Atlas Copco

Swellex pump HC 1 Manual

PM No. 9852 1413 01 2003-01

Atlas Copco
Swellex pump HC 1 Manual

PM No. 9852 1413 01 2003-01

SAFETY INSTRUCTIONS
Before starting, read all instructions carefully. Special attention must be paid to information alongside this symbol. Only use genuine Atlas Copco parts.

1250 0071 04

Copyright 2003, Atlas Copco Rock Drills AB, Sweden

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

Atlas Copco Rock Drills AB

Table of Content
Safety ............................................................................................................. 5 Operators instructions .............................................................................. 15 Maintenance instructions .......................................................................... 23

Safety
Contents................................................................................................................... 7 Safety regulations .................................................................................................... 7 Safety .................................................................................................................. 7 General safety rules ............................................................................................ 7 Prohibitory and warning signs................................................................................. 9 Regulatory signs .................................................................................................... 12 Rig stability ........................................................................................................... 14 Maximum permissible inclination angles ......................................................... 14

Contents
Since the Safety instruction manual contains safety-related information for handling the rig and its peripheral equipment, some sections are not fully adapted for individual components.

Safety regulations
Safety
These instructions contain important sections concerning safety. Special notice should be taken to the boxed texts starting with a warning triangle followed by a cue word.
!

DANGER WARNING CAUTION

indicates imminent risk that WILL result in serious or lethal injury if the warning is not heeded indicates risk or hazardous action that MAY result in serious or lethal injury if the warning is not heeded indicates risk or hazardous action that MAY cause personal injury or damage to property if the warning is not heeded

!
1250 0100 25

Figure 1. Warning headings

General safety rules

Only personnel who are trained for it are allowed to use the equipment. The equipment may only be used for the purposes described in these instructions. Read all instructions carefully and follow them. Make sure that the unit has been maintained in accordance with the appropriate maintenance schedule. Make sure that all controls and emergency stops are in satisfactory working order. Report all damage and defects immediately. Do not operate the system until all faults have been rectified. Make sure that all warning signs and safety labels are posted, clean and fully legible. In regard to locations and part numbers, see the Spare parts list. Find out where the nearest fire extinguisher is located. Always wear a safety helmet, ear protectors and goggles when travelling and drilling. Also observe local safety regulations.

 Always check the safety equipment and emergency stop after moving the rig and also before the start of each shift. Before travelling and before the start of drilling, always make sure that nobody is standing close to the unit or inside the danger area. Never leave the unit before the brakes have been applied and the wheels blocked. Engine exhaust gases are poisonous. Good ventilation is essential when the engine is running. Never carry out service or maintenance work when the unit is running. Switch off the engine before refuelling. Do not handle flammable liquids near hot surfaces, sparks or a naked flame. To prevent injury during service and maintenance work, components that could move or fall down must be securely supported or strapped in place. Make sure that the hydraulic, water and air systems are depressurised and that the electrical system is without current before starting any work on these systems. Do not use the system if any lamp indicating a fault is alight on the electric cubicle. Call service personnel instead so that the fault will be rectified. Only qualified electricians are allowed to carry out any work on the high-tension part of the electrical system. After changing the hydraulic hoses, make sure the replacement hoses have the correct crimped couplings, are the correct quality and are the correct dimension. All pressurised hydraulic hoses have crimped couplings and should therefore be purchased ready made from Atlas Copco. Qualities and hose dimensions are specified in the spare parts catalogue for each rig. Make also sure that hose couplings are clean, in good condition and properly tightened. The drilling machine may only be used for the purposes for which it is intended. All work on tyres and wheels must be carried out by specially trained maintenance personnel as it is extremely important to ensure that correct procedures are followed and that the right tools are used. Make sure that the drilling rig has been maintained in accordance with the appropriate instructions. In the event of a hose fracture, accident or other emergency situation the electric motor, and thus the hydraulic pump, can be stopped immediately by pressing the red stop buttons on the control and operator panels. Caution must be observed when changing a drill bit or drill steel.

 Checks and adjustments that are necessary when the drilling rig is in operation must be carried out by at least two persons. One person must then be present at the operating station and have a good view of the work. Use only genuine Atlas Copco spare parts. Damage or breakdowns caused by other than genuine Atlas Copco spares are NOT covered by Guarantee or Product Liability. Overloading of the equipment could result in damage to the machinery which is not noticed during normal usage. Such damage is not covered by guarantee. Damage that has occurred as a result of substandard repairs, as well as injury to personnel and damage to equipment that is attributable to older unrepaired damage, are not covered by the guarantee. Stay only within the marked areas when carrying out service work on the drilling rig's engine cover. Do not step on open service access covers. When maintenance work is carried out under a raised cab, the cab must be secured in the raised position.

