be without friction & without too much play between the feed and cradle (both when drill feeding and rapid feeding) Clean and oil as necessary see table, page 12 Check chain tension with the cradle in rearmost end position. Slack should be between 25-50 mm. (1"-2") Adjust suitable tension. Coat tension screw with grease Tightening torque 210 Nm (155 lbf.ft.)

Cradle

Movement function

3 4 5

Drill steel support Jockey Chain

Attachment, wear Attachment Lubrication

l l

l l m

l l m

l l m

l l m

Chain tensioner

Tension

Sliding pieces, cradle

Attachment, play

WORM GEAR & PISTON MOTOR COMPLETE SINGLE START FEED UNIT

3162 1663 81

3 5 4

Sr. No.

Check Point

Check Procedure

Delivery check

Interval in hrs of operation 40 125 500 1500 l l l m m

Instructions

1 2 3 4

Worm gear Sprocket Worm gear Worm gear

Wear Wear Oil level Oil changel m m

See table, page 12 See table, page 12 First oil change after 40 hours. -

m m

Air motor

Overhaul

WORM GEAR, PLANETARY & PISTON MOTOR COMPLETE FIVE START FEED UNIT

9718 4259 78

Sr. No.

Check Point

Check Procedure

Delivery check

Interval in hrs of operation 40 125 500 1500 l l m m m m l m m

Instructions

1 2 3 4

Worm gear Sprocket Worm gear Worm gear

Wear Wear Oil level Oil change

See table, last page See table, last page First oil change after 40 hours. -

5 6

Planetary gearing Air motor

Wear Overhaul

l l

ROTATION UNIT - BBR 4 (DTH VERSION)

8032 0101 03

12

11
2

10

Sr. No. 1 2 3 4 5 6 7 8 9 10

Check Point Rotation unit Grease nipples (2 pcs.) Planet gear Motor Gear housing Connection pipe Cover Adapter Rear bearings, Main gear

Check Procedure Attachment Four strokes with a grease gun Attachment Attachment Attachment Attachment Attachment Attachment Fill with grease Fill with grease

Delivery check l

Interval in hrs of operation 40 125 500 1500 l m l m l l l l l l l m l l l l l l l m l l l l l l m m m m m

Instructions Tightening torque 210 Nm (155 lbf.ft.) See table, page 12 Tightening torque 85 Nm (63 lbf.ft.) Tightening torque 50 Nm (37 lbf.ft.) Tightening torque 85 Nm (63 lbf.ft.) Tightening torque 200 Nm (148 lbf.ft.) Tightening torque 75 Nm (55 lbf.ft.) Tightening torque 85 Nm (63 lbf.ft.) During overhaul and service, min. once per year Open this plug of cover for degreasing / greasing main gear Open grease nipple 12, fill grease from 11. See table, page 12

11, 12

Grease nipples

Four strokes with a grease gun

BBC 120F

8311 0603 08

2 2

Sr. No.

Check Point

Check Procedure

Delivery check l

Interval in hrs of operation 40 125 500 1500 l l l l

Instructions

Side bolts

Attachment, function

Tightening torque 196 Nm (145 lbf.ft.) -

Connection pipe

Damage, Leakage

AIR SYSTEM
3

5 7
2

EIVER Type 9 Seria 090 0492 00 lN Volum o. e Max. I. 12 w Test p orking pr.b re a Work ssure bar r(e) 20 (e t Made emp. oc 12 ) 26 0F i Made n by A.C . India

AIR R E C

4 8 9

3217

5431

00

Sr. No.

Check Point

Check Procedure

Delivery check l

Interval in hrs of operation 40 125 500 1500 l l l l

Instructions

Hoses, pipes and couplings Operating controls Water separator Drift filter

Leakage, damage

2 3

Function, leakage Auto-valve function

l l

l l

l l

l l

l l

Separator shall automatically release water in regular intervals during operation -

wire mesh hose chain Lubricating valves

Attachment, damage

Function, setting

Check that the exhaust air from the air motors and rock drill (BBR-4 and BBC 120F rotation only) contains oil See table, page 12 Correct pressure 6 bar -

6 7 8 9

Lubricating oil tanks Pressure regulator Lubricating oil tanks Lubricating oil tanks

