Smartroc d65 Tier 4 Final PDF

SMARTROC D65 TIER 4 FINAL
Maintenance
Translation of the original instructions

2015-12-17 | No: 713991051.3 en
Reference
! NOTE: Always read the information in the Safety document before starting to use the
rig or starting maintenance work.
SmartROC D65 Tier 4 Final Table of Contents
Table of Contents
1 Reference............................................................................................................... 3
2 General................................................................................................................. 11
2.1 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...................................................................................................... 16
2.1.6 Long-term storage .................................................................................................................. 16
2.1.7 Scaling.................................................................................................................................... 17
2.1.8 Tightening torque in bolted joints............................................................................................ 17
2.1.9 Work on painted surfaces....................................................................................................... 18
2.1.10 Welding................................................................................................................................... 18
2.1.11 Welding CAN BUS.................................................................................................................. 19
2.1.12 Diagnostics ............................................................................................................................. 20
2.2 Battery....................................................................................................................................... 20
2.2.1 Environmental considerations regarding batteries ................................................................. 20
2.2.2 Charging the battery ............................................................................................................... 20
2.2.3 Starting with an auxiliary battery............................................................................................. 22
2.3 Steel ropes................................................................................................................................ 23
2.3.1 Scrapping guidelines for steel cables ..................................................................................... 23
2.4 Air conditioning........................................................................................................................ 29
2.4.1 Safety ..................................................................................................................................... 29
2.4.2 Environmental issues when handling refrigerant.................................................................... 29
2.4.3 Changing air filter ................................................................................................................... 29
2.4.4 Diagnostics ............................................................................................................................. 30
3 Transport instructions........................................................................................ 33

3.1 Hoisting..................................................................................................................................... 33
3.1.1 Single-section boom version .................................................................................................. 33
3.2 Transport .................................................................................................................................. 34
3.2.1 Before loading the drill rig onto the transport vehicle ............................................................. 35
3.2.2 Once the drill rig is loaded onto the transport vehicle............................................................. 35
3.3 Towing....................................................................................................................................... 36
4 Hardware RCS ..................................................................................................... 39

4.1 Display, application and CCI module ..................................................................................... 39
4.1.1 Connections............................................................................................................................ 39
4.1.2 Pin configurations ................................................................................................................... 40
4.1.3 LED functions ......................................................................................................................... 40
4.2 Resolver module ...................................................................................................................... 41
4.2.1 Connections............................................................................................................................ 41
4.2.3 LED functions ......................................................................................................................... 42
4.3 I/O module................................................................................................................................. 43
4.3.1 Connections............................................................................................................................ 43
4.3.3 LED functions ......................................................................................................................... 44
4.4 Operator panel.......................................................................................................................... 46
4.4.1 Connections............................................................................................................................ 46
4.5 Decoder, operator panel.......................................................................................................... 47
4.5.1 Connections............................................................................................................................ 47
4.5.2 Pin configurations X1 - X6 ...................................................................................................... 47
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4.5.3 Pin configurations X8 - X9 ...................................................................................................... 48

4.5.4 LED functions ......................................................................................................................... 48
5 RCS drilling system ............................................................................................ 49

5.1 Drill system............................................................................................................................... 49
5.1.1 RCS ........................................................................................................................................ 49
5.1.2 Logging in ............................................................................................................................... 51
5.2 Overview of menus .................................................................................................................. 52
5.2.1 Menu structure........................................................................................................................ 52
5.3 Settings ..................................................................................................................................... 54
5.3.1 General and specific settings ................................................................................................. 54
5.3.2 Parameters ............................................................................................................................. 55
5.3.3 Actuations............................................................................................................................... 56
5.4 Direct selection menus............................................................................................................ 57
5.4.1 Direct selection menu F1........................................................................................................ 57
5.5 System ...................................................................................................................................... 66
5.5.1 Menu System.......................................................................................................................... 66
5.5.2 System - Modules................................................................................................................... 67
5.5.3 System - Levers...................................................................................................................... 70
5.5.4 System - Monitors................................................................................................................... 72
5.5.5 System - administration .......................................................................................................... 73
5.5.6 Loading new software............................................................................................................. 74
5.5.7 System - Engine status........................................................................................................... 77
5.5.8 System - Service Interval........................................................................................................ 78
5.5.9 System - Configuration ........................................................................................................... 79
5.5.10 System - Rig Options.............................................................................................................. 80
5.6 Logging ..................................................................................................................................... 81
5.6.1 Logging Menu......................................................................................................................... 81
5.7 Positioning................................................................................................................................ 88
5.7.1 Positioning menu .................................................................................................................... 88
5.8 Drilling....................................................................................................................................... 95
5.8.1 Menu Drilling........................................................................................................................... 95
5.9 Rig ........................................................................................................................................... 112
5.9.1 Rig menu .............................................................................................................................. 112
5.10 RHS.......................................................................................................................................... 122
5.10.1 RHS menu ............................................................................................................................ 122
6 Hydraulic systems ............................................................................................ 135

6.1 Environmental considerations when handling oil .............................................................. 135
6.2 General.................................................................................................................................... 135
6.3 Repairing hydraulic components ......................................................................................... 136
6.4 Replacement of hydraulic hoses .......................................................................................... 136
6.5 Hydraulic workshops............................................................................................................. 137
6.6 Filter ........................................................................................................................................ 137
6.6.1 Return oil filter ...................................................................................................................... 137
6.6.2 Breather filter ........................................................................................................................ 138
7 Feeder ................................................................................................................ 141

7.1 Feeder chain tension ............................................................................................................. 141
7.1.1 Feeder chain tension ............................................................................................................ 142
7.2 Tension of hoses on the hose drum .................................................................................... 142
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7.3 Climbing chain ....................................................................................................................... 143

7.3.1 Lubricating the sprocket wheel and checking the climbing chain cover. .............................. 143
7.4 Bearing unit and checking the chain guide......................................................................... 144
7.4.1 Replacing the bearing unit (chain feed)................................................................................ 144
7.5 Protective plates .................................................................................................................... 145
7.6 Checking for wear on the sprockets .................................................................................... 145
7.7 Sealing disc ............................................................................................................................ 146
7.8 Replacing the slide pieces in the holder.............................................................................. 146
7.9 Replacement of Slide Bars.................................................................................................... 147
7.10 Lubricating the feeder ........................................................................................................... 148
8 Track frames...................................................................................................... 149

8.1 Stretching the crawler tracks................................................................................................ 149
8.2 Check torques ........................................................................................................................ 150
8.3 Check for wear ....................................................................................................................... 151
8.3.1 Procedures ........................................................................................................................... 151
8.3.2 Check for wear on the track rollers....................................................................................... 151
8.3.3 Check for wear on the limberoller......................................................................................... 151
8.3.4 Check for wear on the front wheel........................................................................................ 152
8.3.5 Check for wear on the track shoe......................................................................................... 153
8.3.6 Check for wear on the link and bushing ............................................................................... 153
8.3.7 Check for wear on the chain................................................................................................. 154
9 Dust collector (DCT) ......................................................................................... 155

9.1 Filter test, dust collector (DCT)............................................................................................. 155
9.2 Adjust the suction capacity .................................................................................................. 156
9.3 Dust collector (DCT) filter change ........................................................................................ 156
10 Radiator.............................................................................................................. 159
10.1 Environmental issues when handling coolant .................................................................... 159
10.2 Coolant.................................................................................................................................... 159
11 Diesel engine ..................................................................................................... 161

11.1 Safety ...................................................................................................................................... 161
11.2 Environmental issues when handling oil............................................................................. 161
11.3 Oil for the diesel motor.......................................................................................................... 161
11.4 Maintenance of components................................................................................................. 162
11.4.1 Air filter for engine and compressor, service intervals.......................................................... 162
11.4.2 Air filter for engine and compressor, maintenance ............................................................... 163
11.4.3 Fuel system .......................................................................................................................... 164
11.4.4 Environmental issues when handling fuel ............................................................................ 166
11.4.5 Fuel tank brackets ................................................................................................................ 166
11.4.6 Draining the fuel tank............................................................................................................ 167
11.4.7 Drive belt .............................................................................................................................. 167
11.4.8 For further instructions, see separate instructions for the diesel engine. ............................. 169
12 Compressor and air system............................................................................. 171

12.1 Safety ...................................................................................................................................... 171
12.2 Compressor description........................................................................................................ 171
12.3 Maintenance ........................................................................................................................... 174
12.3.1 Draining the condensate in the pressure tank ...................................................................... 174
12.3.2 Draining the water separator filter ........................................................................................ 175
12.3.3 Replacing the filter element in the water separator filter ...................................................... 175
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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 .................................................................................... 180
12.3.10 Checking the start protection................................................................................................ 180
12.3.11 Checking the minimum charge pressure .............................................................................. 180
12.4 Control system ....................................................................................................................... 180
12.4.1 System description ............................................................................................................... 180
12.4.2 Setting the percussion pressure ........................................................................................... 181
13 Oil and fuel......................................................................................................... 183

13.1 Environmental issues when handling fuel .......................................................................... 183
13.2 Filling fuel ............................................................................................................................... 183
13.3 DEF (Diesel Exhaust Fluid) ................................................................................................... 184
13.3.1 Filling DEF (Diesel Exhaust Fluid)........................................................................................ 184
13.3.2 Storing DEF (Diesel Exhaust Fluid)...................................................................................... 184
13.4 Environmental considerations when handling oil .............................................................. 185
13.5 Compressor oil....................................................................................................................... 185
13.6 Oil sampling............................................................................................................................ 186
13.7 Hydraulic oil............................................................................................................................ 186
13.8 Lubrication.............................................................................................................................. 187
13.9 For engine oil and fuel, see chapter "Diesel engine". ........................................................ 188
13.10Draining the fluids.................................................................................................................. 188
13.10.1 Draining DEF (Diesel Exhaust Fluid).................................................................................... 189
13.11Recommended oils and lubricants....................................................................................... 189
13.11.1 Engine oil.............................................................................................................................. 189
13.11.2 Hydraulic oil .......................................................................................................................... 189
13.11.3 Lubricating oil tank (ECL) (ECG) (HECL) ............................................................................. 190
13.11.4 Grease nipples and CLS ...................................................................................................... 190
13.11.5 Rotation unit ......................................................................................................................... 190
13.11.6 Traction gears, carrier rollers................................................................................................ 191
13.11.7 Oil recommendations for two-stage compressor .................................................................. 191
13.11.8 Coolant ................................................................................................................................. 191
14 Options............................................................................................................... 193
14.1 GPS.......................................................................................................................................... 193
14.1.1 General................................................................................................................................. 193
14.1.2 General data......................................................................................................................... 193
14.2 Service equipment ................................................................................................................. 195
14.2.1 Service tool bag RCS ........................................................................................................... 195
14.2.2 Checking the power supply and the CAN network ............................................................... 196
14.2.3 I/O module ............................................................................................................................ 198
14.2.4 Resolver module................................................................................................................... 203
14.2.5 Replacing the module........................................................................................................... 205
14.3 RC - Reverse Circulation ....................................................................................................... 205
14.3.1 General................................................................................................................................. 205
14.3.2 Lubrication ............................................................................................................................ 206
14.3.3 Maintenance of components ................................................................................................ 208
14.3.4 Blow adapters....................................................................................................................... 214
14.3.5 Metzke Blowdown Valve....................................................................................................... 214
14.3.6 Fault finding in the event of air leakage................................................................................ 215
14.3.7 Conversion to normal drilling ................................................................................................ 215
14.4 Fire suppression system....................................................................................................... 216
viii
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 ......................................................................................................... 217
14.5.4 Adjusting - Drum brake......................................................................................................... 218
14.5.5 Cable .................................................................................................................................... 218
ix
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SmartROC D65 Tier 4 Final 2 General
2 General
2.1 General
2.1.1 Safety
When maintenance work is carried out on the rig, observe the following points:
n Never carry out service or maintenance work while the drill rig is running.
n To prevent personal injury during service and maintenance work, all components that
can be brought into motion or fall down must be thoroughly secured.
n Ensure that the hydraulic and pneumatic systems are depressurised before starting
work on them.
n All controls must be inactivated during service and maintenance.
n When changing hydraulic hoses, ensure they are replaced with hydraulic hoses fitted
with the correct crimp couplings of correct quality and dimension. All pressurised hy-
draulic hoses have crimped couplings and should therefore be purchased ready made
from Atlas Copco. Quality classes and hose dimensions are specified in the spare
parts catalogue. Ensure also that all hose connections are clean, undamaged and se-
curely tightened.
2.1.2 Target group and objective
! NOTE: This chapter (General) contains general recommendations for maintenance of

the drill rig and its peripheral equipment. This means that certain sections may not be
fully adapted to individual components.
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.
Regular maintenance is a precondition for planning necessary interruptions in operation
such as reconditioning and repairs. This allows maintenance to be carried out when most
suitable with regard to production instead of causing complete breakdown.
2.1.3 Contact details
Country Address Phone and fax number
Argentina Estados Unidos 5335 Phone: +54 - (0) 3327 43 18 00

B1667JHQ Malvinas Argentinas Fax: +54 - (0)3327 - 43 18 66
Buenos Aires
Australia P O Box 6134 Delivery Centre Phone: + 61 - (0)2 - 9621 9700

Blacktown Fax: + 61 - (0)2 - 9621 9813
NSW 2148
Austria Postfach 108 A-1111 Wien Phone: + 43- (0)1 -76 01 20
11
Fax: + 43 - (0)1 - 76 01 24 16
Bolivia P.O. Box 290 Santa Cruz de la Phone: + 591 - (0)2 - 211 20 00
Sierra Fax: + 591 - 0(2) - 211 78 01
Brazil P O Box 1080 Barueri - SP Phone: + 55 - (0)11 - 41 96 87

06460-970 00
Fax: + 55 - (0)11 - 41 95 37 22
Bulgaria 7, Iskarsko Shousse Blvd. Build- Phone: + 359 - (0) - 2 489 31 78

ing 3, Office 4 Fax: + 359 - (0) - 2 999 97 64
1528 Sofia, Bulgaria
Canada 1025 Tristar Drive Mississauga Phone: + 1 - 289 - 673 67 11

Ontario, L5T 1L8 Fax: + 1 - 289 - 562 01 00
Chile Panamericana Norte 5001 - Phone: + 56 - (0)2 - 442 36 00

Conchali Fax: + 56 -(0)2 - 623 44 60
Santiago, Chile 6553935
Conchali
China 1 No 2 HengTai Road Nanjing Phone: + 86 -(0) 25 - 85 75 75

Economic & 00
Technological Development Fax: + 86 - (0) 25 - 85 75 75 30
Zone Nanjing
Postal code 210038
China 2 No. 12 Kun Ming Hu Street Phone: + 86 -(0) 24 - 25 81 17

Shenyang 19
Economic & Technological De- Fax: + 86 - (0) 24 - 25 81 18 67
velopment Zone
CN-Shenyang 110027
CMT International S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00

Fax: + 46 - (0)8 - 702 21 29
Colombia A.A. 95310 Santafé de Bogotá, Phone: +57 - (0)1 -419 92 00

D.C. Fax: +57 - (0)1 - 419 92 22
Czech Republic Prumyslova 10 Praha 10, Post Phone: + 420 - (0)2 - 25 43 42

Code 102 00 20
Fax: + 420 - (0)2 - 25 43 42 22
Egypt 520 El-Obour Market Cairo Phone: + 20 - (0)2 - 461 00 337

Fax: + 20 - (0)2 - 461 00 341
Finland Tuupakankuja 1 SF-01740 Phone: + 358 - (0)2 - 07 18 94

Vantaa 35
Fax: + 358 - (0)2 - 07 18 94 02
France BP 27055 Saint Ouen l'Aumône Phone: + 33 - (0)1 - 39 09 30 00

FR-95052 Fax: + 33 - (0)1 - 39 09 30 22
12
Cergy Pontoise Cedex
Germany Postfach 10 02 25 D-46002 Es- Phone: + 49 - (0)201 - 217 70

sen Fax: + 49 - (0)201 - 21 77 360
Ghana P O B 10071 Accra North Phone: + 233- (0) 302 77 45 12

Fax: + 233 - (0) 302 77 61 47
Great Britain Swallowdale Lane Hemel Phone: + 44 - (0) 1442 - 26 12

Hempstead 01
Herts. HP2 7EA Fax: + 44 - (0)1442 - 23 35 06
Greece 93, Koropiou - Varis, Avenue Phone: + 30 - (0)210 - 349 96

Thesi 00
Klossari, GR-194 00 Koropi Fax: +30 - (0)210 - 345 47 83
Hong Kong P O Box 1516 Shatin Central Phone: + 852 - 27 97 66 00

Post Office Fax: + 852 - 23 41 43 13
New Territories
India Sveanagar Bombay Pune Road Phone: + 91- (0)20 -39 85 24 15

Dapodi Fax: + 91 - (0)20 - 27 14 59 48
Pune 411 012
Indonesia P O Box 7021/JKS CCE Jakarta Phone: + 62 - (0) 21 780 10 08

12075 Fax: +62 - (0)21 780 18 37
Iran PO Box 13145-1311 Tehran Phone: + 98 - (0) 21 -669 377

1345654551 11
Fax: +98 - (0)21 - 669 273 14
Ireland Kylemore Road Bluebell Dublin Phone: +353 - (0)1 - 450 59 78

12 Fax: +353 - (0)1 - 456 7686
Italy Casella Postale 77 IT-20092 Phone: + 39 - (0)2 - 61 79 91

Cinisello Fax: + 39 - (0)2 - 61 79 95 20
Balsamo MI
Japan Sumitomo Fudosan Shipa Bldg Phone: + 81 - (0)3 - 57 65 78 07