Prohibitory and warning signs

Table 1. Warnings Symbol Description
Prohibitions No admittance. No admittance to unauthorised personnel. Violation can cause personal injury.

Symbol

Description
Prohibitions Don't step here.

1250 0098 91

1250 0098 97

Warning High tension Incorrect handling could be fatal. All work on the electrical system must be carried out by especially trained personnel.

Warning
1250 0098 98

Danger of swinging and crushing parts. Could cause severe injuries. Keep out of the hazardous area during operation.

1250 0099 80

Symbol

Description
Warning High noise level. Could cause permanent hearing impairment. Use approved ear defenders.

Symbol

Description
Warning The rig's operating cycle is preprogrammed and can start automatically without the presence of an operator. May cause severe personal injury. Keep out of the machine's working area. Danger of tipping when moving rig. Injuries and damage to machinery could occur. When travelling, rigs may only have booms and service platforms swung out within the rig's turning radius. In the event of a breakdown or during service work the boom falls diagonally. Injuries or machinery damage could occur. During service work the boom must be secured in place with straps or supports. Danger of crushing injuries. Injuries could be sustained. A manned service platform may only be operated from the cage, not from the operator panel. Danger of scalding and pressure. Can cause serious injuries. The pressure must be released before the cap is removed.

1250 0099 81

1250 0099 82

Warning Stability. See section Rig stability.

Max.
Ma x.

Warning

Max.

1250 0099 00 1250 0099 83

Warning
1250 0099 84

Warning

Tipping risk during drilling. Injuries and damage to machinery could occur. The jacks on a rig in operation must be fully extended, have contact with the ground and take the weight fully off the wheels. Danger of moving and rotating parts. Could cause severe injuries. Keep out of the machine's working area when it is in operation.

1250 0099 85

Warning
1250 0099 79

Warning
1250 0098 99

Warning Danger of broken wire. Can cause serious injury or damage to property. Do not use the winch with less than four turns of wire remaining.

Warning
1250 0100 13

1250 0100 12

10

Symbol

Description
Warning Danger of air pressure. Can cause serious injuries. The pressure must be released before the cap is removed.

Symbol

Description
Warning Slip risk

1250 0100 14

Warning Laser beam.

Warning Laser beam. Danger of injury to the eyes. Do not look into the beam.

LASER RADIATION DO NOT STARE CLASS 1 LASER PRODUCT CLASS 2 LASER PRODUCT
1250 0100 07 1250 0100 04

INTO BEAM

Warning Laser beam. Danger of injury to the eyes. Do not look into the beam. Do not put optical instruments in the way of the beam.
LASER RADIATION AVOID EXPOSURE TO BEAM CLASS 3B LASER PRODUCT
1250 0100 06

Warning Laser beam. Risk of personal injury. Avoid exposure to radiation.

LASER RADIATION DO NOT STARE INTO BEAM OR VIEW DIRECTLY WITH OPTICAL INSTRUMENTS CLASS 3A LASER PRODUCT
1250 0100 05

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Symbol

Description
Warning Maximum load on service platform. (Illustration of Max. load 1000kg) Overloading can cause personal injury and machine damage. Maximum load in cage including one person.

Symbol

Description
Warning Refrigerants under pressure. Danger of serious personal injury. Risk of compressor breaking down. Service of refrigerant system must be carried out by authorised personnel. Do not use the air conditioning/climate unit with low refrigerant levels, leaks or other faults are present.

MAX 1000kg
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Other loads that can occur: 250kg, 300kg, 350kg, 400kg, 500kg and 560kg.

R134a Max 32 bar

Regulatory signs
Table 2. Regulatory signs Symbol Description
Regulation Read the instruction manual before using the rig. Incorrect use of the machine may cause personal injury and damage to machinery. Serious injuries and damage will be avoided if you heed the warning signs and follow the instructions.

Symbol

Description
Regulation Read the instructions. This rig is equipped with a battery switch.

1250 0099 89

12

Symbol

Description
Regulation Read the instructions. The carrier's battery supplies the hydraulic oil level switch with current. The battery switch must be turned on when drilling is in progress. Switch off the battery disconnector when the rig is not in operation. If this is not done the battery will be discharged.

Symbol

Description
Regulation Read the instructions. This rig is equipped with data boxes. Isolate or remove data boxes when giving the battery a booster charge or carrying out welding on the rig.