Oil level / refill Setting Drain off condensate Clean tanks

m l

m l l

m l l l

10

HYDRAULIC SYSTEM

4 4 4

5
Max. Max. 9106 1073 06 9106 1073 21

4 4

9106 1071 00

3 7

3 2 6 1

8
Sr. No. Check Point Check Procedure Delivery check m Interval in hrs of operation 40 125 500 1500 m l m l m l m l Instructions

1 2

Hydraulic oil tank Hydr. oil return filter

Oil level Clogging

See table, page 12 Check pressure gauge while hydraulic pump is running (oil temperature should be at least 200C (680F)). Immediately replace filter if the needle is in the red field. Replace filter at the latest after 1500 hrs. -

Hose, pipes and couplings Hydraulic cylinders double check valves Operating controls Ventilation filters Pump unit Hydr. oil tank

Damage, leakage

Function, leakage

5 6 7 8

Function, leakage Renew Attachment Oil change

l l

l l l m

See table, page 12

11

Recommended hydraulic oils and lubricants

Lubricating point Hydraulic oil tank Recommendation Use mineral-based hydraulic oils with good anti-wear, anti-rust, anti-oxidation and foam inhibiting properties and with good air and water separation characteristics. Choose an oil with viscosity grade (VG) and viscosity index (VI) in accordance with the table below. An oil with a high viscosity index is less sensitive to the effects of temperature: Hydraulic oil temperature in tank C (F) Viscosity Viscosity Normal operating temp. Min. starting temp. Max. temp grade VG index VI (viscosity 25-50 mm2/s (cST)) (viscosity min. (ISO 3448) 1000 mm2 /s (cST)) + 45 to + 60 (113 to 140) -5 (23) 75 (167) ISO VG 68 min. 100 + 35 to + 50 (95 to 122) -10 (14) 65 (149) ISO VG 46 min. 100 + 25 to + 40 (77 to 104) -15 (5) 55 (131) ISO VG 32 min. 100 + 10 to + 25 (50 to 77) -25 (13) 45 (113) ISO VG 15 min. 100 NB: When operating in extremely low temperature, installation of additional heating equipment is recommended. If the oil temperature exceeds +60 C (140 F) during long periods, a tropical oil cooler should be installed.
l l

Lubricating oil tank Feed chains

Mineral-based air-tool oils Ambient temperature C (F) -30 to 0 (22 to 32) -10 to + 20 (14 to 68) + 10 to + 50 (50 to 122) Viscosity grade (ISO 3448) VG 32 - 68 VG 68 - 100 VG 100 - 150

or
l

Transmission oils of hypoid type SAE HD 80W/90 Valid for ambient temperatures -30 to + 50 C (22 to 122 F) Specification: MIL-L-2105C, EP tests L27 and L42 Operating temp. C (F) Max. 100 (212) Max. 140 (284)

Grease nipples Feed beam

l l l

Universal grease NLGI 2 lithium/molybdenum additive Synthetic sodium or calcium grease

Traction gears Feed gear Air motro (Power pack)

Use mineral-based transmission oils (for cars) that conform to quality SAE HD 80W/90 and to the norm MIL-L-2105C Use mineral-based engine oils that conform to quality SAE20 W / 40

Volumes
Lubricating oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic oil system, total . . . . . . . . . . . . . . . . . . . . . . Hydraulic oil tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Traction unit, planetary gear (each) . . . . . . . . . . . . . . Feed gear (single boom version) . . . . . . . . . . . . . . . . Air motor power pack. . . . . . . . . . . . . . . . . . . . . . . . . . 12 l 85 l 80 l 0.25 l 1l 1.2 l 2.69 Imp.gal 18.7 Imp.gal 18 Imp.gal 0.055 Imp.gal 0.22 Imp.gal 0.26 Imp.gal 3.17 US.gal 22.5 US.gal 21 US.gal 0.066 US.gal 0.26 US.gal 0.31 US.gal

Tightening torques
Size M 10 M 12 M 16 M 20 Wrench size 17 mm 19 mm 24 mm 30 mm Tightening torque in Nm (lbf.ft.) 8.8 12.9 49 (36) 69 (51) 86 (63) 120 (89) 210 (156) 295 (218) 410 (303) 580 (428)

12