4 11F 2-13-4 Fax: + 81 - (0)3 - 57 65 31 95
Shiba, Minato-ku, Tokyo
105-00014
Kazakhstan Floor 2, 8A Kurmangaliyev Phone: + 7 - (0)727 - 258 85 34

Street. Fax: + 7 - (0)727 - 258 85 35
050010 ALMATY
Kenya PO Box 400 90 - 00100 Nairobi Phone: + 254 - (0) 70 - 305

4000
Fax: + 254 - (0) 20 - 82 54 72 /
(0) 20 - 82 52 15
13
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
Seoul
Malaysia 26, Jalan Anggerik Mokara Phone: + 60 - (0)3 - 5123 88 88

31/47 Kota Fax: + 60 -(0)3 - 51 23 89 49
Kemuning, Section 31 40460
Shah Alam,
Selangor West Malaysia
Mexico Apartado Postal Box 104 54000 Phone: + 52 - (0) 55 - 22 82 06

Tlalnepantla 00
Edo. De Mexico Fax: + 52 - (0) 55 - 53 90 15 20
Morocco P O Box 13 844 20 100 Casab- Phone: + 212 - (0) 522 -63 40
lanca 00
Fax: + 212 - (0) 522 - 60 05 22
Mongolia Building BP9, Tavan Erdene Phone: + 976 - (0)11 - 34 49 91

(MISHEEL) Fax: + 976 - (0)11 - 70 13 02 23
Center, 2nd Khoroo, Khan Uul
District,
Chinggis Avenue, Ulaanbaatar,
Mongolia
Norway P O Box 334 N-1401 Ski Phone: + 47 - (64) 86 03 00 00

Fax: + 47 - 64 - 86 03 30 30
Peru Apartado 662 Lima 100 Phone: + 51 - (0)1 - 224 86 80

Fax: + 51 - (0)1 - 224 01 53
Philippines P.O. Box 1373 MCPO 1200 Phone: + 63 - (0)2 - 843 05 35

Makati City Fax: + 63 - (0)2 - 843 02 42
Poland Aleja Krakowska 61A Sekocin Phone: + 48 - (0) 22 - 572 68 00

Nowy Fax: + 48 - (0) 22 - 572 68 09
PL-05-090 Raszyn
Portugal Apartado 14 PT-2796-953 Phone: + 351 - 21- 416 85 00

Linda-a-Velha Fax: + 351 - 21 - 416 01 66
Russia 15, Vashutinskoe Road, Khimki Phone: + 7 - 495 - 933 55 52

Moscow Region, 141402 Fax: + 7 - 495 - 933 55 58
Saudi Arabia P O Box 7330 Jeddah 21462 Phone: + 966 - (0)2 - 693 33 57
Fax: + 966 - (0)2 - 693 28 92
Singapore Jurong Point P O Box 438 Phone: + 65 - (66) 68 62 28 11

Singapore 916415 Fax: + 65 - (66) 68 63 60 98
14
South Africa P O Box 14110 Witfield 1467 Phone: + 27 - (0)11 - 821 90 00

Fax: + 27 - (0)11 - 821 92 02
Spain Apartado 43 E-28820 Coslada Phone: + 34 - (9)1 - 627 91 00

Madrid Fax: + 34 - (9)1 - 627 92 39
Sweden SE-195 82 Märsta Phone: + 46 - (0)8 - 58 77 85 00

Fax: + 46 - (0)8 - 59 11 87 82
Switzerland Büetigenstrasse 80 CH-2557 Phone: + 41 - (0)32 - 374 15 00

Studen/Biel Fax: + 41 - (0)32 - 374 15 15
Taiwan P O Box 14-45, Chungli Tao Phone: + 886 - (0)3 - 479 68 38

Yuen Hsien Fax: + 886 - (0)3 - 479 68 20
Thailand 125 Moo 9 Wellgrow Industrial Phone: + 66 - (0)38 - 56 29 00

Estate Bagna Fax: + 66 - (0)38 - 56 29 01
Trad Km 36 Bnagwua Bang-
pakong
Chachoengsao 24180
Turkey Istasyon Mah. Ibisaga Cad. No Phone: + 90 - (0)216 - 581 05

6 81
34940 Tuzla - Istanbul Fax: + 90 - (0)216 - 581 05 82
Ukraine 9, Moskovskiy Avenue Building Phone: + 380 - (0)44 499 18 70

3 04073 Kiev Fax: + 380 - (0)44 499 18 77
USA PO Box 1159 Commerce City Phone: + 1 - 303 - 287 88 22

CO 80022 Fax: + 1 - 303 - 217 28 39
Venezuela Apartado 76111 Caracas 1071 Phone: + 58 - (0)212 - 300 83

00
Fax: + 58 -(0)212 - 300 83 49
Vietnam Lot F, Street No 12, Song Than Phone: + 84 - (0) - 127 27 56

II - 699
Industrial Zone, Di An District, Fax: + 84 - (0) 650 - 373 84 85
Binh Duong
Zambia P O Box 11291 Chingola Phone: + 260 - (0)2 - 12 31 12

81
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
15
2.1.4 Signs for outsourced components

Signs are placed on the larger components of the drill rig. When ordering spare parts or
making enquiries in regard to the drill rig, the type designation and serial number must al-
ways be stated. 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
CAUTION
Risk of injury
Exercise extreme caution when slinging and hoisting heavy objects
u Can cause personal injury
u Hoisting must take place at the centre of gravity
u Only use slings which are intact and designed for the load they shall carry
u Fasten the straps to lifting eyes, when available
Before transporting in shafts or the like it may be necessary to fully or partially dismantle
the drill rig. Observe the following when dismantling, hoisting and assembling:
n Before dismantling, hose the entire rig clean with water and/or detergent containing a
grease solvent.
n Observe the strictest cleanliness when dismantling hydraulic, compressed air and wa-
ter flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes, or seal
and protect them from dirt in some other suitable way.
n Mark hoses, pipes and other connections, where this has not already been done, to
make reassembly easier and prevent mix-ups.
n Use properly secured lifting tackle of generous dimensions.
! NOTE: When the drill rig is scrapped, all materials that are harmful to the environment
must be disposed of in a manner prescribed by the authorities.
2.1.6 Long-term storage

The following points must be observed for long-term storage of the drill rig. In the event of
special conditions e.g. a dusty or corrosive environment, additional measures may be ne-
cessary.
n The rig must have protection from rain, snow and strong sunshine.
n Untreated steel surfaces must be rustproofed.
n The water mist system must be drained and rinsed with antifreeze.
n The battery must be disconnected. If the temperature falls below freezing point then
the battery must be stored indoors.
n The rock drill's shank adapter must be greased.
n The rock drill's gas accumulator must be drained.
n If the rig is to be shutdown for a long time then the rock should drill should be removed
and stored protected.
n Fuel and oil tanks must be filled.
16
Inspection and maintenance during the shutdown period

The following action must be carried out every month.
n Check oil and coolant levels.
n Start the diesel engine and let it run until normal operating temperature has been
reached.
n Operate the rig a few metres back and forth so that the tramming gears are lubricated.
n Operate the tilt cylinders, boom, feeder, drill support and rod handling so that all cylin-
ders reach their end positions.
n Drain condensed water from the hydraulic oil tank and compressor oil tank.
2.1.7 Scaling
When the entire drill rig or part of the rig is to be scrapped, local regulations in force re-
garding handling, waste management, recycling and destruction must be followed. Collect
and dispose of:
n Rest oil and oil spill
n Oil waste such as filters
n Rest fuel and fuel spill
n Rest grease and grease spill
n Batteries
n Discarded refrigerant, air conditioning
n Chemicals such as flushing additives, other additives and coolants
n Metals, e.g. steel and aluminium (metals that are recyclable)
n Plastics and rubber (often marked in various classifications for recycling)
n Electrical components such as cables, electronics
n 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.
Size Strength class Torque in Nm. Tolerance ±
M6 8.8 8 2
M8 8.8 20 5
M10 8.8 41 10
M12 8.8 73 18
M14 8.8 115 25
M16 8.8 185 45
M20 8.8 355 85
M24 8.8 600 150
M12 x 1.25 10.9 135 6
M16 x 1.25 10.9 315 15
M18 x 1.25 10.9 460 20
17
Size Strength class Torque in Nm. Tolerance ±
M6 12.9 14 3
M8 12.9 34 8
M10 12.9 70 17
M12 12.9 120 30
M14 12.9 195 45
M16 12.9 315 75
M20 12.9 600 150
M24 12.9 1020 250
Table 2: Atlas Copco Standard torques.
2.1.9 Work on painted surfaces
WARNING
Serious injury
This rig has been painted with oxyran ester paint and polyester powder.
u Substances are formed when the paint is heated which are hazardous to health and
amongst other things could cause eczema, eye irritation, respiratory system difficulties
and in severe cases asthma or other illnesses.
u Welding, grinding and other hot work involving paint being heated must only be carried
out where sufficient ventilation can be used. In addition, use personal safety equip-
ment: compressed air powered breathing protection, eye protection and gloves.
2.1.10 Welding
n Applies to drill rigs equipped with one of the following engines:
l CAT C13, Tier 4
l 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

n Alternator
n Battery
n All sensors on boom and feeder
n All cables in the cabin
n All connections to electric cabinet, A1
n Engine electronic unit - ECM. See the instructions for diesel engine.
n All contacts to GPS and ProCom units.
18
Points to be observed when welding

n Grind off rust and paint from the area that is to be welded and carefully prepare the
joint.
n Weld in a dry area.
n Connect the welding ground cable to a clean surface as close as possible to the weld-
ing area. Avoid welding close to bearings and bushes. If these cannot be removed,
connect ground cables on both sides of the weld.
n Alterations and reinforcements must not be made without previous consultation with
Atlas Copco.
n DO NOT weld the hydraulic oil tank, valve block, compressed air tank, pressure lines
or the engine exhaust cleaning unit (CEM).
n See separate instructions for diesel engines for work on the exhaust cleaners soot
sensors.
n Welding on the exhaust cleaning unit frame and bracket is prohibited.
n Always keep a fire extinguisher for oil fires near at hand during all types of welding,
cutting and grinding. Screen off the work area from flammable materials.
n Always protect hoses, cables and electric components.
n Grind off spatter after welding. If possible, also grind the surface of the weld smooth
and treat it with anti-corrosion paint.
Electrode recommendations
Use only intact and clean electrodes that have been stored in a dry place. The generally
recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the equivalent in
accordance with the standard below:
ISO: 2560 E51 5B 120 20 H
SS: 14 3211 H10
DIN 1913: E51 55 B10
AWS: A/SFA 5.1 E 7018
Table 3: Electrode recommendations

The use of MIG welding equipment is perfectly acceptable. The generally recommended
type of electrode is ESAB-OK Autrod 12.51 or the equivalent in accordance with the stand-
ard below:
SS: 14 3403 3423
DIN 8559: 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:
n Cable KC50A is removed from the right-hand rear pillar outside the cabin.
n Cable KC50B is removed from the right-hand rear pillar outside the cabin.
19
n Cable D530X1 is removed from D530/X1

n Contact P61 is removed from J61 "Customer connection" to the ECM.
n The battery ground cable is removed.
2.1.12 Diagnostics
Fault finding is a logical sequence of activities to locate a fault, thereby making it possible
to rectify the fault as soon as possible.
Always try to investigate the location of the fault in order to limit fault finding to a certain
system or function.
2.2 Battery
2.2.1 Environmental considerations regarding batteries
NOTICE
Environmental effect
Think of the environment!
u Batteries contain acids and heavy metals. For this reason, expended batteries can be
hazardous to the environment and to health.
u Expended batteries must be sent for destruction in accordance with local regulations.
2.2.2 Charging the battery
WARNING
Serious injury
Risk of fire and explosion
u May cause serious personal injury and damage to property
u Flammable hydrogen gas
u Corrosive fluid
u Avoid naked flames and sparks
u Always detach the negative terminal first, and connect it last
The battery is normally charged by the drill rig's alternator. If the battery is fully discharged
for some reason, it must be recharged using a battery charger. Follow the instructions
carefully. Cell plugs should be unscrewed but left in the holes during charging.
20
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.
Rapid charging, when carried out correctly, will not damage the battery. However, it should
not be undertaken too often and is not recommended for old batteries.
Repeated discharging for long periods, especially with low current such as leaving the
lights on while the engine is stationary, will impair the service life of the battery. Dischar-
ging with high current is not normally harmful. The battery must be left to rest between start
attempts, however.
Since the drill rig's 24V electrical system is powered by two 12V batteries in series, the fol-
lowing points should be observed:
n The batteries must have the same capacity (Ah).
n The batteries must be the same age. This is because the charging current required to
bring a battery up to a certain voltage changes with age.
n The batteries must not be loaded unevenly.
n Series coupling maintains the same capacity but increases the voltage (double). When
2 x 12V 60Ah batteries are connected in series, the voltage will be 24V but the capa-
city remains at 60Ah.
n Ensure that the correct voltage is used before connecting a battery charger. Use a 24V
charger when recharging both batteries and a 12V charger when charging each bat-
tery individually.
Proceed as follows (24V charger)
Before charging
1. Inactivate battery isolation switch S300.
2. Detach the cable between chassis ground and the negative cable on the battery G1B.
3. Connect the positive battery charger cable to the positive terminal on G1A.
4. Connect the negative charger cable to the negative terminal on G1B.
5. Start the battery charger.
After charging
1. Turn off the battery charger
2. Detach the battery charger's negative lead from the negative terminal on G1B.
3. Detach the battery charger's positive lead from the positive terminal on G1A.
4. Connect the cable between chassis ground and the negative terminal on G1B.
5. Activate battery isolation switch S300.
Proceed as follows (12V charger)
Before charging
1. Turn off the battery isolation switch S300.
21
2. Remove the jumper lead between the negative terminal on battery G1A and the posit-
ive terminal on battery G1B.
3. Connect the positive battery charger cable to the positive terminal on G1A.
4. Connect the batter charger's negative lead to the negative terminal on G1A.
5. Start the battery charger.
6. Once battery G1A is fully charged: Turn off the battery charger.
7. Detach the battery charger's negative lead from the negative terminal on G1A.
8. Detach the battery charger's positive lead from the positive terminal on G1A.
9. Detach the cable between chassis ground and the negative cable on the battery G1B.
10. Repeat steps 3 - 8 on G1B.
After charging
1. Turn off the battery charger.
2. Reconnect the jumper lead between the negative terminal on battery G1A and the
positive terminal on battery G1B.
3. Connect the cable between chassis ground and the negative terminal on G1B.
4. Activate battery isolation switch S300.
2.2.3 Starting with an auxiliary battery
! NOTE: Owing to the surge of current, the batteries could explode if a fully-charged bat-
tery is connected to a completely flat one.
NOTE: The connections to the drill rig's batteries must under no circumstances be
broken during operation as this could lead to faults arising in the alternator.
Condition p For this reason, proceed as follows:
1. Check that the auxiliary starting batteries (1) have the same voltage as the batteries
on the chassis.
Starting assistance
1 Auxiliary batteries
2 Chassis batteries
22
2. First connect the positive terminal of the auxiliary battery to the positive terminal of the
chassis battery (2).
3. Then connect the negative terminal of the auxiliary battery (1) to ground on the
chassis (not to the chassis battery's negative terminal).
4. Once the engine has started, first remove the starter cable between the chassis and
the negative terminal on the auxiliary battery (1).
5. Then remove the cable between the positive terminals of the batteries.
2.3 Steel ropes
2.3.1 Scrapping guidelines for steel cables

Steel cables should be scrapped when they display any of the following:
n Wire break at attachment
n Occurrence of strand breaks
n Concentrations of wire breaks
n Effects of heat
n Occurrence of wire breaks due to operating time.
n Reduced elasticity
n Decreased cable diameter
n Certain number and type of wire breaks
n Corrosion
n Surface wear
n Deformation of the cable
n Permanent extension of the cable
Wire break at cable mounting

Broken wires at cable ends indicate that they have been heavily loaded and can be caused
by faulty end mountings.
Shorten the cable and reattach it. Check that the remaining cable is sufficiently long.
Occurrence of strand breaks

If there are strand breaks, the cable must be scrapped.
Concentrations of wire breaks

If there are concentrations of cable breaks, the cable must be scrapped.
If such concentrations occur within a length less than 60 cm or on an individual strand, the
cable must be scrapped.
If this is the case, the cable must be scrapped even if the number of wire breaks is less
than the maximum specified in the table.
Effects of heat
Cables exposed to extreme heat must be scrapped. The effects of heat can be established
through annealing colour.
23
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.
This can then be used to estimate the future increase in wire breaks and the foreseeable
time point for scrapping.
Reduced elasticity
Under certain conditions, the cable loses its elasticity.
Reduced elasticity is difficult to detect. If in doubt, consult a specialist.
If the cable has lost elasticity, the following characteristics usually appear:
n Decrease in cable diameter
n Extension of the cable
n No gap between individual wires and between the strands. This is caused by its com-
ponents being pressed together.
n Fine, brown dust inside the strands.
n Even if there are no visible wire breaks, the cable is noticeably stiffer.
n The cable's diameter decreases more quickly than during normal wear of the individual
cable strands.
Reduced elasticity can lead to sudden cable breaks during heavy loads. The cable should
be scrapped.
Decrease in cable diameter

Decrease in cable diameter through material fatigue in the cable can have the following
causes:
n Inner surface wear and surface wear nicks
n Inner surface wear through friction between the strands and wires in the cable
n Fatigue of plastic core
n Break in steel core
n Break in inner layer in multi-strand cable
If the cable's diameter decreases more than 10% in relation to the nominal diameter of the
cable, it must be scrapped.
It should be scrapped even if no wire breaks have been detected.
Certain number and type of wire breaks