1250 0100 09

1250 0100 08

Regulation Read the instructions. This rig is equipped with an alternating current generator (alternator). Disconnect the battery cables before removing the generator or regulator and when giving the battery a booster charge. Also disconnect and insulate the regulator's leads when carrying out electric welding on the rig or equipment mounted on it. Read the instructions. Fill with engine oil.

1250 0099 90

1250 0099 91

Regulation

1250 0099 93

1250 0100 11

CLP
Regulation Read the instructions. The hydraulic system must be filled with hydraulic oil. Regulation Read the instructions. Fill with brake fluid.

13

Symbol

Description
Regulation Read the instructions. Fill with lubricant.

Symbol

Description
Regulation Read the instructions. Emergency stop.

1250 0100 10

1250 0101 41

Rig stability
Maximum permissible inclination angles
Maximum permissible inclination angles depend on the type of rig, see relevant manual.

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Operators instructions
1. Swellex pump......................................................................................................... 17 HC 1....................................................................................................................... 17 Swellex arm ........................................................................................................... 18 System description................................................................................................. 18 Before installing a bolt .......................................................................................... 19 Safety ................................................................................................................ 19 Before bolting ................................................................................................... 19 Installing bolts ....................................................................................................... 20 Safety ................................................................................................................ 20 Installing bolts with the Swellex arm ............................................................... 20

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1. Swellex pump
HC 1

1 2 3 4 5 6 7 8 9

Pump unit Directional valve Y533 Shut-off valve Strainer Electrical box Pressure switch B317:2 = 240/300 bar Pressure gauge Flow regulator Pressure regulator

Figure 1.1. Swellex pump

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Swellex arm

A B C D

Pressure gauge Chuck Trigger Inductive sensor B397

Figure 1.2. Swellex arm

System description
The Swellex pump HC 1 is a hydraulic pump that is intended for Atlas Copco Swellex bolts only. The control system ensures bolting is done completely and to the correct pressure. The operator starts the swelling process by pressing the trigger (C) on the Swellex arm. An inductive sensor (D) will send a signal to the control system, which opens the directional valve (2) on the pump. Once the bolt has swelled to correct pressure and duration, the pressure switch (6) will send a signal to the control system that makes the directional valve drain the bolt. Note If any faults should occur in the control system or if the electric power supply should go down, bolting can be done temporarily with a standard Swellex arm connected to the outlet (8) on the pump. see section Connecting the Swellex pump. Bolting using the outlet (8) should only take place in emergencies and the operator must be very observant to the pressure and duration.

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Before installing a bolt

Safety

CAUTION
The bolt expands in the hole and the resultant pressure could cause a fall of nearby stones. Could cause injury. Thoroughly scale the rock before installing a bolt. Pipe sleeves may be used if there are surface cracks in the rock. Adapt the length of the pipe sleeves to the quality of the rock. Several pipe sleeves may be used.
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Before bolting
1. The operator has to check that the pumps water pressure is set according to the type of bolt to be installed. The pumps water pressure can be set to 240 or 300 bar. A pull test must be done on the first bolt. Atlas Copco takes no responsibility for bolts installed with incorrect water pressure. Bolt type Swellex Mn12, Mn24, Standard Swellex and Super Swellex should be swelled with a pressure of 300 bar. Bolt type Swellex Mn16 and Midi Swellex should be swelled with a pressure of 240 bar. 2. Make sure the equipment is not damaged. 3. Connect hydraulic and water. see maintenance instructions Connecting the Swellex pump.

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Installing bolts
Safety

CAUTION
Risk of falling stones Never stand directly under a bolt which is being installed Use the full length of the installation arm to stand under safe rock when the bolt is expanded

1250 0035 30

Installing bolts with the Swellex arm

1. Make sure the bolt sleeve is clean and not damaged. 2. If a washer is being used, mount it on the bolt before the bolt is inserted into the hole. Use a tube sleeve if necessary. 3. Insert the bolt a short way into the hole if the bolt is lower than two metres. 4. Insert the bolt into the chuck on the Swellex arm. Make sure the bolt reaches to the bottom of the chuck.

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Figure 1.3. Mounting the bolt in the chuck

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5. Insert the bolt into the bore hole using the Swellex arm. Press the bolt hard against the opening of the bore hole.

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Figure 1.4. Bolt installation 6. Start the swelling process by pressing the trigger (C) on the Swellex arm.

Figure 1.5. Swellex arm 7. When the bolt has swelled to correct pressure and duration, the pressure switch (6) will send a signal to the control system that makes the directional valve drain the bolt. Then take down the installation arm from the bolt.