The cable drums are designed in such a way that the cables do not have an unlimited ser-
vice life. Wire breaks can therefore occur during operation.
On 6 and 8-strand cables, wire breaks are primarily superficial.
The cables should be scrapped if the number of wire breaks specified in the table have
been detected
Number of load- Number of visible wire breaks 2 that require scrapping

bearing wires in
the outer strand 1 Machine groups M1 and M2
n Cross lay Equal lay
24
Over a length of Over a length of
6d 30d 6d 30d
201 - 220 9 18 4 9
221 - 240 10 19 5 10
d = Cable diameter
1
= Filler wire is not considered load-bearing.
In cables with several layers of strands, only the outer, visible layer is considered.
In cables with steel cores, the core is regarded as an inner strand and is not included.
2
= In the event of a wire break, two ends can be visible.
Corrosion
Corrosion is especially problematic in marine environments and in areas where the air is
polluted by industrial emissions.
Corrosion can reduce operational strength through rust spots and static tensile strength
through a reduction in the cross section of the metallic cable.
Severe corrosion can reduce elasticity.
Outer corrosion: Outer corrosion can be easily detected through visual examination.
Inner corrosion: Inner corrosion is more difficult to detect. Inner corrosion is character-
ised by the following:
n Absence of gap between the strands in the outer layer of the cable, often in combina-
tion with wire breaks in the strands.
n The cable diameter varies.
The parts of the cable that are bent over discs usually have a decreased diameter. At any
sign of corrosion, the cable should be checked by an authorised person. If inner corrosion
is detected, the cable must be scrapped.
Surface wear
Inner surface wear is caused by friction between the wires and the strands.
Outer surface wear is caused by friction between the cable drums (rolls) and the cable un-
der pressure (acceleration and braking). Outer surface wear is visible through the forma-
tion of reflected images on the outer wires.
Surface wear is increased through faulty or no lubrication, thereby increasing the effect of
dirt and dust.
Surface wear reduces static tensile strength through reduction in the cable's metallic cross
section and dynamic strength through surface wear nicks.
If the cable's diameter decreases more than 7% in relation to the nominal diameter of the
cable, it must be scrapped.
It should then be scrapped even if no wire breaks have been detected.
Deformation of the cable

Deformations are characterised by visible deviations from the cable's normal form that lead
to uneven voltage distribution in the cable.
The following are the primary types of deformations:
n Wire displacement
25
n Strand displacement
n Waviness
n Cracking
n Kinks
n Flattening
n Local cable diameter decrease
n Local cable diameter increase
n Basket formation
Wire displacement
Individual wires or wire groups stick out like hairpins on the side facing away from the
drum. Wire displacement is caused by spasmodic loads.
Cables with wire displacement must be scrapped.
Example of wire displacement
Strand displacement
Strand displacement, which often occurs in conjunction with basket formation, is when the
steel core pushes out between the strands.
Cables with strand displacement must be scrapped.
Waviness
Waviness is a deformation that gives the cable's longitudinal axis a helical curve.
Even though wave formation does not necessarily cause weakening of the cable, such a
deformation can cause a pulsing movement.
After a long time of operation, this can increase surface wear and wire breaks.
In the event of waviness, the cable should be scrapped if
d 1 > 4d/3
d = Cable's nominal diameter
d 1 = Diameter of the circle that would be formed if the cable were not deformed. Check
over a length not exceeding 25d.
26
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.
Strand pitch is altered, which leads a great deal of surface wear and, in severe cases, very
low static strength.
Cables with kinks must be scrapped.
Kinks
Flattening
Flattening is deformation caused by mechanical damage.
Cables with severe flattening must be scrapped.
27
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.
Cables with severe cable diameter decrease must be scrapped.
Local cable diameter decrease
Local cable diameter increase

This means repeated thickening of the cable over a long stretch. At the thicker spots, the
core pushes out of the cable and causes unevenness of the outer strands.
Cables with severe cable diameter increase must be scrapped.
Local cable diameter increase
Basket formation
Basket formation occurs on cables with steel reinforcement or steel core when the outer
strand layer becomes longer than the inner strand layer.
Basket formation can also be caused by shock loads on slack cables.
Cables with basket formation must be scrapped.
Basket formation
28
2.4 Air conditioning
2.4.1 Safety
WARNING
Serious injury
Refrigerant under pressure
u Risk of serious personal injury
u 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. Otherwise, there is risk of the compressor breaking down.
2.4.2 Environmental issues when handling refrigerant
NOTICE
Care for the environment!
u Discarding air conditioning refrigerant can be hazardous to the environment.
u Air conditioning refrigerant must be sent for destruction in accordance with applicable
local regulations.
2.4.3 Changing air filter
Filter - air conditioning.
29
Changing the main filter:

n Undo the screws around the cover (C).
n Open the cover and lift out the filter.
n Fit the new filter in place and screw back the cover.
Changing the prefilter:
n Undo the screws on the louvre cover (D).
n Lift away the louvre cover and the filter.
n Fit the new filter in place and screw back the louvre cover.
Changing the circulation filters:
n Undo the screws on the covers (b).
n Lift away the covers and the filters.
n Fit the new filters in place and screw back the covers.
2.4.4 Diagnostics
No cooling
Check the following points:
n Fuses, electric connections, compressor ground, electromagnets, switches and pres-
sure switches
n V-belt and compressor
n Expansion valve and temperature control valve
n Coolant hoses
Poor cooling
n Fresh-air fan and V-belt tension
n That the air does not evade the evaporator in the unit
n That the evaporator and condenser are not clogged by rubbish and the filter in the air
intake is not dirty
n That the expansion valve capillary tube is firmly against the evaporator outlet pipe
n That the thermostat does not cut out too early
Uneven cooling
n That connections to circuit breaker, magnetic coupling or pressure switch are not loose
n That the expansion valve is not clogged
n That the system is filled and the thermostat is not defective
Abnormal noise
n That the multi-V-belt to the compressor is thoroughly tightened and that the com-
pressor retaining bolts are tightened.
n That the system is filled sufficiently and not overfull
n That the expansion valve is in working order
n That the airflow across the evaporator is sufficient
n That the condenser is clean and the airflow is sufficient
30
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.
The difference between the pressure on the suction side and the pressure side also affects
the level of noise. A compressor with low suction makes more noise than a compressor
with high suction. Likewise, a compressor with high high-pressure makes more noise be-
cause it puts more load on bearings, etc.
31
32
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
u Do not approach a hanging load
u Only use lifting equipment and lifting straps with adequate lifting capacity
u Risk of dumping
u Lock the track oscillation cylinders before the drill rig is raised
Hoisting
Make sure the chassis is not damaged when you position the feed in the transport/hoisting
position.
n Run the rock drill/rotation unit to is rearmost (upper) position
n Use the boom and feed controls to lower the feed onto the feed support.
n Make sure that the hydraulic jack is retracted.
n Track oscillation cylinders to LOCKED position (Button 25).
33
Left control panel

n 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.
n Place the hoisting slings under both crawler tracks at points A and B as shown in the il-
lustration Hoisting.
3.2 Transport
WARNING
Serious injury
Risk of dumping
u Lock the track oscillation cylinders before the drill rig is raised
u Transportation equipment must be adapted for the dimensions and weight of the drill rig
Normal tramming position
34
3.2.1 Before loading the drill rig onto the transport vehicle
n 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).
3.2.2 Once the drill rig is loaded onto the transport vehicle
n Lower the hydraulic jack (extra equipment).
n Track oscillation cylinders to LOCKED position (Button 25).
Left control panel

n Support the feed beam against the vehicle to prevent overloading.
n Switch off the diesel engine.
n Strap the drill rig securely onto the vehicle.
Attach straps or chains to the lifting eyes on the machine and vehicle.
35
3.3 Towing
WARNING
Serious injury
Danger of moving parts
u Position a wedge under both of the track frames, before disengaging the traction gears
NOTICE
Risk of damage
Risk of damage if the machine is towed with low oil level in the traction gears.
u Make sure that there is sufficient oil in the traction gears before disengagement takes
place.
NOTICE
Risk of damage
The traction gears may be damaged if dirt or mud gets into them.
u Make sure that the track frames are completely free of all dirt and mud before the cover
plate for the traction gears is removed.
Traction gear for track frames
A Cover for traction gear
B Cover
C Centre shaft
D O-ring
E Cylinder barrel
F Countersunk screw
G Carrier
36
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.
1. Remove the four countersunk screws (F) from the cover plate (B).
2. Screw two 80 mm M8 screws into the threaded holes in the cover plate (B). Screw the
screws in evenly so that the cover plate (B) is pressed away from the cover for the
traction gear.
3. Remove the cover plate (B), O-ring (D) and cylinder barrel (E).
4. Screw an 80 mm M8 screw into the thread in the centre of the centre shaft (C).
5. Use the screw head to pull out the centre shaft.
6. Remove and check the condition of the O-ring (D). Replace it with a new O-ring if it is
damaged or worn.
7. Refit the O-ring (D) and the cylinder barrel (E). Reattach the cover plate (B) in position
using the 4 countersunk screws.
8. Proceed in the same way on the other track frame.
The machine can now be towed.
37
38
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
X1 Power supply module
X2 CAN network 2
X3, X4 CAN network 1
X5 Address plug
X6 COM2
X7 USB/COM1
X8 Video
X9 Ethernet
Table 5: Functions of connections
39
4.1.2 Pin configurations
Contact Type Pin 1 Pin 2 Pin 3 Pin 4 Pin 5
X1 Four-pin +24V supply +24V supply GND GND

M12, male voltage voltage
contact
X2, X3, X4 Five-pin NC (Not CAN +24V CAN GND CAN Hi CAN
M12, male Connected)
contact (X2,
X4) or fe-
male contact
(X3)
X5 Five-pin Bit 2 Bit 1 GND Bit 0 Bit 3

M12, male
contact
Each address bit is connected to GND (ground). The address plug can be connected
to four different addresses.
4.1.3 LED functions
Module status (D16)

n LED colour is green.
n When the system starts the LED flashes twice per second.
n When CAN communication is in progress the LED will flash once per second.
n When there is no CAN communication or if the I/O module is starting up the LED will
flash five times per second.
CAN status network 1 (D14) and network 2 (D15)

n LED colour is red.
n The LED flashes when communication is established.
n Black LED means no communication.
Supply voltage CAN network 1 (D19) and CAN network 2 (D20)

n LED colour is green.
n Fixed green glow means supply voltage maintained.
n Black LED means no supply voltage.
40
4.2 Resolver module
Resolver module
4.2.1 Connections
Contact Function
X3, X4 CAN network
X5 Address plug
X6-X9 Resolver inputs
X10 Encoder input
X11, X12 Analogue inputs
Contact Type Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
X1 Four-pin M12, +24V sup- +24V sup- GND GND

male contact ply ply
voltage voltage
41
Contact Type Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
X3, X4 Five-pin M12, NC (Not CAN CAN GND CAN Hi CAN Lo

male contact Connec- +24V
(X3) or female ted)
contact (X4)
X5 Five-pin M12, Bit 2 Bit 1 GND Bit 0 Bit 3

male contact
Each address bit is connected to GND (ground). The address plug can be connected to
four different addresses.
X6, X7, Six-pin conin- Ref + Ref - Sine sig- Sine GND Cosine Cosine
X9 verse, male nal signal GND
contact
X10 Six-pin conin- +15V +15V Signal A GND Signal B GND

verse, male
contact
X11, X12 Five-pin M12, GND +15V NC NC Cosine

male contact GND
4.2.3 LED functions
Status View
n Green
l When the system starts the LED flashes twice per second.
l When CAN communication is in progress the LED will flash once per second.
l When there is no CAN communication or if the I/O module is starting up the
LED will flash five times per second.
n Red
l The LED flashes in the event of CAN communication error.
42
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 DI/DO PWM
X11, X12, X17, X18 DI/DO PNP
X13 Address plug
43
Contact Function
X1, X19 Five-pin Screen CAN +24V CAN GND CAN Hi CAN Lo
M12, male (connected
contact to ground)
X2, X3, X4, Five-pin +24V supply 0 - 5V input GND 0 - 20mA in- +5V supply
X20, X21, X22 M12, female voltage signal put A voltage
contact sensor sensor
X5, X23 Five-pin +12V supply Input or out- GND Input or out- GND
M12, female voltage put B put A
contact sensor
X7, X8, X9, Five-pin +24V supply Output B GND Output A GND
X10, X14, M12, female voltage
X15, X16, X24 contact
There are two outputs per contact, but only one output can be activated at a time.
Output current is between 50mA and 2.0A.
The amplitude is adjustable from 0 to 500mA in steps of 50mA.
X11, X12, Five-pin +24V supply Input or out- GND Input or out- GND
X17, X18 M12, female voltage put B put A
contact
X13 Five-pin Bit 2 Bit 1 GND Bit 0 Bit 3

M12, male
contact
Each address bit is connected to GND (ground). The address plug can be connected
Bit 3 is used for baud rate. Unconnected = 125 kbit, connected = 250 kbit
X25 Five-pin +24V supply +24V supply GND GND +24V logic
7/8", male voltage voltage voltage for
contact CPU and
communica-
tion
The current output for the contact is up to 18A.
4.3.3 LED functions
Module status (X25)

44
n 5V supply for CAN control.
n 24V supply for valves and sensors.
Analogue inputs
n Green LED indicates 5V and 24V supply voltage.
n Red LED indicates short circuit to ground of sensor supply voltage.
The supply voltage must be reset after one second when the short circuit is broken.
Digital inputs and outputs
! NOTE: The left-hand LED has a signal from pin 2 (B) and the right-hand LED has a
signal from pin 4 (A).
Function/Con- Black Green Orange* Red

tact
PNP output Load not activated Open circuit Output activated Output activated,
Output not activ- and actuated but short circuit to
ated ground
PNP input Input voltage low Voltage on input Does not arise if Does not arise if
No signal on input Input active the port is initial- the port is initial-
ised as input. ised as input.
NPN output Not activated Output activated The output is ac- Output activated,
externally tivated and actu- but short circuit to
Short circuit to ated ground
ground.
NPN input No signal Input activated Does not arise if Does not arise if
Input voltage too (closed to ground) the port is initial- the port is initial-
high. ised as input. ised as input.
PWM output Not activated Open circuit Output activated Output activated
Load present Output not activ- and actuated (low current) or
ated short circuit to
ground
PWM input Input voltage low Voltage on input Does not arise if Does not arise if
No signal on input Input active the port is initial- the port is initial-
ised as input. ised as input.
* Orange appears by means of the LED emitting red and green simultaneously.
45
4.4 Operator panel
4.4.1 Connections
Operator panel
Contact Function
X1 Supply voltage
X3 CAN network end plug
X4 CAN network (to display D501)
X5 Address plug
D569 Aim Device
A Emergency stop (NOT CAN network)
46
4.5 Decoder, operator panel
Decoder, operator panel
4.5.1 Connections
Contact Function
X1 Supply voltage
X3 Can network
X4 Can network
X5 Address plug
X6 RS232
X8, X9 Input/output contacts
4.5.2 Pin configurations X1 - X6
X1 Four-pin +24V supply +24V supply GND GND

M12, male voltage voltage
contact
X3 Five-pin NC (Not CAN +24V CAN GND CAN Hi CAN Lo

M12, male Connected)
contact
X4 Five-pin NC (Not CAN +24V CAN GND CAN Hi CAN Lo

M12, female Connected)
contact
X5 Five-pin ID 2 ID 1 GND ID 0 ID 3
M12, male
contact
47
Each address ID is connected to GND (ground). The address plug can be connected
X6 Five-pin RXD 1 GND TXD 1 RXD 0 TXD 0

M12, male
contact
4.5.3 Pin configurations X8 - X9
Pin X8 X9 Pin X8 X9
1 GND LED FEED 20 Ain 10 LED OUT 19
2 Ain 1 LED OUT 1 21 GND LED OUT 20
3 POT FEED LED OUT 4 22 Din 1 LED OUT 21
4 Ain 2 LED OUT 3 23 Din 2 LED OUT 22
5 GND LED OUT 4 24 Din 3 LED OUT 23
6 Ain 3 LED OUT 5 25 GND LED OUT 24
7 POT FEED LED OUT 4 26 Din 4 LED OUT 25
8 Ain 4 LED OUT 3 27 Din 5 LED FEED
8 GND LED OUT 4 28 Din 6 Kbd IN 1
10 Ain 5 LED OUT 9 29 GND Kbd IN 2
11 POT FEED LED OUT 4 30 Din 7 Kbd IN 3
12 Ain 6 LED OUT 3 31 Din 8 Kbd IN 4
13 GND LED OUT 4 32 Din 9 Kbd IN 5
14 Ain 7 LED OUT 13 33 GND Kbd OUT 1
15 POT FEED LED OUT 4 34 Din 10 Kbd OUT 2
16 Ain 8 LED OUT 3 35 Din 11 Kbd OUT 3
17 GND LED OUT 4 36 Din 12 Kbd OUT 4
18 Ain 9 LED OUT 17 37 GND Kbd OUT 5
19 POT FEED LED OUT 4
4.5.4 LED functions
Status View
48
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).
The number of electronic modules varies from rig to rig depending on the options it has
been equipped with.
n Lever modules 500:1, 500:2. Display D500.
n Application modules: D100
n I/O modules: D101, D102, D510 and D511
n CAN bridge D530
System layout and component locations are shown in the following figures, which are also
in the menu system.
System Layout
49
Rig Layout
Feeder Layout
50
The operator display panel is the main computer that controls all the information to the ap-
plication module. The application module processes and governs the information from the
operator panel, the I/O modules and the resolver module, and provides the correct informa-
tion to the I/O modules. The I/O modules provide each valve with the correct signal in order
to obtain the right motion or function, while they are receiving information from various
sensors, e.g. the pressure sensors.
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. After starting the drilling system, press the Enter button while you
are in the start menu.
This will display a box in which you can enter your access code and confirm with Enter. A
message User approved will be displayed. Press ESC.
Menu, Logging in.

A start screen with different menus is now displayed.
There are four possible access levels when logging in.
n Operator (OP)
n Service (SE)
n Atlas Copco sales (AC)
n Atlas Copco production (ACP)
51
5.2 Overview of menus
5.2.1 Menu structure
Direct selection menu

F1

F2.1

F2.2

F3
Direct selection menu Performance log

F3

F4

F5
Main menu
System
System Modules Status View
System Modules System layout
System Modules Rig Layout
System Modules Feeder Layout
System Levers
System Levers Calibration
System Guards
System Administration
System Engine status
System Service interval
System Configuration
System Configuration Rig Options
Logging
Logging Event Log
Logging Save
52
Logging MWD
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
Drilling Sensors Calibration
Drilling Actuations
Drilling Parameters
Drilling Parameters Feed Speed
Drilling Parameters Feed pressure
Drilling Parameters Feed pressure Calibration
Drilling Parameters Rotation
Drilling Parameters Rotation Calibration
Drilling Parameters Lubrication
Drilling Parameters Times
Drilling Parameters Drill bit
Drilling Parameters Miscellaneous
Drilling DCT
Drilling DCT Parameters
Drilling DCT Actuations
Rig
Rig Sensors
Rig Sensors Power Pack
Rig Sensors Power Pack Calibration
Rig Sensors Wagon Frame
53
Rig Sensors Wagon Frame Calibration
Rig Actuations
Rig Actuations Power Pack
Rig Actuations Wagon Frame
Rig Actuations Cooling fan
Rig Parameters
Rig Parameters Tramming
RHS
RHS Sensors
RHS Sensors Calibration
RHS Actuations Left Digital Lever
RHS Actuations Right Digital Lever
RHS Actuations Bit Breaker
RHS Parameters RHS
RHS Parameters Threading
RHS Parameters Length Sensor
RHS Cradle positions
RHS Auto RHS parameters
RHS Auto RHS parameters Feed Speed
RHS Auto RHS parameters Rotation
RHS Auto RHS parameters Times
Table 10: Menu structure
5.3 Settings
5.3.1 General and specific settings

The speed of the hydraulic cylinders is set separately for each cylinder. These menus have
a choice list from which you can choose the desired cylinder (boom extension, feed exten-
sion, etc.).
Pressure and flow settings for drilling are divided into a number of menus. Several of these
settings can be done specifically for different types of drill bit. The parameters that can
have different values for different types of drill bit are marked with a drill bit symbol. These
menus have a choice list from which the drill bit can be selected.
54
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.
Table 11: Symbols
5.3.2 Parameters
Example of Parameters
The parameter menus are used for settings of different values.
n Highlight the desired function using the cursor keys and press ENTER.
n Specify the desired parameter value with the arrow keys. The value may be in milli-
amps (mA) or in some cases 1 (on) or 0 (off).
n Press Enter to confirm the selected value.
55
5.3.3 Actuations
Example of Actuations
The actuation menus are used for forced operation of a certain function or to test a func-
tion, e.g. for fault finding on components. This function can also be used if you want to
check that a certain function is actuated from the I/O module outputs.
n Highlight the desired function using the cursor keys and press ENTER.
n Specify the desired actuation value. The value may be in milliamps (mA) or in some
cases 1 (on) or 0 (off).
n 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.
56
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.
Symbol Name Explanation
Tank pressure Shows the current tank pressure

(bar).
Lubrication oil pressure Shows the current lubricating oil

pressure (bar).
Water amount Shows the percentage loading

of the watermist pump.
57
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.
Current hole length The value at the top shows the

Penetration rate current hole length (m) and the
bottom value the penetration
rate (m/min). During auto
drilling, the average penetration
rate for the latest rod is shown.
If the automatic drill stop for at-
tained hole length has been
reached, the average penetra-
tion rate for the entire hole will
be shown.
Drill bit position Shows the position of the drill bit

in metres.
Shortcut, drill plan Here you can get direct access

to the drill plan, if applicable.
Desired hole depth This is where the value for the

desired hole length (0-99.9m) is
entered. Drilling will be stopped
automatically once this hole
depth has been reached.
Rod indication Shows the number of drill steel

in the hole.
Hole number Current hole number in the drill

plan if used.
Feed pressure Shows the current feed pressure

while forward and reverse feed
is being used (bar).
Table 12: Explanation of the symbols in direct selection menu F1.

n Pressure gauges: The pressure gauges show, from left: rotation pressure, percus-
sion pressure and drill feed pressure.
Under the pressure gauge for rotation pressure is a box where you can set the amperage
that controls the flow to the rotation unit.
Under the pressure gauge for drill feed pressure is a box where you can directly set the
drill feed pressure.
n Status bar: Shows directly warnings and information on the engine and drilling sys-
tem. A green box indicates that an automatic function is active. A red box immediately
turns off the diesel engine while a yellow one provides information that there is some-
thing that must be seen to (see status bar icon).
58
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).
n Automatic close of drill support: The drill supports are closed automatically after a
certain drilling length following collaring.
n Final air blow before removal: Extra blow-cleaning of the borehole when drill depth
is achieved.
n Half rod flushing: Extra blow-cleaning of the borehole when half of the rod is drilled.
The number indicates for how many rods blow-cleaning should apply. For example,
number 3 indicates that the blow-cleaning will be for the first three rods.
n Extra flushing: Extra blow-cleaning of the borehole when half of the rod is drilled.
The number indicates for how many rods blow-cleaning should apply. For example,
number 3 indicates that the blow-cleaning will be for the first three rods.
n Cleaning: When the rod is fully drilled the whole rod is fed up and then down during
blowing before auto drilling takes place. The number indicates for how many rods the
cleaning should apply. For example, number 3 indicates that the blow-cleaning will be
for the first three rods.
n Automatic rod extraction:.
l Off: Normal extraction
l Rotation: Rotation and blowing during extraction
l Rotation and air: Rotation during extraction
n Hole Length/Hole depth: Selection of method of measurement.
n Activate HECL-Pump manually: Pump up oil to the rotation unit for a certain time
without flushing air being on. Used for example when you have a new down-the-hole
drill.
59
n 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.
n Emergency mode, Length Sensor: Used if the length sensor has stopped working.
None of the pre-programmed stops will work but the rig can be used until the length
sensor has been rectified. Use rapid feed with great care as none of the stops are
working.
n Emergency mode RHS: Used if an RHS sensor has stopped working. No stops are
working but the rig can still be used with great care.
n Emergency mode, Break Table: Normally, the breaking is semi-automatic. Activa-
tion allows full manual breaking.
n Emergency mode, Water Mist: Normally the watermist system is switched off when
the water level in the tank is low (warning in the status bar). If, for example, the level
sensor is inoperative then the watermist system can still be used.
n Beacon on: Indicates when the warning beacon should be switched on.
n Units of Measurement: Select Metric/Imperial units.
n Increase (+) or decrease (-) the brightness of the display.

n Activate HECL-Pump manually: Pump up oil to the rotation unit for a certain time
without flushing air being on. Used for example when you have a new down-the-hole
drill.
n 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.
n Emergency mode, Length Sensor: Used if the length sensor has stopped working.
None of the pre-programmed stops will work but the rig can be used until the length
sensor has been rectified. Use rapid feed with great care as none of the stops are
working.
n Emergency mode RHS: Used if an RHS sensor has stopped working. No stops are
working but the rig can still be used with great care.
n Emergency mode, Break Table: Normally, the breaking is semi-automatic. Activa-
tion allows full manual breaking.
n Emergency mode, Water Mist: Normally the watermist system is switched off when
the water level in the tank is low (warning in the status bar). If, for example, the level
sensor is inoperative then the watermist system can still be used.
n Beacon on: Indicates when the warning beacon should be switched on.
n Units of Measurement: Select Metric/Imperial units.
n Water Mist Draining: When Enter is pressed the watermist system is blown clean for
20 seconds. The compressor must be switched on and flushing air must be switched
off. After blow-cleaning the watermist system must be switched off and flushing air
must be switched on in order to blow away the water from the flushing air hose.
60
Direct selection menu F2 Settings 2

n Laser Plane: Selection of laser plane function.
n Dist. Laser Sens. to Drill Bit
n Dist. to Ref. Laser Plan:Used when there are several laser planes present. The ref-
erence plane is always the uppermost laser plane.
n Magazine Direction Automatic Rod Add
l CW: The carousel rotates clockwise
l CCW: The carousel rotates anticlockwise
n Automatic Switching: Jaw / Drill Support: Automatic function switching for Lever
36 on the left-hand operator's panel. In manual mode Button 3 must be used.
n Try Rod Add Without Adapter-Rod-Break: Simplified unthreading without breaking.
If unthreading does not succeed then full breaking takes place automatically. Only ap-
plies during automatic drilling.
n MWD logging (Option): Activates the MWD function. MWD presents a range of values
from drilling in the ROC Manager. Requires a USB memory stick in the socket on the
right post at the display.
USB Socket
61
n Use Drillplan: Used if import of drill plan from ROC Manager is executed.
Diesel consumption Resettable counter for showing

diesel consumption since last
reset.
Diesel engine hours Counter for diesel engine hours.

Resettable upper, total number
of hours below.
Percussion hours Counter for percussion hours.

Resettable upper, total number
of hours below.
Tramming hours Counter for tramming hours. Re-

settable upper, total number of
hours below.
Drill meter Counter for number of drill

metres. Two resettable upper,
total number of metres below.
62
Save Save to USB memory stick for

printing on PC.
Grinding interval Resettable counter for grinding

interval.
n View performance log:

n Angle position: Upper value on left shows current tilt of feeder. Next to this value is
an adjustable field where the desired tilt angle can be set.
n Resetting drill meter: Resetting number of drill metres.
n Angle position: The bottom value shows the current swing position of the feeder.
Next to this value is an adjustable field where the desired tilt angle can be set.
In order to change the setting, this field must be highlighted and the field activated by
pressing the enter button on the display screen or the right drill panel. The value can then
be changed using the arrow keys on the display screen or on the right drill panel. Once the
desired value has been set, it must be confirmed by pressing the enter button.
n The graphic on the right: Used as a working tool or aid to quickly find the correct
angle setting.
To get the lever to the desired value, the positioning lever must be moved in the opposite
direction to the way the needle is pointing. This will make the end of the needle shown on
the display screen move towards the centre of the graphic image.
63
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).
n Drill Plan Handling: Create and change drill plan.
5.4.5 Direct selection menu F5
Direct selection menu F5

Direct selection menu F5 activated by pressing the button Fn , and then button F1 on the
display. (The Fn button is active for 3 seconds after each press)
This menu shows the values for the diesel engine.
Fuel gauge Shows the level of diesel fuel in

the tank. There is a safety level
of 80 litres to prevent the tank
from running dry. A warning will
be shown on the display when
the fuel level becomes too low.
Diesel engine rpm Reads and displays the current

engine speed
64
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
engine will be switched off auto-
matically and an information box
will be shown on the display.
External temperature Displays the external temperat-

ure
DEF gauge Shows the level of DEF (Diesel

Exhaust Fluid) in the tank
Engine load Displays the instantaneous load

the diesel engine is exerted to in
percent
Oil pressure Displays the engine oil pressure

when running. Low oil pressure
will automatically turn off the
diesel engine and an information
box will be shown on the display
Charge air temperature Displays the instantaneous

charge air temperature when
running
Fuel rate Displays the instantaneous fuel

consumption when running
Boost pressure Displays the instantaneous

boost pressure when running
Battery status Displays the charge status of

the battery. If there is no charge,
an information box will be dis-
played in the status bar.
65
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

tion until automatic regeneration of
the diesel engine's particulate
filter
5.5 System
5.5.1 Menu System
System
n Modules
n Levers
n Guards
n Administration
66
n Engine Status
n Service Interval
n Configure
5.5.2 System - Modules

Four different views can be selected:
1. Status View
2. System Layout
3. Rig Layout
4. Feeder Layout
Status View
The status of all the modules can be checked in this menu:
n D500:1 Left lever module
n D500:2 Right lever module
n D501 Operator's display
n D569 Aim
n D100 Application module
n D510 I/O module
n D511 I/O module
n D512 I/O module
n D530 CAN bridge
n D101 I/O module
n D170 Boom articulation sensor
n D171 Feed Inclinometer Sensor
67
n D102 I/O module

n 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.)
System Layout
68
Rig Layout
Feeder Layout
69
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. If a lever is replaced or if the lever gives an actuation value lower
than 115 or higher than 127 units, all the levers must be recalibrated (see Calibration
levers below). The function of the rocker switch can also be tested by pressing in the left/
right-hand side of the lever head and the button Left/Right should then be indicated on the
display screen.
n Boom Lever Left
n Drill Lever
n Boom Lever Right
n Tram lever
n RHS Lever Left
n RHS Lever Right
70
System - levers - calibration
Calibration
n Calibration status: Indicates whether the levers have been calibrated
n 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.
n Calibrated: Calibration is performed by moving the levers to their end positions on all
axes, also the lever's side button.
71
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.
The monitors in the top box turn off the diesel engine.
n Emergency stop tripped
n Hydraulic Oil Level, Low
n Hydraulic Oil Temp, High
n Engine Coolant Level, Low
n Compressor Temp. High Stage, High
n Compressor Temp. Low Stage, High
n Chair Switch, On
n Hydraulic Jack Up
n Engine air filter press. high
n Compressor Air Filter Press High
72
5.5.5 System - administration
Administration
In this menu, you can save drill parameters for later retrieval in case of fault finding or up-
grading of existing software to a later version. 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.
! NOTE: For all reprogramming, first make sure that all the parameters are saved on a
USB memory stick so they can be downloaded into the new version of the software
later.
73
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.
1. Insert the USB memory stick into the USB socket.
2. Use the arrow keys to move to Save parameters or to Load parameters and press
Enter.
! NOTE: A text box will appear on the screen and when the operation
is complete "OK" will be displayed.
3. Remove the USB memory stick.
5.5.6 Loading new software
! NOTE: All settings are deleted when new software is loaded. Before loading new soft-
ware, the parameter settings must therefore be saved onto a USB memory stick.
In certain cases a new "boot program" must be loaded in conjunction with new software.
The boot program is loaded as described below. The boot program must always be loaded
first.
1. Turn off the RCS system with button (23) RCS.
74
Control panel for operator's cabin.
2. Insert the USB memory stick with the new software into the USB socket.
USB Socket
3. Start the RCS system.
! NOTE: The system now reads the new software and displays the
"Load ready!" message on the screen when finished. Remove the
USB memory stick and restart the control system.
75
4. Remove the USB memory stick and switch off the RCS system again.
5. Restart the RCS system.
6. If you want to use the same settings as previously and they are saved on a USB
memory stick, they can now be loaded into the system. 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.
Many settings are made by changing an existing numerical value, e.g. setting the date and
time in the Administration menu.
Date and time in the Administration menu
1. Move the cursor to the current numerical value using the arrow keys. The entire value
will be highlighted.
2. Press the enter button. One individual number will now be highlighted in another col-
our.
3. Increase the value with the up-arrow key and lower the value with the down-arrow
key.
4. Complete by pressing Enter.
In certain cases the numerical value may have several digits. In such cases, change one
digit at a time. Use the left and right arrow keys to move the cursor to the desired digit
(ones, tens, etc.).
76
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.
This code can be translated to clear text in the diesel engine manufacturer's manual.
n 100 Engine Coolant Temp Sensor
n 103 Intake Manifold Temp Sensor
n 101A Engine Oil Temp Sensor, Mid
n 101B Engine Oil Temp Sensor, End
n 200 Turbo Outlet Pressure Sensor
n 201 Engine Oil Pressure Sensor
n 203 Atmospheric Pressure Sensor
n 204 Injection Pressure Sensor
n 401 Primary Engine Speed Sensor
n 402 Secondary Engine Speed Sensor
n B362 Hydraulic Oil Temp Sensor
n B366A Compressor Oil Temp Sensor High Stage
n B366B Compressor Oil Temp Sensor Low Stage
77
5.5.8 System - Service Interval
Service Interval
n Time To Service
n Service Interval
n Service Done
n Distance to grinding
n Grinding interval
n Grinding Done
78
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.
n Engine type
n Boom type
n Feeder type
n Rod Handling Type
n Length Sensor Type
n Sensor type: Compr. temp
n Sensor type: Ambient temp
n Aim Device Type
n HMS GPS receiver
79
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.
n Laser plane
n Angle Indication
n Hole navigation
n Electr. Compass
n Automatic positioning
n Automatic rod handling
n Maintenance Logging
n MWD logging
n Water mist on
n Thread Greasing Spray
n Cold Start
n Beacon
80
5.6 Logging
5.6.1 Logging Menu
Logging
n Event Log
n Save
n MWD
n Trace Log
n Signal Log
n Aux. Temp.
81
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
keys, press Enter.
82
Logging - Save
Save
n Statistics: Save statistics from the rig. Can be saved as text or spreadsheet depend-
ing on what it is going to be used for.
n Blast log: Used when the log from the round is to be exported to ROC Manager.
n Performance log: Used when saving the last thirty holes.
n Assert log
83
Logging - MWD
MWD
n MWD Logging: Off or On.
n Sample distance: The interval with which MWD is saved.
84
Logging - Trace Log
Trace Log
Only used after contact with staff from Atlas Copco.
85
Logging - Signal Log
Signal Log
86
Logging - Auxiliary Temperature Logging
Aux. Temp.
n Threshold
n Resolution
87
5.7 Positioning
5.7.1 Positioning menu
Positioning.
n Sensors
n Actuations
n Parameters
88
Positioning - sensor
Positioning - sensor.
n Adjustable sensors are:
l Feed swing
l Feed dump
l Boom swing
l Aim device
89
Positioning - Sensor - Calibration
Calibration
n Sensors
l Feed swing
l Feed dump
l Boom swing
l Aim device
n Raw val
n Value
n Calibrate
n Offset
n Coefficient
The sensors for the angle instrument can be reset in the Calibration menu.
n Be sure to adjust the cabin's aim device directly forward 90° towards the cabin wind-
screen.
n Adjust the boom straight forward so that it is parallel with the cabin's aim device inside
the cabin.
n Use a spirit level and adjust the feeder vertically in both feed swing and feed tilt
modes.
n Now the sensors can be reset by selecting the relevant sensor and resetting by press-
ing the Enter key.
90
Positioning - Actuations
Actuations.
n Boom lift
n Boom swing
n Feed dump
n Feed swing
n Feed extend
91
Positioning - Parameters
Parameters
n Valve Parameters
The parameters used when the positioning cylinders are operated manually.
n Auto Parameters
The parameters used when the Semi-automatic boom positioning (optional equipment) is
used.
92
Positioning - Parameters - Valve Parameters
Valve Parameters
n Boom lift
n Boom swing
n Feed dump
n Feed swing
n Feed extend
n Cylinder in
l Lowest valve current
l Highest valve current
n Cylinder out
n Time Acceleration ramp
93
Positioning - Parameters - Auto Parameters
Auto Parameters
n Feed dump
n Feed swing
n Cylinder in
n Cylinder out
n Calibration aid
l Actuated value
l Relative velocity
94
5.8 Drilling
5.8.1 Menu Drilling
Drilling
n Sensors
n Actuations
n Parameters
n DCT
95
Drilling - Sensor
Sensors
n Rotation pressure
n Percussion
n Feed pressure
n Pump pressure HECL
n Oil level HECL
n Laser Sensor
n Water Level, WM-Tank
Drilling - Sensor Calibration