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Maintenance instructions
1. Swellex pump......................................................................................................... 25 HC 1....................................................................................................................... 25 Swellex arm ........................................................................................................... 26 System description................................................................................................. 26 Pressure setting when bolting................................................................................ 27 Pressure setting ................................................................................................. 27 Safety..................................................................................................................... 27 Technical data........................................................................................................ 28 HC 1.................................................................................................................. 28 Connecting the Swellex pump............................................................................... 28 Component parts.................................................................................................... 30 Electrical system ............................................................................................... 30 Water strainer.................................................................................................... 31 Swellex arm ...................................................................................................... 32 Changing chuck seals................................................................................... 32 Fitting/adjusting the inductive sensor .......................................................... 32 Test running ........................................................................................................... 33 Long-term storage ................................................................................................. 33 Freeze prevention measures .................................................................................. 33 Draining the Swellex pump .............................................................................. 33 Fault finding .......................................................................................................... 34 General.............................................................................................................. 34 Fault tracing help .............................................................................................. 34

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24

1. Swellex pump
HC 1

1 2 3 4 5 6 7 8 9

Pump unit Directional valve Y533 Shut-off valve Strainer Switch box Pressure switch B317:2 = 240/300 bar Pressure gauge Flow regulator Pressure regulator

Figure 1.1. Swellex pump

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Swellex arm

A B C D

Pressure gauge Chuck Trigger Inductive sensor B397

Figure 1.2. Swellex arm

System description
The Swellex pump HC 1 is a hydraulic pump that is intended for Atlas Copco Swellex bolts only. The control system ensures bolting is done completely and to the correct pressure. The operator starts the swelling process by pressing the trigger (C) on the Swellex arm. An inductive sensor (D) will send a signal to the control system, which opens the directional valve (2) on the pump. Once the bolt has swelled to correct pressure and duration, the pressure switch (6) will send a signal to the control system that makes the directional valve drain the bolt. Note If any faults should occur in the control system or if the electric power supply should go down, bolting can be done temporarily with a standard Swellex arm connected to the outlet (8) on the pump. see section Connecting the Swellex pump. Bolting using the outlet (8) should only take place in emergencies and the operator must be very observant to the pressure and duration.

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Pressure setting when bolting

Pressure setting
The Swellex pumps water pressure can be set to 240 or 300 bar. When changing the water pressure the pump has to be marked with the right marking plate. Atlas Copco takes no responsibility for bolts installed with incorrect water pressure.

Figure 1.3. Marking plates Bolt type Swellex Mn12, Mn24, Standard Swellex and Super Swellex should be swelled with a pressure of 300 bar. Bolt type Swellex Mn16 and Midi Swellex should be swelled with a pressure of 240 bar.

Safety

WARNING
Extremely high water pressure from the pump. Risk of injury. Rectify any leakage in high-pressure lines and couplings without delay. Before carrying out any work on the pump, turn off the main switch for the power supply. Before starting work on the pump, check that the hydraulic system is depressurized. Before starting work on the pump, check that the water system is not under pressure. Do this by pressing the release button on the Swellex arm.
1250 0035 31

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Technical data
HC 1
Water pressure, water consumption and water temperature Water pressure, in Max. water pressure, out Max water consumption Max water temperature Hydraulic pressure and flow rates Min hydraulic pressure Max hydraulic pressure Flow Installation data Voltage 24 VDC/2A (Min 22V, Max 28V) 120 bar 250 bar 40 litres/min 2-20 bar 420 bar 10 litres/min 70C

Weight Swellex arm with valve chuck Chuck only Pump unit Size Pump unit (length x width x height) xxxx x EC - Declaration of conformity CE marked Miscellaneous Vibration in installation arm Sound level at operator's ear Unmeasurable Unmeasurable Yes 6.5 kg 1.0 kg 38 kg

Connecting the Swellex pump

The pump has to be mounted on a flat surface and it must be possibly to check if there is coming any water och hydraulic oil from the overflow hole under the pump.

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It is recommended to install a shut-off valve on the incoming hydraulic oil.

Figure 1.4. Swellex pump connections Table 1.1. Descriptions of Swellex pump connections Pos. Function
1 2 3 X6 X1 6 7 8 9 10 11 Reset Water connection Pressure gauge External connection 24 VDC/2A Oil, pressure in Oil, return Extra outlet Draining Swellex arm, signal Swellex arm, water 1/4 3/8 1/2 3/8 1/4 Min 22V, Max 28V see Technical data 3/4

Connection dim.