Calibration of the sensors involved in the drilling process can be carried out in the Calibra-
tion menu.
96
n Ensure that the system is depressurised.

n Select the Set to zero by the relevant pressure sensor.
n Press Enter to Set to zero the sensor. The pressure sensor is then reset and automat-
ically receives an offset value and a coefficient.
97
Drilling - Actuations
Actuations
n Feed speed
n Rapid feed
n Feed pressure
n Rotation Speed
n Rotation pressure threading
n Air flow, reduced
n Air flow, full
n Lubrication
n Thread greasing spray (air valve)
n Thread greasing spray (grease valve)
n Water mist clean system
n Water mist flow control
98
Drilling - parameters
Parameters
n Feed speed
n Feed pressure
n Rotation
n Lubrication
n Timers
n Drill bit
n Others
99
Drilling - Parameters - Feed Speed
Feed speed
n Min current, drill feed
n Max current, drill feed
n Min current, rapid feed
n Max current, rapid feed
n Min speed braking, forward
n Min speed braking, backward
n Speed, calibration
n Max speed, automatic collaring
n Speed drilling, forward
n Speed drilling, backward
100
Drilling - Parameters - Feed Pressure
Feed pressure
n Feed pressure, collaring
n Feed pressure, drilling
n Max feed pressure, drilling
n Min feed pressure, drilling
n Pressure increase rock contact
101
Drilling - Parameters - Feed Pressure - Calibration
Calibration
n 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. A flag will then appear when cal-
ibration is finished.
102
Drilling - Parameters - Rotation
Rotation
n Rotation speed, drilling
n Rotation pressure, jamming
n Pressure decrease, free
103
Drilling - Parameters - Rotation - Calibration
Calibration
Clamp the adapter in the break table and start the calibration.
104
Drilling - Parameters - Lubrication Oil
Lubrication
n Frequency lubrication, HECL-pump
n Min HECL Pressure
n Time Before HECL Guarding
n Timeout HECL Pressure
n Thread Greasing Spray, Pulse Duration
n Thread Greasing Spray, Start Delay
n Thread Greasing Spray, Stop Delay
105
Drilling - Parameters - Times
Timers
n Min collaring time
n Air flushing time
n Half rod flushing, time
n Extra flushing, time
106
Drilling - Parameters - Drill Bit
Drill bit
n Feed pressure, drilling
n Max speed, automatic collaring
n Speed drilling, forward
n Speed drilling, backward
n Rotation speed, drilling
n Pressure increase, jamming
107
Drilling - Parameters - Miscellaneous
Others
n Min air pressure
n Air pressure, drill out
n Initial collar length
n M4 offset
108
Drilling - DCT
DCT
n Parameters
n Actuations
109
Drilling - DCT - Parameters
Parameters
n Time clean pulse
n Pause time
n Number of after clean pulses
110
Drilling - DCT - Actuations
Actuations
n DCT Fan
n DCT Flap
n Filter clean A
n Filter clean B
n Filter clean C
n Filter clean D
111
5.9 Rig
5.9.1 Rig menu
Rig menu.
n Sensors
n Actuations
n Parameters
112
Rig - sensor
Rig - sensor
n Power Pack
n Wagon Frame
113
Rig - sensor - drive unit
n Start Key Ignition:

n Start Key Start:
n Fuel Meter: Shows the volume in litres in the fuel tank.
114
n Calibrate by selecting and setting the box to zero.
Rig - sensor - chassis frame
Rig - sensor - chassis frame.

n Hydraulic Oil Temp: Shows the temperature of the hydraulic oil.
n Hyd Filter pressure: Shows hydraulic filter pressure.
n Compressor Temp. High Stage: Shows the compressor temperature in the high-
pressure stage.
n Compressor Temp. Low Stage: Shows the compressor temperature in the low-
pressure stage.
n Compressor Vessel Pressure: Shows the tank pressure.
n Outer Temp.: Shows the outside temperature.
115
n Calibrate by selecting and setting the boxes to zero.
Rig - actuations
Actuations.
116
n Power Pack
n Wagon Frame
n Cooling Fan
Rig - actuations - drive unit
n ECM Enabled
n Start Engine On
n Enable diesel filler pump
n Load Compressor
n Loading Valve, High Pressure
n Hydraulic oil heat
n Reverse Warning
n Signal horn
n Warning Lamp - Auto
n Pilot Pressure Tramming
n Beacon
117
Rig - actuations - chassis frame
n Tramming high speed

n Hydraulic Jack In
n Hydraulic Jack Out
n Track oscillation lock
n Left Track Oscillation Fwd
n Left Track Oscillation Bwd
n Right Track Oscillation Fwd
n Right Track Oscillation Bwd
n Left Track, Fwd/Rev
n Right Track, Fwd/Rev
n Pump 1: Tramming / Drilling
n Positioning In Trammode
118
Rig - actuations - cooling fan
n Cooling fan engine

n Cooling fan hyd. oil/compr.
119
Rig - parameters
Parameters.
n Tramming
120
Rig - parameters - tramming
n Left Track Forward

n Right Track Forward
n Left Track Reverse
n Right Track Reverse
n Time Acceleration Ramp
121
5.10 RHS
5.10.1 RHS menu
RHS
n Sensors
n Actuations
n Parameters
n Cradle positions
n Auto RHS Parameters
122
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.
n Cradle Position (pulses)
n Upper Calibration Sensor
n Lower Calibration Sensor
n Arm in magazine
n Arm in middle position
n Arm in drill centre
n Rod in Magazine Outlet
n Stop pos magazine rotation CCW
n Stop magazine rotation CW
123
RHS - Sensor - Calibration
Calibration
n Sensors
l Cradle position (pulses)
l Cradle position (length)
n Value
n Set to zero
n Offset
n Coefficient
n Activate learn mode calibr. sensor
n Distance to upper calibration sensor
n Distance to lower calibration sensor
n Operate the cradle to mechanical stop.
n Set to zero by checking the boxes Set to zero and Activate learn mode calibr.
sensor.
n Slowly operate the cradle down until it has passed the lower calibration sensor.
n The distance will automatically appear in boxes.
n Exit with ESC.
124
RHS - Actuations
Actuations - Left Digital Lever

n Actuate desired value
n Function
l Grippers in Guide Position
l Grippers open
l Magazine outlet open
l Rotate Gripper Towards Drill Centre
l Rotate Gripper Towards Magazine
l Arm to drill centre
l Arm to magazine
l Magazine rotation CW
l Magazine rotation CCW
n Actuated value
n Desired value
n Module
n Contact
n Marking
125
Actuations - Right Digital Lever

n Function
l Lower Drill Support Closed
l Lower Drill Support Open
l Upper Drill Support Closed
l Upper Drill Support Open
l Suction Hood Up
l Suction Hood Down
n Actuated value
n Desired value
n Module
n Contact
n Marking
126
Actuations - Break table

n Function
l Breaking cylinder, CW
l Breaking cylinder, CCW
l Break out jaws, lower open
l Break out jaws, lower closed
l Break out jaws, upper open
l Break out jaws, upper closed
n Actuated value
n Desired value
n Module
n Contact
n Marking
127
RHS - Parameters
Parameters - RHS
n Drill Rod / Drill Tube
Parameters - Threading
n Feed speed, threading
128
n Feed speed, unthreading

n Feed pressure forward, RHS
n Feed pressure backward, RHS
n Feed pressure, threading
n Feed pressure, unthreading
n Rotation speed, threading
n Rotation speed, unthreading
Parameters - Length Sensor

n Pulses per revolution
n Wheel diameter
129
RHS - Cradle positions
Cradle positions
n Current position
n Set Current Position
n Break distance
n Position tolerance
n 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).
n M2: Position for breaking of adapter-rod (applies when automatic rod handling is ac-
tivated on the right-hand control panel).
n M3: Rapid feed stop forward.
n M4: Position for breaking rod-rod. Requires that Automatic rod extraction is activ-
ated in Direct selection menu F2.
n M5: Position for inserting rods into the carousel. Requires that Automatic rod ex-
traction is activated in Direct selection menu F2.
n M6: Cradle in upper position.
n M7: Position when the upper drill-steel support can be closed when the first rod is
drilled.
130
RHS - Auto RHS parameters
Auto RHS Parameters

n Feed speed
n Rotation
n Timers
n Others (Not used)
131
RHS - Auto RHS parameters - Feed speed
Feed speed
n Feed Speed, Asyncronous Threading/Unthreading
132
RHS - Auto RHS parameters - Rotation
Rotation
n Max. Rotation Pressure Threading, Adapter-Rod (Y155)
n Max. Rotation Pressure Threading, Rod-Rod (Y155)
n Threshold Value For Threading Completed, Adapter-Rod
n Threshold Value For Threading Completed, Rod-Rod
n Max. Allowed Rotation Pressure, Unthreading(B101)
133
RHS - Auto RHS parameters - Times
Timers
n Rotation Time For Loosening Adapter-Rod Joint
134
SmartROC D65 Tier 4 Final 6 Hydraulic systems
6 Hydraulic systems
6.1 Environmental considerations when handling oil
NOTICE
u Leaking hydraulic connections and lubrication grease are environmentally hazardous
u Changing oils, replacing hydraulic hoses and different types of filter can be environ-
mentally hazardous
u Always collect used oil, oil spillage, waste with oil content and lubrication grease
residue and spillage. Treat in accordance with local regulations in force.
u 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
WARNING
Serious injury
Danger of burn injuries
u The hydraulic oil may reach a temperature of 80 °C
CAUTION
Risk of injury
Hazardous hydraulic oil pressure
u Risk of personal injury
u Working on the hydraulic system can involve a high risk of danger. Ensure the system
is depressurised before starting work
u The hydraulic system may also be pressurised for a short time after the motor has been
switched off
135
! NOTE: The pressure in the hydraulic hoses may vary depending on the operating
mode selected.
CAUTION
Risk of injury
Hazardous hydraulic oil and water pressure
u Never replace high pressure hoses with hoses of lower quality than the originals or with
hoses fitted with removable couplings
The hydraulic system is sensitive to impurities. The environment in which a drill rig nor-
mally operates is usually unsuitable for repairing hydraulic components. Work on the hy-
draulic system on-site should therefore be limited to absolute necessities, i.e. only chan-
ging components. When changing valves, the unit in question must be well strapped and
supported. Components should then be repaired in a suitable environment.
Observe the following points to avoid breakdowns and interruptions in operation due to
fouled hydraulic oil:
n Keep the drill rig clean. Hose it down at regular intervals, preferably with an added
grease solvent.
n Before opening any connection, clean the area round it thoroughly.
n Use clean tools and work with clean hands.
n Always plug hydraulic connections immediately after they have been detached.
n Use clean protective plugs.
n Hydraulic components, such as hoses, valves, motors, must always be kept with suit-
able protective plugs fitted.
n Spare parts for hydraulic components must always be kept in sealed plastic bags.
n Change filter cartridges as soon as the filters indicate clogging.
6.3 Repairing hydraulic components

Repairing and/or reconditioning hydraulic components should be carried out by expert per-
sonnel and in a suitable place. The following alternatives are possible:
n Suitable premises for hydraulic repairs to be arranged at the workplace. Repairs to be
carried out by your own specially trained personnel, the manufacturer's technicians or
Atlas Copco personnel.
n Components to be sent to the manufacturer's local agent for repair.
n 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. All hydraulic hoses are
fitted with pressed couplings and should therefore be purchased ready-made from Atlas
Copco. Hose dimensions and qualities are specified in the spare parts lists for the drill rig.
136
6.5 Hydraulic workshops

Workshops used for the repair of hydraulic components must:
n Be separate from activities which generate dust and particles, such as welding, grind-
ing, the transportation of vehicles, etc.
n Have their own suitable washing equipment which is required for repairing the com-
ponents.
n Have the necessary tools, both standard and special, that are only used in the hy-
draulic workshop.
n Have a ventilation system that does not admit dust into the premises.
n Have well-trained mechanics.
6.6 Filter
6.6.1 Return oil filter
General
The return oil filter cleans the oil before it returns to the tank.
There are two return oil filters connected in parallel. A return oil filter consists of a tube con-
taining two filter inserts. The tubes are mounted inside the hydraulic oil reservoir.
The filter inserts should be replaced according to the maintenance schedule but if the re-
turn filter's pressure gauge on the operator display indicates "Clogged filter" (red zone on
the scale), all return oil filters must be changed immediately.
Symbol for clogged filter
! NOTE: The filter cartridges cannot be cleaned but must be replaced when they are
clogged.
137
Changing the return oil filter

The filter inserts can be dismantled by removing the cover and lifting them up.
1. Clean on and around the filter cap and unscrew the nuts (A).
Changing filter
2. Lift off the cap (B) and replace the O-ring (C) if it is damaged.
3. Lift up the whole filter canister by the handle.
4. Detach the overflow valve (E) by pressing down and turning the handle anticlockwise.
5. Take out the filter cartridges (D) and replace with new ones.
6. Refit the overflow valve and filter canister and screw on the cap.
6.6.2 Breather filter
General
There is a breather filter (A) fitted on the hydraulic oil reservoir. The purpose of the
breather filter is to equalise the pressure differences in the tank that would otherwise arise
when the level in the tank changes if, for example, a jack is lowered.
138
Breather filter
The breather filter must be replaced as set forth in the maintenance schedule and also if it
is severely fouled.
! NOTE: If the breather filter becomes covered in oil it will be ruined. This can happen if
the tank is overfilled. The filter must then be changed.
Changing the breather filter

1. Wash clean on and around the filter (A).
2. Unscrew the old filter.
3. Fit a new filter.
4. Tighten the filter by hand.
139
140
SmartROC D65 Tier 4 Final 7 Feeder
7 Feeder
7.1 Feeder chain tension
Correct feeder chain tension
1 Feed beam
2 Gear
3 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.
When the feeder chain is correctly tensioned it should come into contact with the inner
edge of the lower prism on the feed beam at point (B) when the feeder is aligned in a hori-
zontal position, e.g. tramming position.
141
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. A small amount of grease should also be ap-
plied directly to the threads at the same time.
The distance (A) must be at least 280 mm.
7.2 Tension of hoses on the hose drum

1. Move the rotation unit halfway down on the feeder.
2. Fit a chain pulley block between the hose drum cradle and the top of the feeder.
3. Remove the cover plate on the hose drum cradle that holds the chain in place on the
sprocket wheel.
4. Lift up the chain from the sprocket wheel using a crowbar or similar.
5. Pull the hose drum cradle along the feeder with the chain pulley block until the hoses
are tensioned.
6. Remove the crowbar, refit the cover plate and remove the chain pulley block.
142
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.
If the climbing chain cover (1) is worn then it must be replaced.
After a while the chain links will start to chafe against the jack chain cover. When this takes
place, replace the jack chain cover.
143
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.
Check the chain guide (1) for wear every 500 engine hours. If it is damaged or too worn
then it should also be replaced with a new one.
144
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.
7.6 Checking for wear on the sprockets
A worn sprocket
Check whether there is any unevenness or if it jams when the chain engages and disen-
gages from the gears.
Inspect the teeth for reduced area and bent tips. If the teeth are too worn then the sprocket
wheels should be replaced. (See figure: A worn sprocket).
Do not run a new chain on worn gears. It will lead to the new chain wearing out very
quickly.
Do not run a worn chain on new gears since this will lead to the new gears wearing out
quickly.
As a general rule, replace the gears every third chain replacement.
145
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.
7.8 Replacing the slide pieces in the holder

Each holder has replaceable slide pieces. The slide piece (C) is kept in place by three keys
(D). The slide pieces must be replaced at regular intervals so that the steel in the holder
does not wear against the beam. Replace if there is less than 1 mm of wear allowance on
the slide piece. It is a good idea to change all the slide pieces at the same time, even if
some of them are slightly thicker.
Replacing slide pieces
146
1. Prise off the slide pieces (C) from the holder using a screwdriver and remove the keys
(D).
2. Slide a new slide piece into the holder track and fit the new keys.
3. 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.
7.9 Replacement of Slide Bars
! NOTE: Always replace the slide pieces when replacing slide rails!
Slide rails should be replaced if they are worn or severely scratched.
Replacement of Slide Bars

The slide rails are divided up to facilitate replacement.
Before replacing the front slide rails, run the rock drill/rotation unit to its rear end position.
Before replacing the rear slide rails, run the rock drill/rotation unit to its front end position.
1. Remove the cradle for the rock drill, intermediate drill-steel support and the hose
drum from the beam.
2. Remove the old slide rails A by prising the lower edges of the bars outwards using a
screwdriver.
3. Clean the beam surfaces thoroughly.
4. Fit the new slide rails. The larger edge on the slide rail must be facing upwards. The
rails should be pressed in place by hand.
5. Refit the rock drill cradles, intermediate drill-steel support and hose drum. Ad-
just the holders on the cradles as described in the instructions.
147
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
grease regularly.
148
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").
! NOTE: The grease nipple should not be filled with grease during normal inspection.
Track tension is checked between the front wheel (3) and limberoller (1) when the drill rig is
parked on a level surface with the tracks under normal load.
Crawler tracks
1. Place a straightedge (2, see illustration: Crawler track) on top of each track.
2. Pack with grease via the nipple (4) to tension the track.
3. If necessary, grease can be removed from the tension cylinder by unscrewing the
nipple (4).
149
8.2 Check torques
Tightening torques for track frames
Size Torque in Nm Quantity/track Comments

frames
A M16 295 20
B1 M12 86 4 T45, C50, D50,

D55, T50SF,
C65SF
B2 M16 210 1 T50LF, D60, D65,

C65LF
C M16 210 32
D M12 90 3
E M16 295 18
F1 9/16" UNF 260 ± 10 176 T45, C50, D50,

D55, T50SF,
C65SF
150
Size Torque in Nm Quantity/track Comments

frames
F2 M16 370 ± 20 176 T50LF, D60, D65,

C65LF
G M16 210 28
G M16 210 10
Table 13: Tightening torques for track frames
8.3 Check for wear
8.3.1 Procedures
n Components on the track frames that show wear of 100% must be replaced by new
components.
n Regular and accurate measuring is required in order to establish the extent of the wear
and when replacement is necessary.
n The components must be thoroughly cleaned for measuring.
n Measuring must take place at several points. The degree of wear is determined by the
maximum value, not the average value.
8.3.2 Check for wear on the track rollers

Check the wear by measuring the dimensions (A) and (B).
Track roller
Wear New track 25% 50% 75% 100%

roller
A mm 155.0 152,4 149,5 146,0 142,0
B mm 17.5 18,8 20.3 22.0 24.0
8.3.3 Check for wear on the limberoller

Check the wear by measuring the dimensions (A) and (B) on the limberoller.
151
Limberoller T45, C50, D55, T50SF, C65SF
Limberoller T50LF, D60, D65, C65LF
Wear New 25% 50% 75% 100%

limber-
oller
A mm 100.0 98,5 96,7 94,6 92,0
B mm 7,5 8.2 9.1 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.
Front wheel
152
Wear New front 25% 50% 75% 100%

wheel
mm 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.
Track shoe
Wear New track 25% 50% 75% 100%

shoe
mm 25.0 20,4 15,7 10.9 6.0
Table 14: Triple grouser
8.3.6 Check for wear on the link and bushing

Check the wear by measuring the dimensions (A) and (B) on the link and bushing.
Link and bushing
Wear New link/ 25% 50% 75% 100%

bushing
A mm 89.0 87,6 86,0 84,2 82.0
B mm 50,7 49,8 48,7 47,4 45,9
153
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.
Track shoe
Wear New chain 25% 50% 75% 100%
mm 686,0 688,5 691,4 694,8 698,7
154
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.
Measure the pressure drop while air flushing is activated. If the drop is greater than an 800
mm (wg) column of water, all the filters should be replaced.
! NOTE: If pump 3 does not maintain preset pressure it may be due to the dust collector
filter being clogged.
NOTE: If the dust collector is operated with a deficient filter then the fan wings are
worn.
155
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.
The pressure is adjusted with set screw CT3 and the fan wheel's brake time is adjusted
with CT4.
You should aim for a distribution of 70% (pre-separator) - 30% (DCT). Brake time should
be 8 - 10 seconds. Factory setting 140 bar.
9.3 Dust collector (DCT) filter change

The dust collector filter is located inside the dust collector. Open the door (a) and change
all the filters.
Use a ring spanner to unscrew the filters. Screw the nuts on the bottom of the filters anti-
clockwise.
Recommended tightening torque when fitting the new filters is 18-20 Nm.
156
Dust collector
157
158
SmartROC D65 Tier 4 Final 10 Radiator
10 Radiator
10.1 Environmental issues when handling coolant
NOTICE
u Chemicals, e.g. flushing additives, other additives and coolants, can be environmentally
hazardous.
u Treat in accordance with local regulations in force for both handling and waste dis-
posal.
10.2 Coolant
WARNING
Serious injury
Danger of scalding and pressure
u Can cause serious personal injury
u Release the pressure in the radiator before removing the radiator cap
The drill rig has two radiators. The left-hand radiator is for the compressor oil and hydraulic
oil. The right-hand radiator is for the engine's coolant.
Checking and filling coolant takes place in a separate expansion tank. Only CAT ELC
coolant may be used.
159
SmartROC D65 Tier 4 Final 10 Radiator
Radiator and expansion tank
160
SmartROC D65 Tier 4 Final 11 Diesel engine
11 Diesel engine
11.1 Safety
WARNING
Serious injury
Danger of rotating parts
u Hot engine and components
u Very high exhaust temperatures
u Maintenance work on the drill rig must only be carried out when the engine is switched
off
11.2 Environmental issues when handling oil
NOTICE
u Leaking hydraulic connections and lubrication grease are environmentally hazardous.
mentally hazardous.
u Always collect oil residue, oil spillage, waste with oil content, and lubrication grease
u Use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products
wherever possible. Contact your local Atlas Copco office for further information.
11.3 Oil for the diesel motor
! NOTE: See also the separate operating instructions for the diesel motor, for details of
diesel motor maintenance.
! NOTE: Top up (2) if the oil level is below or level with the lower mark on the dipstick.
161
! NOTE: See the chapter Oils and fuel for oil grade.
1. Check that the oil level is between the upper and lower marks on the dipstick (1).
Diesel engine
1. Dipstick
2. Filling up
2. 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").
11.4 Maintenance of components
11.4.1 Air filter for engine and compressor, service intervals

The air filters consist of filter housing with cover, filter cartridge, safety cartridge, indicator
and evacuation valve. Cleaning is carried out in two stages. The first stage comprises a
cyclone and the second stage a normal filter. Both cleaning stages take place in the filter
housing.
A filter's performance will improve right up until it becomes clogged. For this reason the fil-
ter cartridge should not be replaced at regular intervals, but only when it starts to become
clogged. The filter cartridges must never be cleaned as this impairs filtration and also risks
damaging the filter element.
There is an indicator fitted onto the filter housing to advise when the filter cartridge is
clogged. It is connected to the HEC display in the cabin, or the LCD display on the left-
hand side of the rig for cabinless rigs. A yellow warning symbol is visible on the status bar
at the bottom of the display if a filter starts clogging. The indicator must be checked every
1000th engine hour.
Warning symbols on the rig's HEC display
A Warning symbol for compressor air filter
B Warning symbol for engine air filter
162
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.
If maintenance and replacement at fixed intervals is necessary for any reason, which is not
normally recommended, then the following guidelines apply.
Hours 0 500 1000 1500 2000
Replacing the filter New X X X X

cartridge and
cleaning the filter
housing
Replacing the New - - Changing -

safety cartridge
Indicator test - X X
Table 15: Intervals for filter maintenance
11.4.2 Air filter for engine and compressor, maintenance
! NOTE: Never clean the filter cartridges.

NOTE: When an evacuation valve is damaged, replace it.
NOTE: If the warning symbol for clogged air filter remains visible, the safety cartridge
must also be replaced.
Replacing the filter cartridge

1. Undo clamps (1) and remove the cover (2).
Air filter
2. Remove the main cartridge (3).
3. Clean inside the filter housing and lid with a clean, dry rag.
163
! 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.
4. Check that the evacuation valve (4) is not damaged. Change it if necessary.
5. Remove any adhesive tape there may be on filter housing air outlet.
6. Install a new main cartridge and a new safety cartridge if required.
7. Refit the cover and fasten the clamps.
Checking the indicator
To ensure filter clogging is detected, the function of the indicator (6) must be checked regu-
larly. This is done by gradually blocking the air intake with a piece of wood or similar. The
indicator should then signal and the warning symbol should be visible, or the warning light
should illuminate. If the warning does not indicate, start by checking the cable connections.
If there are no problems with the connections, then the indicator is faulty and must be re-
placed.
! NOTE: The indicator is not included in the filter housing, but is ordered separately.
Take care to use a whole and clean piece of wood so that dirt or other particles do not
enter the filter housing.
11.4.3 Fuel system
Fuel quality
See the chapter Oils and fuel.
Filter
There are two types of fuel filter for the diesel engine, a primary filter and two secondary fil-
ters.
The diesel engine fuel filter must be changed and not cleaned.
164
Primary and secondary filters
Primary and secondary filters

Drainage
n 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
n Remove the filter bowl (D) and clean with pure diesel fuel.
n Remove the fuel filter (C) and then clean the sealing surface on the base of the filter.
Make sure all the remnants of the gasket have been removed.
n Apply pure diesel oil to the new fuel filter gasket.
n Screw on the new fuel filter on the base of the filter until the gasket makes contact with
the filter base. Use the twist marks to aid tightening. Tighten the filter a further three
quarters of a turn by hand. Do not tighten the filter too hard.
n Screw the clean filter bowl (D) back in place.
Replacing the secondary filter
n Close the fuel cock for the primary filter (B).
n Slacken off the secondary filters (A) using a suitable tool and remove them.
n Collect any residual fuel.
n Clean the filter holders seal surfaces of dirt.
n Apply a thin layer of oil to the new fuel filter rubber seals.
! NOTE: The primary filter/water separator can be filled with fuel in advance so that the
engine does not run unevenly or stop due to air bubbles. Do not fill the secondary fuel
filter with fuel before installation. The fuel would not then be filtered and could be con-
taminated. Contaminated fuel increases the wear on the components of the fuel sys-
tem.
Filter for DEF tank

Changing the DEF tank filter:
n See separate instructions from diesel engine.
165
11.4.4 Environmental issues when handling fuel
NOTICE
u Fuel spill is a hazard to the environment and a fire hazard.
u Always collect fuel residue and spillage. Treat in accordance with local regulations in
force.
11.4.5 Fuel tank brackets
WARNING
Serious injury
Never remove the protective plate from the underneath of the drill rig without first
checking that ALL fuel tank retaining bolts (front and rear) are tightened to 73 Nm and
that the tank is secured in the rear bracket.
u When performing maintenance on a rig, be aware that you will be working under a sus-
pended load. Before starting work, the machine must be supported with appropriate
jack stands.
166
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.
11.4.6 Draining the fuel tank

Always fill the fuel tank with clean diesel oil and fuel of the correct grade for the temperat-
ure.
1. Undo the front protective plate on the underside of the drill rig.
2. Undo the bottom plug by holding the nut with a 22 mm ring spanner and unscrewing
with an 8 mm Allen key. Allow the water to drain.
3. Use track oscillation to tilt the drill rig in order to drain the tank completely.
4. Tighten the plug so the diesel oil cannot leak out.
11.4.7 Drive belt
Replacing the multi-belt

Make sure the engine is switched off.
1. Remove the belt cover.
167
2. 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.
3. Secure the tensioner wheel in the position where the belt is slack using a pin (A).
4. Undo and pull out the four bolts (4) in the shaft coupling until there is play.
Undo the bolts
5. Replace the belt by inserting it through the clearance between the coupling rubber
and the shaft flange.
6. Screw back the coupling rubber and tighten the bolts (185Nm).
168
7. The belt is tensioned automatically when the lock-out assembly is removed from the
tensioning wheel.
8. Refit the belt cover.
11.4.8 For further instructions, see separate instructions for the

diesel engine.
169
170
SmartROC D65 Tier 4 Final 12 Compressor and air system
12 Compressor and air system
12.1 Safety
WARNING
Serious injury
High system pressures and temperatures
u Never perform maintenance work while the drill rig is operating
u Make sure that the hydraulic, water and air systems are depressurised and that the
electrical system is de-energised before starting work on the rig.
u The use of incorrect or used oil, or mixing oils, may involve a risk of fire or explosion in
the compressor system.
u Risk of fire if the intervals for changing compressor oil are not observed
The compressor may emit pressure up to 35 bar. The compressor oil must cool down be-
fore work on the compressor is started. 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. Such a procedure could lead to immediate fatality.
Hoses must be considered as consumable items. For this reason, all hoses between com-
pressor and pressure tank must be replaced at a maximum interval of 5 years.
12.2 Compressor description

The rig is equipped with a two-stage screw compressor which is driven by the diesel en-
gine. The compressed air from the compressor flows to an air receiver which also functions
as an oil separator. The majority of the oil is removed in the air receiver by means of centri-
fugal force. The remainder is separated in an oil separator element in the air receiver. The
separated oil is collected in the lower part of the air receiver, which functions as an oil tank.
171
3
2
21
4
14
15 22
1
16
12 17 24
6 5 9 10 26 25
13 27
7 8 11 23
18
19
20
Diagram, compressor system
1 Loading valve Y210B
2 Loading valve Y210A
3 Control valve, high percussion pressure
4 Control valve, low percussion pressure
5 Intake valve
6 Air filter
7 Filter indicator
8 Drain valve
9 Compressor, low pressure stage
10 Compressor, high pressure stage
11 Oil stop valve
12 Pressure Relief Valves
13 Check valve
14 Pressure gauge, tank pressure
15 Pressure gauge, intermediate stage pressure
16 Temperature sensor, low pressure stage
17 Temperature sensor, high pressure stage
18 Oil filter
172
19 Thermostat
20 Radiator
21 Pressure relief valve (extra equipment)
22 Pressure tank sensor, B456
23 Water separator filter
24 Safety valve
25 Minimum pressure valve
26 Air receiver
27 Restriction
Compressor parts
3 Control valve, high percussion pressure
4 Control valve, low percussion pressure
5 Intake valve
9 Compressor, low pressure stage
10 Compressor, high pressure stage
11 Oil stop valve
13 Pressure Relief Valves
14 Check valve
15 Pressure gauge, tank pressure
16 Pressure gauge, intermediate stage pressure
19 Oil filter
173
25 Safety valve
26 Minimum pressure valve
27 Air receiver
28 Restriction
29 Oil separator element
30 Water separator filter
12.3 Maintenance
Right and left-hand draining points
1 Engine radiator
2 Hydraulic oil cooler
3 Compressor cooler
4 Compressor element
5 Engine oil
6 Compressor tank
12.3.1 Draining the condensate in the pressure tank

The pressure tank must be drained of condensate daily, preferably before the start of the
work shift. The rig must have been switched off for at least 1 hour. Draining is performed
from the cock (6) at the draining point on the left-hand side of the rig.
174
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.
12.3.3 Replacing the filter element in the water separator filter
The filter element (A) must be replaced in accordance with the interval in the maintenance
schedule.
12.3.4 Checking the oil level

Check the oil level daily.
175
1. Make sure the rig is standing level.
2. Switch off the rig and allow the oil level to settle for at least 5 minutes.
3. Check the compressor oil level. The indicator on the gauge (1) must be in the green
zone.
4. Fill with oil at (2), if required.
! NOTE: Never fill with too much oil. Overfilling results in high oil consumption.
NOTE: Take care to use the correct oil grade". See "Recommended oils and lubric-
ants".
12.3.5 Changing oil and oil filter

The intervals for oil change are determined by oil grade and operating temperature. The
prescribed interval (see maintenance schedules) is based on up to a certain oil temperat-
ure and normal operating conditions (see oil temperature under the heading "Safety" in the
chapter "Compressors and air system" in the maintenance instructions). Oil should be
changed more frequently when working in high ambient temperatures or very dusty or
damp conditions.
1. Run the compressor to operating temperature. Switch of the engine and wait until the
pressure has eased through the automatic outlet valve. Unscrew the oil filler plug one
turn. This uncovers a ventilation hole which releases pressure from the system.
2. Drain the oil through the removed drain plugs for compressor tank, compressor cooler
and compressor element. Collect the oil in a receptacle. Screw out the plug on the fil-
ter housing to speed up the draining. Tighten the plugs after draining.
3. Remove the oil filters, for example by means of a special tool. Collect the oil in a re-
ceptacle.
4. Clean the filter seat on the filter housing using oil, and make sure that no dirt falls
down into the system. Lubricate the gasket on the new filters. Screw the filters in
place until the gasket makes contact with the seat. Then screw a further half turn.
176
5. 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. Fit and tighten the filler plug once again.
6. Operate the unit without any load for several minutes in order to circulate the oil and
force out any air in the oil system.
7. Stop the compressor. Allow the oil to settle for several minutes. Check that the sys-
tem is depressurised. Unscrew the filler plug (2) and fill with oil until the indicator on
the oil level gauge (1) is once again in the green zone. Fit and tighten the filler plug
once again.
! NOTE: If the oil has been destroyed due to the use of incorrect oil or excessive tem-
perature, or overextended operating time following the latest change, then the system
must be flushed clean before new oil is filled. See "Changing to new type of oil" for the
method.
NOTE: Never fill with too much oil. Overfilling results in high oil consumption. Take
care to use the correct oil grade". See "Recommended oils and lubricants".
12.3.6 Changing to new type of oil