Comment:
Pushbutton see Technical data Water pressure 0-400 bar

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Component parts
Electrical system

Figure 1.5. Switch box Table 1.2. Switch box Description

1

Symbol

Function
Reset

2 3 4 X1

Relay, controls respite duration on the handle Relay, duration of swelling after pressure has reached 300 or 240 bar. Relay, directional valve Connection, 24 VDC/2A (Min 22V, Max 28V)

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Description
X6

Symbol

Function
External connection (Option)

X2=B317:2

External connection, pressure switch

X3=B397

External connection, inductive sensor in handle

X4

External connection, directional valve

X5

External connection, reset

X7

External connection, directional valve

Water strainer
The water strainer is cleaned by opening the valve (3) and flushing with water through the strainer for a few seconds.

31

Swellex arm
Changing chuck seals The chuck seals must be changed if the chuck leaks while installing bolts. This can be done on site. Other chuck repairs must be carried out in a workshop. 1. Undo nut (1).

Figure 1.6. Chuck 2. Remove the seals (2) and spacer ring (3). 3. Clean all parts thoroughly. Change the seals, spacer ring (3) and any damaged parts. 4. Lubricate the plunger 4 with waterproof grease. 5. Fit the chuck with the new seals. 6. Tighten the nut (1). Fitting/adjusting the inductive sensor

Figure 1.7. Swellex arm with inductive sensor

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Test running
1. Make sure the equipment is not damaged. 2. Connect hydraulics and water to the pump. see the section Connecting the Swellex pump. 3. Check that all hoses are tightened securely and that none of them have been damaged. 4. Check the water pressure to the Swellex pump. see section Technical data. 5. Check that the water strainer is clean. 6. Check that the gaskets in the chuck (B) are intact and that the chuck is clean. For changing gaskets, see section Component parts, Swellex arm.

Figure 1.8. Swellex arm

Long-term storage
Protect the pump with rust inhibitor. Always drain the pump prior to storage and store it in a frostfree place. See section Freeze prevention measures. Note Starting a frozen pump can cause extensive damage.

Freeze prevention measures

Draining the Swellex pump
If the ambient air temperature around the pump is below 0C (32F), the water system must be drained to prevent the pump freezing. 33

1. Undo the water hose from the connection (2) on the pump. 2. Undo the Swellex arm, outlet (11) from the pump. 3. Connect compressed air to the Swellex arm. 4. Run the pump for about 10 seconds by pressing the Swellex arm trigger. 5. Cancel by pressing the reset button (1) on the pump. 6. Turn off the compressed air. 7. Drain the water strainer by opening the valve (3) Note Protect the Swellex pump against frost by storing it in an abovefreezing environment if possible.

Fault finding
General
Start by determining what is functioning normally and what is malfunctioning so that fault tracing can be confined to a certain system or a certain function. Then refer to the table below for help in fault tracing the pump.

Fault tracing help

Table 1.3. Fault finding FAULT
No water when pressing in the Swellex arm handle.

CAUSE

Action

Green and yellow LED on connec- Is there power to the pump? Check cables. tion X1 do not come on.

Green LED on handle does not come on. Yellow LED on handle does not come on when the handle is pressed in. No or little flow of hydraulic fluid. Reverse flow of hydraulic fluid.

Check the cable between the pump and the handle. Inductive sensor defective or out of adjustment.

Adjust the hydraulic flow rate. Check the connection of the hydraulic hoses. The delivery hose must be fitted to connection (6) and the return to connection (7). Adjust the hydraulic pressure.

Hydraulic pressure too low.

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FAULT

CAUSE

Action

Water flow too low. Insufficient hydraulic flow or pres- Adjust to the recommended hydraulic flow rate sure. and pressure. Water pressure too Insufficient hydraulic flow or pres- Adjust to the recommended hydraulic flow rate low. sure. and pressure. Leaking seals in Swellex arm chuck. Insufficient water flow. Change seals. Check the hose and connections. Use a pressurised supply of water if possible. Check the diameter of the hose and change as necessary.

Pulsing water pres- The pump is cavitating because sure. water hose diameter too small.

The pump is cavitating due to the Check the water hose and rectify any faults. water connection drawing in air. Check the hose and the connections.

The pump is not re- The water hose is not connected ceiving water. or leaking. Leakage. Hydraulic oil leak. Water leak.

The water connection is clogged. Check and clean the water strainer. Check bolted joints, couplings and seals. Check bolted joints, couplings and seals.

The hydraulic oil or water is leak- If the number of drops exceeds 10 per minute, ing from the overflow hole under the pump seals must be changed. see Manual the pump. Dynaset.

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