To avoid problems when changing to a new type of oil (see table below), a special proced-
ure for compressor oil flushing must be followed. The table is only applicable if the re-
placed oil has not passed its expiration date. Old oil is best detected by using an analysis
program for oil samples, SOS (Scheduled Oil Sampling). Indications that the oil is old are
that it smells strongly, that there are contaminants such as sediments inside the oil reser-
voir and the stop valve, or that the oil has a brownish colour.
Paroil M Paroil S Paroil Sxtreme
Paroil M drainage* flushing flushing
Paroil S drainage** drainage* drainage
Paroil Sxtreme drainage** drainage drainage*
* When changing to the same oil within the interval between changes, drainage is suffi-
cient. ** Change not recommended
177
A Underside of reservoir cover plate
B Inside of reservoir
C Hose connections
D Oil stop valve
E Pipe
Procedure for compressor flushing

1. First of all, the system must be drained thoroughly when the oil is hot so that as little
oil as possible is left in the system, especially in inaccessible areas. If possible the oil
system must also be pressure washed so that the remaining oil will be blown out. See
step 1 and 2 under the heading "Change of oil and oil filter" for detailed description.
2. Remove the oil filters (a).
3. Open the cover plate on the air receiver and remove the oil separator element.
4. 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.
5. Insert a new oil separator element, screw on the new oil filter and close the valve in
accordance with the instructions under the heading "Changing oil and oil filter".
178
6. Fill the oil reservoir with the minimum amount of oil permissible and run the com-
pressor unloaded in light mode for 30 minutes.
7. 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. If possible the oil system must also be
pressure washed so that the remaining oil will be blown out.
8. Fill the system to full level.
9. Run the compressor unloaded in light mode for 15 minutes and check for leaks.
10. Check the oil level and fill if necessary.
11. Collect all surplus lubricant and discard it in accordance with regulations for handling
waste lubricants. See the chapter "Oils and fuel" in the maintenance instructions.
12.3.7 Cleaning the oil cooler

Keep the compressor oil cooler clean using compressed air in order to maintain efficient
cooling.
12.3.8 Test pressurising the safety valve

1. Disconnect the cables for the flushing air valves Y115 and Y116:
2. Load the compressor (S180 in the cabin).
3. Activate high percussion (S446 in the cabin).
4. Note the current pressure on the pressure gauge 15.
5. Adjust the regulator for high pressure until the safety valve is triggered. The pressure
must then not have exceeded maximum triggering pressure in accordance with the
table below.
Rig model Maximum triggering pressure
FlexiROC D50 32 bar
FlexiROC D55 35 bar
FlexiROC D60 32 bar
SmartROC and FlexiROC D65 35 bar
6. Adjust the regulator for high pressure so that the pressure returns to the previous
value.
7. Reconnect the cables for the flushing air valves Y115 and Y116:
! NOTE: The regulator must not be adjusted during drilling.

NOTE: Under no circumstances may the set pressure of the safety valve be changed
to a pressure other than that stamped on the valve.
179
12.3.9 Checking the pressure sensor B456
Pressure tank's top side
A Valve plate
B 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.
12.3.10 Checking the start protection

If tank pressure exceeds 1.5 bar then the engine cannot be started.
1. Switch off the engine without unloading the compressor.
2. Try to start the engine again immediately while the pressure exceeds 1.5 bar. The en-
gine cannot be started.
12.3.11 Checking the minimum charge pressure

If tank pressure is less than 4 bar then the compressor cannot be loaded.
1. Set the drill rig in Tramming position with button (5) on the left-hand operator's panel.
2. Set engine speed to 1500 rpm.
3. Load the compressor with button (5) on the right-hand operator's panel.
4. Check that the compressor does not load until the tank pressure reaches 4 bar.
12.4 Control system
12.4.1 System description

The control system consists of:
n Control valve for low percussion pressure
n Control valve for high percussion pressure
n Loading valve (solenoid valve) Y210A
180
n Loading valve (solenoid valve) Y210B

n Flushing air valve Y115
n 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.
When low percussion is activated (S38 moved halfway forward) the low flushing air valve
(Y116) will be activated and release air to the hammer. On the low flushing air valve it is
possible to adjust the air flow to the down-the-hole drill to a moderate flow for collaring.
When high percussion is activated (S38 moved fully forward) Y210 B will also be activated
(closed). This results in the air being directed over the high-pressure regulator (3). Now the
high flushing air valve will also open (Y115) which results in full pressure and full air flow to
the hammer.
12.4.2 Setting the percussion pressure

Setting the percussion pressure is carried out by setting the tank pressure during disen-
gaged percussion.
Recommended tank pressure is 32 bar for high percussion pressure and 20 bar for low
percussion pressure
1. Make sure the percussion is switched off.
2. Load the compressor. (Button (5) on the right-hand control panel.)
3. Adjust both control valves (3, 4) alternately until the recommended high percussion
pressure is obtained on pressure gauge (15).
4. Adjust the control valve for low percussion pressure (4) until the recommended low
percussion pressure is obtained on pressure gauge (15).
! NOTE: The adjustment must not be made during drilling.

NOTE: Percussion pressure is affected by many factors such as rock properties, size
of and wear on the down-the-hole rock drill, the drill bit, drill feed pressure, down-the-
hole rock drill air consumption etc.
181
182
SmartROC D65 Tier 4 Final 13 Oil and fuel
13 Oil and fuel
13.1 Environmental issues when handling fuel
NOTICE
u Fuel spillage is environmentally hazardous and a health risk.
u Always collect fuel residue and spillage. Treat in accordance with local regulations in
force.
13.2 Filling fuel

Switch off the engine before topping up the fuel. Do not handle fuel in the vicinity of hot
surfaces, sparks or naked flames.
Cleanliness is important when filling with fuel. Ensure that the tank and tank cover are
clean. Fuel should not be added if there is a risk that it is contaminated, for example in
windy or wet weather, or when there is dust in the air.
Fuel which is stored must not have contact with the air, but should be stored in a closed
vessel. The vessel must be approved for its purpose and shall be clean.
Filling fuel
1 Location of fuel filler orifice
183
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.
When the DEF tank is almost empty, a series of warnings will be shown on the rig's dis-
play. When the tank is empty, the engine is switched off.
13.3.1 Filling DEF (Diesel Exhaust Fluid)
DEF (Diesel Exhaust Fluid) tank (1)

The DEF tank (1) is topped up at each refuelling.
(2) DEF filler location. Do not overfill the tank. In cold climates DEF freezes and needs
space so that the fluid can expand in the tank.
Do not use a contaminated container or funnel when filling the DEF tank.
13.3.2 Storing DEF (Diesel Exhaust Fluid)

DEF (Diesel Exhaust Fluid) degrades over time and no longer meets the requirements for
the DEF system. DEF (Diesel Exhaust Fluid) degrades even faster in hot temperatures.
Read the CAT manual for more information about DEF.
184
13.4 Environmental considerations when handling oil
NOTICE
u Leaking hydraulic connections and lubrication grease are environmentally hazardous.
mentally hazardous.
u Always collect oil residue, oil spillage, waste with oil content, and lubrication grease
u Always use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products
wherever possible. Contact your local Atlas Copco office for further information.
13.5 Compressor oil
WARNING
Serious injury
Danger of rotating parts
u Hot engine and components
u Maintenance work on the drill rig must only be carried out when the engine is not run-
ning
Check the oil level daily.
1. Make sure the rig is standing level.
185
2. Switch off the rig and allow the oil level to settle for at least 5 minutes.
3. Check the compressor oil level. The indicator on the gauge (1) must be in the green
zone.
4. Fill with oil at (2), if required.
! NOTE: Never fill with too much oil. Overfilling results in high oil consumption.
13.6 Oil sampling

An oil sample gives a good indication of how well the hydraulic system has been main-
tained.
13.7 Hydraulic oil
CAUTION
Risk of injury
Protect your eyes from hydraulic oil
! NOTE: Do not fill up with too much hydraulic oil as it might then clog the ventilation fil-
ter.
The hydraulic oil level can be read in the sight glass on the front of the hydraulic oil reser-
voir. The lower sight glass (2) should be full and the upper sight glass (1) should be half
full.
n Check the hydraulic oil level (1 and 2)
n Fill with the hand pump (3) if necessary (see the chapter "Recommended oils and lub-
ricants")
186
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.
Fill (3) if necessary (see the chapter "Recommended oils and lubricants").
187
! 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.
13.9 For engine oil and fuel, see chapter "Diesel engine".
13.10 Draining the fluids
1 Engine radiator
2 Hydraulic oil cooler
3 Compressor cooler
4 Compressor element
5 Engine oil
6 Compressor tank
188
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 Atlas Copco Fluids
-30 to 0 Engine 200
>0 Engine 100
Table 16: Ambient temperature °C
13.11.2 Hydraulic oil

Use mineral based or synthetic (polyalphaolefin or diester) hydraulic oil with good rust,
wear, oxidising and foam inhibitive properties and good air and water separation ability.
Select an oil with viscosity grade (VG) and viscosity index (VI) specified in the "Ambient
temperature" table. Oil with high viscosity index is less temperature dependent.
! NOTE: Surplus oil should be disposed of in an environment-friendly manner as pre-

scribed by the authorities.
189
Ambient temperature. 25-50 Viscosity grade VG (ISO Viscosity index VI

(°C) St. 3448)
+ 25 to +50 ISO VG 68 Min. 150
0 to +25 ISO VG 46 Min. 150
-30 to 0 ISO VG 32 Min. 150
Table 17: Ambient temperature °C
! NOTE: When operating in extremely low temperatures, installation of an extra heater is

recommended.
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.
If COP OIL is not available then the oil should have the following properties:
n Use an oil with good lubricating properties intended for compressed air tools.
n Depending on ambient temperature, the oil should have the following viscosity grades
if the viscosity index (VI) is about 100:
Ambient temperature °C Viscosity grade (ISO 3448)
-30 till +-0 VG 32 - 68
-10 till +20 VG 68 - 100
+10 till +50 VG 100 - 150
n The oil must have additives that prevent foam formation.
ASTM D 2783 Min. 250 kg
ASTM D 4172 (40 kg) Max. 0.5 mm
n The oil must have good adhesion capacity.

n The oil must have additives that prevent foam formation.
13.11.4 Grease nipples and CLS
Working temperature °C
Universal grease NLGI 2 Max. 100 °C

Lithium/molybdenum additives
Synthetic sodium or calcium grease Max. 140 °C
Table 18: Grease nipples and CLS
13.11.5 Rotation unit

Grease: lithium complex, mineral oil based EP grease. NLGI 2, Viscosity 300-600 cSt at 40
°C. Mechanically stable. Intended for use in vibration applications (Shell: Limona LX2).
190
! NOTE: Do not use other types of grease, as some of them are not miscible.
13.11.6 Traction gears, carrier rollers

Use mineral-based transmission oil with EP additive to ISO VG class 220. Meets ACMA
specification for R & O EP oils. Classified as ISO-L-CKC according to ISO 6743/6 and SS-
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.
Ambient temperature Oil
Below +30 °C PAROIL S
Above -10 °C PAROIL S EXTREME
Never mix oils of different brands.
13.11.8 Coolant
Never mix propylene with ethylene glycol. Use only ready-mixed coolant that meets ASTM
with DG210.
191
192
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.
14.1.2 General data
Voltage 24V DC
Current usage 0,2 A
Operating temperature +70°C - -30°C
Enclosure class IP65
Precision <0.3° rms
Start-up time <60 s
CAN test report form CAN Open
GPS compass
A Voltage cable
193
B CAN BUS cable
C CAN BUS cable
1 PWR: Green lamp that indicates that the supply

voltage is OK.
2 GPS lock : Yellow lamp that indicates that the

satellite reception is OK.
3 HDG : Green lamp that indicates that the drill

rig's direction data has been sent onward to the
CAN BUS.
4 Primary antenna
5 Secondary antenna
GPS cables
Wire Conductor 1 Conductor 2 Conductor 3 Conductor 4 Conductor 5
A brown 24V white GND blue Tx data black Rx -

data
B - white 24V blue GND black CAN grey CAN

HI LO
C - white 24V blue GND black CAN grey CAN

HI LO
! NOTE: * The voltage cable's 24V conductor (1) has a 1 A fuse connected.
194
14.2 Service equipment
14.2.1 Service tool bag RCS
Service bag
A CAN tester
B Resolver tester
C Multimeter
D Encoder tester
E CAN Open cable
F I/O tester
G Signal cable
H Test cables
I Test box
J Connectors
K Torque tools
L Torque tools
M Contact
195
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.
! NOTE: Always use the torque tools to tighten cable connections.
n MAIN POWER lights if power is being supplied to the module.

n CAN POWER comes on if there is a voltage present to the CAN network.
n CAN HI and CAN LO flash while communication is in progress on the CAN network.
CAN tester
A Multimeter
B CAN tester
Pin Function
1 Screen / Shield
2 CAN +
3 CAN -
4 CAN HI
5 CAN LO
Table 19: Pin configuration, CAN inputs and outputs, I/O modules
196
Pin Function
1 NC / not connected
2 CAN +
3 CAN -
4 CAN HI
5 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. The red pin goes to V/Ohm on the multimeter. Set the multi-
meter range to DC Volt.
CAN measurement
Connect the tester's 5-pin connectors to the CAN network requiring measurement:
n Decoder: contact X3 or X4.
n Display, application and master modules: connector X2, X3 or X4.
n I/O modules: contact X1 or X19.
n Resolver modules: contact X3 or X4.
Normal state
n Supply voltage (MAIN POWER) 24-28 V (shines green).
n CAN power supply (CAN POWER) 20-24V (shines green).
n CAN communication (CAN HI), about 2.5V (flashes green).
n CAN communication (CAN LO), about 2.3 V (flashes green).
Fault indication
n CAN HI glows red constantly for short circuit to ground.
n CAN HI glows green constantly for voltage above 3.5 V.
n CAN LO glows green constantly for short circuit to ground.
n CAN LO glows red constantly for voltage above 3.5 V.
n If neither CAN HI nor CAN LO is lit, then there is no communication even though
power is being supplied to CAN.
n If any light is flashing red, then CAN communication is at the wrong level or is inverted.
Supply voltage
Connect the tester's 5-pin connector to the module's power supply:
n I/O modules: contact X25. 7-pin contact. Use enclosed T-cross.
n Other modules: connector X1. 4-pin connectors.
The power supply (MAIN POWER) must be 24-28V (lights green).
CAN cable test
! NOTE: System is to be shut down.
197
1. 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.
2. Connect the tester's 5-pin connectors to the CAN network requiring measurement:
Decoder: contact X3 or X4.
Display, application and master modules: connector X2, X3 or X4.
I/O modules: contact X1 or X19.
Resolver modules: contact X3 or X4.
3. Select CABLE TEST on the CAN tester. The multimeter should read about 60-65
Ohms if the cable is intact.
Fault indication
n If the multimeter reads 120 Ohm, the end plug is missing or there is a break in a cable.
! NOTE: Because of the internal resistance in the tester, the multimeter reads about 100
kOhm if the cables are not connected or if there is an open circuit in one of the cables.
14.2.3 I/O module
Checking the digital inputs

There are two digital inputs designated A and B at each contact Normally, the signal is 0V
for an open contact and +24V for a closed contact.
Pin Function
1 +24V DC
2 Signal B
3 GND
4 Signal A
5 GND
Table 21: Pin configuration
198
Measuring voltage/power
Connecting the I/O tester
1. Connect the I/O tester between the I/O module input and the guard as illustrated.
2. Measure the voltage according to the table.
Checking the digital outputs

There are two digital outputs designated A and B in each contact.
Pin Function
1 +24V DC
2 Signal B
3 GND
4 Signal A
5 GND
1. 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.
199
2. Connect the 5-position connector on the I/O tester to an unoccupied 5-position con-
nector in the I/O module.
3. Connect the multimeter between GND and the +A or +B output that is of interest.
4. Activate the function. Normally, the multimeter will read ~ 24V.
Fault indication
n If the valve is not activated, there is an open circuit in the cable running to the valve or
in the coil in the valve.
Measuring current
200
2. Connect the multimeter in series with the +A or +B output that is of interest.
3. Activate the function. Normally, the multimeter is to read ~1A.
Fault indication
n If the multimeter reads 0.00A and the solenoid coil diode is lit, there is an open circuit
in the coil in the valve.
Checking the analogue inputs
Pin Function
1 +24V DC
2 0-5V
3 GND
4 4-20mA
5 +5V DC
1. Connect the 5-position connector on the I/O tester between the input of interest on the
I/O model and the sensor as illustrated.
2. Measure currents according to the table.
Checking the PWM outputs

There are two PWM outputs designated A and B in each contact.
201
Pin Function
2 out +B
3 out -B
4 out +A
5 Out -A
Measuring current
2. Connect the multimeter in series with the +A or +B output that is of interest.
3. Actuate the function and check that the current corresponds with the actuated value
on the display.
Encoder inputs (pulse sensor) X12, X18

Each encoder connector has two signals, A and B.
Pin Function
1 +24V DC
2 B
3 GND
4 A
202
Pin Function
5 GND
14.2.4 Resolver module
Checking resolver inputs X6 - X9

Pin configuration:
Pin Function
1 Ref +
2 Ref -
3 Sine signal
4 Sine GND
5 Cosine signal
6 Cosine GND
1. Connect the resolver tester to the relevant cable. Turn the test sensor slowly and
check that the angle shown on the sensor menu changes.
Resolver tester
If the angle changes, the sensor on the boom is faulty.
If the angle does NOT change, the cable on the boom must be checked.
2. Connect the test sensor and test cable directly to the resolver module input. Turn the
test sensor slowly and check that the angle on the sensor menu changes.
If the angle changes, the cable on the boom is faulty.
If the angle does NOT change, the resolver module is faulty.
Checking the encoder input (Pulse sensor input) X10
Pin Function
1 +15V
2 +15V
3 Signal A
4 GND
203
Pin Function
5 Signal B
6 GND
1. Connect the encoder tester to the end of the relevant cable. Turn the test sensor
slowly and check that the length measurement shown on the sensor menu changes.
Encoder tester
If it changes, the sensor on the boom is faulty.
If it does NOT change, the cable on the boom must be checked.
2. Connect the test sensor with test cable directly to the resolver module input. Turn the
test sensor slowly and check that the length measurement shown on the sensor menu
changes.
If the measured value changes, the cable on the boom is faulty.
If the measured value does NOT change, the resolver module is faulty.
Checking analogue input channels X11 and X12
Pin Function
1 GND
2 + 4.5V power supply out
3 Signal in
4 (Not used)
5 (Not used)
Table 28: Pin configuration for input channel X11
Pin Function
1 GND
2 + 15V power supply out
3 Signal in
4 (Not used)
5 (Not used)
Table 29: Pin configuration for input channel X12
1. Connect the resolver module connector X11 or X12 to test box connector (B).
204
Test box
2. Connect the multimeter to test box pins 2 and 3.
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. Continue fault finding as follows:
a. Connect the cable (C) on the test box to resolver module input X11 or X12 and
measure between 1 and 2.
b. Recheck the multimeter reading. If it is 0V, there is a fault on the resolver module
input (X11 or X12).
14.2.5 Replacing the module

1. Make certain the module has the correct address plug and that the end plug (if any) is
mounted in place.
2. When any of the application module, I/O or resolver module is replaced, the program
must be read into the system again.
3. Insert the USB memory stick with the program into the USB port and start the RCS
system.
4. When the program has been fully loaded, the following will appear on the display:
"Remove card and restart the system!"
5. Switch off the system - remove the USB memory stick and start the system once
again.
! NOTE: Make certain that electric power is present at the rig or that
the diesel engine is running before loading the program. Avoid
starting the diesel engine while the program is being loaded. Never
turn off the system while the program is being loaded.
14.3 RC - Reverse Circulation
14.3.1 General
Most maintenance work consists of checking leakage and wear, as well as replacing wear
parts. All parts that come into contact with cuttings are wear parts. The components that
wear the most are the inner tubes and deflectors, the former in particular.
205
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.
For maintenance of the rotation unit, see the separate documentation.
For maintenance of the down-the-hole rock drill, see the supplier's documentation.
14.3.2 Lubrication
The lubrication points are on the arm, the rotary actuator, the outlet swivel and the air
swivel. For the rotary actuator, lubrication is recommended every two months or every 500
engine hours. Other points must be lubricated daily.
CAUTION
Risk of injury
Special tools are required for service: Article number 9495 6730 00 - 6x screws, 12:9
quality when fitting the adapter.
206
Lubrication points
A Outlet swivel
B Air swivel
C Shaft
D 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.
In addition, lubrication is recommended after cleaning the equipment.
Recommended Lubricants:
n Castrol APX T Grease
n Shell Albida Grease HD 2
n Fuchs Renolite LX- EP2
n BP Energrease LC 2
207
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. If it is allowed to become too short or too thin then the pipe's
end breaks and jams under the piston during the down stroke, which leads to piston failure
and cylinder damage.
Most inner tubes for down-the-hole rock drills have a wear indicator that shows when it is
time for replacement. It can be seen and/or felt inside the bottom of the down-the-hole rock
drill when the drill bit is removed. Often, this is obvious when it becomes more difficult to
obtain the sample through the drill bit.
The service life for the down-the-hole rock drill's inner tube can vary greatly with a probable
average life of around 800 m, but in some abrasive rock types the service life can be as
low as 300 m.
Drill pipe
The drill pipes wear on the outside and need to be measured if you are worried about size.
The diameter is measured at the weld seam because this is the weakest point when it is
worn. For a drill pipe of 114.3 mm (4.5") the time for replacement is at a size of 109 mm. A
pipe of 101.6 mm (4") needs to be replaced at about 96 mm. Underdimensioned drill pipes
could fail which could lead to costly losses.
Drill pipes and inner tubes, as well as inner tubes for adapters, are wear parts. The degree
of wear depends largely on rock conditions.
The inner tube on top of the drill pipe is changed by removing the circlip. A damaged inner
tube results in considerable loss of pressure and is therefore easy to diagnose.
CAUTION
Risk of injury
A damaged inner tube causes a considerable increase in the wear of other parts. Stop
drilling immediately if you suspect a damaged inner tube.
208
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. DO NOT OVER LUBRICATE - Too
much lubrication can pressurise the seals and lead to heat development which damages
seals and bearings.
The normal service life of a seal can be up to 2000 hours, and the service life for shaft and
bearing may be many times this service life. However, seal replacement is unavoidable.
During dismantling, the lock nut (6), retaining washer (7) and holder washer (3) are re-
moved so that the shell (1) can be removed from the shaft (2). Check the seal's running
surfaces on the shaft. If it is very grooved then the shaft is replaced. Check the other parts
in terms of wear/damage and replace if necessary. Replace seals and assemble.
Some consider it necessary to tack weld the air swivel's shaft (2) onto the rotation unit's
shaft. If this is done then brazing lugs must be used on both shafts. The seam between
the shafts must not be welded.
CAUTION
Risk of injury
Tightening must be secure before tack welding.
209
Outlet swivel (with Metzke Blowdown Valve)
1 Metzke Blowdown Valve
2 Seal
3 Seal
4 O-ring
5 Seal
6 Hex head screw
7 Washer
8 Short adapter housing
9 Washer
10 Socket head cap screw
210
11 O-ring
12 Spindle adapter
13 Spindle DHR6RC
14 Circlip
15 Inner tube
16 Outer tube
17 O-ring
18 Hex head screw
19 Deflector 1
20 Deflector 2
Seal 5 on the outlet swivel requires regular lubrication. There is a grease nipple for this on
the adapter housing (8). Grease must be applied daily to this seal (5) via the grease
nipple.
Replace the seals when they start leaking. Leaking cutting seals can cause water and dirt
penetration in the rotation unit. The sealing sleeve around which the seals rotate may also
require replacing if rutted.
211
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). As
the service life varies greatly depending on rock conditions this block should be checked
every month or every 250 engine hours, until a replacement programme has been estab-
lished.
The second deflector (B) has a longer service life, but this also depends on rock condi-
tions.
The connection cover plate (C) becomes worn and is normally checked when replacing the
sample hose.
212
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.
The end of the sample hose needs to be replaced on occasion. The hose is often used un-
til it breaks, in which case it must be replaced immediately. The hose must have safety
sleeving fitted. When fitting a hose it is important to ensure that the clamps engage in the
retaining groove in the collar.
The sample hoses must have hose protection (sleeving) fitted on both ends of the hose in
the event of a functional breakdown. The hose protection must be attached with shackles
onto the attachment points on the hubs.
DANGER
Serious injury or death
Burst hoses can cause personal injuries.
Cyclone and splitter

The cyclone has replaceable wear plates inside the shell and inlet. These need to be mon-
itored and replaced when they are badly worn.
The cone splitter's knife valves have rope seals. If the sample begins to leak this seal can
be tightened until the leak stops. This is performed by tightening the 8 screws holding the
seal holder in place. This can be performed several times before the seal needs replacing.
Be careful not to tighten too hard as this could cause the knife blade to lock. The rope
seals must be replaced as necessary.
About inner tubes

All components from the rotation head shaft down contain an inner tube.
Along with deflectors the inner tubes are the components that wear the most. There are in-
ner tubes in the down-the-hole hammer, the drill pipes, the different adapters, the air swivel
as well as the shaft that runs through the rotation unit and rotation head. It is not possible
to measure the remaining service life of an inner tube, which often leads to the inner tubes
being used until they break. Apart from the tube in the rotation unit, a damaged inner tube
causes significant pressure loss and it is therefore easy to diagnose. This may lead to the
surrounding components being damaged, and at best lead to continued drilling not being
possible.
All inner tubes are replaceable and are removed through the top of the component by re-
moving the component from the drill string, removing the circlip and sliding the tube out.
The inner tube in the rotation head is hardened and is much thicker than other inner tubes
so it lasts longer, but visual inspection (with regard to wall thickness) is important when
possible (if the swivel is removed or if the seals in the rotation head are replaced).
The cost of a few inner tubes is often made worthwhile by the reduced downtime that the
replacement of all tubes can result in when one of them needs to be replaced.
213
All inner tubes are sealed with O-rings in order to separate the high-pressure air from re-
turn air. It is critical that these O-rings are in place and in good condition. When you access
them it is prudent to replace any O-rings whether or not they are worn.
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. We
recommend contacting an Atlas Copco service engineer before making any changes to the
rig.
Blow-up adapter
DANGER
Serious injury or death
There are blow-up adapters on the market that direct the compressed air upwards
through the deflectors and the sample hose to the cyclone. It is very easy to subject the
sample hose to damage, which may also cause injury if anyone is in the vicinity. Due to
this you are advised against using blow-up adapters.
14.3.5 Metzke Blowdown Valve

The Metzke Blowdown Valve directs the compressed air down through the inner tube and
so clears away any blockages and forces return air to the outside of the drill pipe.
WARNING
Serious injury
The blowdown valve works with air under high pressure. Air under high pressure is ex-
tremely dangerous.
u Remove or isolate the air or hydraulic inputs before service or maintenance.
u The valve has internal moving parts that can be dangerous due to pressure forces. Do
not position any part of the body or any objects in the valve ports during tramming.
A daily visual inspection should be carried out in order to check for abnormal wear, hy-
draulic leaks and damaged components. Replace parts when necessary.
The Metzke Blowdown Valve does not have any lubricating points.
The spool sleeve, upper and lower inserts, and seals will wear over time - this is normal.
With this in mind, regular inspections must be made through the top of the valve. It is es-
sential that these parts are replaced before being worn. Any further wear will cause consid-
erable damage to other components in the valve.
The hardened inserts have a goods thickness of 6 mm and an original inside diameter (ID)
of 50 mm. They should be replaced if the inside diameter exceeds 58-60 mm.
214
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. Inner pipes in bad condition can impact negatively on
test flow and cause extra wear to the blowdown valve.
There is an indicator hole in the cylinder housing. If oil or air starts to leak from this hole, it
means the cylinder rod seal is leaking and must be replaced.
CAUTION
Risk of injury
Serious damage or lethal injuries can occur if changes or repairs are performed on this
system by unauthorised persons.
u We recommend always getting in touch with a qualified service engineer before per-
forming any work on this system.
14.3.6 Fault finding in the event of air leakage

If the down-the-hole rock drill appears to be obtaining less pressure than expected, or if
there are difficulties with sample return, the most likely cause will be missing O-rings or
holes in an inner tube.
A circular cover plate is used during fault finding (test sub - check in spare parts list for cor-
rect part number) that blocks the flow of compressed air between the inner and outer tubes
so that compressed air is contained. Look in the spare parts list for the correct part num-
ber.
A drill rod or rotation head is screwed on by hand and the air is switched on. If air is flowing
from the centre of the cover plate then this indicates that O-rings are either missing or are
in poor condition, or that there is a hole in one of the inner tubes above the cover plate. If
the leaking air hisses out then the problem is probably missing O-rings, if the air is blowing
out then it is probably a hole in an inner tube.
By using the method of elimination, the adapter can be moved up or down on the drill string
in order to determine which component is generating the problem. As each step in the test
is taken, one component is removed and checked until you have found which one is de-
fective. The problem must be rectified, i.e. the part must be replaced or repaired, and a test
performed to confirm that this was the only problem. It is important not to assume that a
particular component is faultless - all must be tested in a logical sequence until the problem
is found.
14.3.7 Conversion to normal drilling

If there is a requirement to convert from RC drilling to normal drilling, there are several
ways to achieve this, each with a different scope:
n A normal down-the-hole rock drill is used on RC tubes together with an adapter for API
threads. A stop plug is also fitted in the inner tubes at the down-the-hole rock drill or at
the spar adapter in order to prevent air from flowing out through the inner tubes. This is
not an option in the long-term because the increased vibration tends to damage the in-
ner tubes.
n The inner tubes can be removed from the RC tubes. The deflectors and sample hoses
can also be removed. If the sample hose is removed then the deflectors must also be
removed and vice versa.
215
n 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.
This is a longer-term adaptation and is used if normal drilling is to be carried out over
several weeks or more.
14.4 Fire suppression system
14.4.1 Daily checks and maintenance

If there is a pressure gauge fitted, then check that the needle on the pressure meter for the
containers is within the green zone.
On semi-automatic fire fighting systems, check that the LEDs are working as specified
in the Operator's Manual. Perform a test - press the green test button (7) for at least 1
second. The diodes come on successively and conclude with an alarm test of signal and
lamp.
14.4.2 Annual maintenance

In many countries, insurance companies require proof that a qualified engineer has inspec-
ted and approved the fire fighting system annually. We recommend checking with your in-
surance company to find out if they have any requirements concerning this system.
14.4.3 Electric Welding, Steam Cleaning and High Pressure Cleaning
CAUTION
Risk of injury
The operator's panel on semi-automatic fire fighting systems must be disabled for the
following tasks:
u Electric welding, battery charging and start help. Harmful currents can damage the
electronics.
u Steam cleaning. The heat detectors are triggered at 120°C and could be activated by
the steam.
u High-pressure washing. Components or cables could be damaged by the jets and trig-
ger the system.
Once the semi-automatic fire fighting system is enabled again, make sure the LEDs and
the system work as specified in the Operator's Manual. Perform a test - press the green
test button on the operator's panel for at least 1 second. The diodes come on successively
and conclude with an alarm test of signal and lamp. A description of the operator's panel
can be found in the Operator's Manual
14.5 Service Winch
14.5.1 Cleaning
Always clean the winch after use.
216
14.5.2 Transmission
Check the oil level regularly. Replace the oil every 8000 engine hours.
Service winch, oil filling orifice
1 Oil drain plug
2 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. (2)
14.5.3 Disengagement device
Service Winch
1 Disengagement device
2 Oil filling orifice cover plate
3 Drum brake adjusting screw
Lubricate the disengagement device (1) every 1000th engine hour.
217
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

1. Undo the lock nut on the adjusting screw (3).
2. Rotate the brake nipple clockwise one quarter turn (3).
3. Tighten the locking nut.
Decrease braking force

1. Undo the lock nut on the adjusting screw (3).
2. Rotate the brake nipple anticlockwise one quarter turn (3).
3. Tighten the locking nut.
14.5.5 Cable
CAUTION
Risk of injury
Check the cable regularly. Do not use the winch if the cable is damaged.
218
14 Options
219
2015-12-17 | No: 713991051.3
www.atlascopco.com

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What maintenance is required for the winch?

SMARTROC D65 TIER 4 FINAL

Translation of the original instructions

3 Transport instructions........................................................................................ 33

4 Hardware RCS ..................................................................................................... 39

4.5.3 Pin configurations X8 - X9 ...................................................................................................... 48

5 RCS drilling system ............................................................................................ 49

6 Hydraulic systems ............................................................................................ 135

7 Feeder ................................................................................................................ 141

7.3 Climbing chain ....................................................................................................................... 143

8 Track frames...................................................................................................... 149

9 Dust collector (DCT) ......................................................................................... 155

11 Diesel engine ..................................................................................................... 161

12 Compressor and air system............................................................................. 171

12.3.4 Checking the oil level............................................................................................................ 175

13 Oil and fuel......................................................................................................... 183

14.4.1 Daily checks and maintenance............................................................................................. 216

2.1.2 Target group and objective

! NOTE: This chapter (General) contains general recommendations for maintenance of

2.1.3 Contact details

Country Address Phone and fax number

Argentina Estados Unidos 5335 Phone: +54 - (0) 3327 43 18 00

Australia P O Box 6134 Delivery Centre Phone: + 61 - (0)2 - 9621 9700

Austria Postfach 108 A-1111 Wien Phone: + 43- (0)1 -76 01 20

Country Address Phone and fax number

Brazil P O Box 1080 Barueri - SP Phone: + 55 - (0)11 - 41 96 87

Bulgaria 7, Iskarsko Shousse Blvd. Build- Phone: + 359 - (0) - 2 489 31 78

Canada 1025 Tristar Drive Mississauga Phone: + 1 - 289 - 673 67 11

Chile Panamericana Norte 5001 - Phone: + 56 - (0)2 - 442 36 00

China 1 No 2 HengTai Road Nanjing Phone: + 86 -(0) 25 - 85 75 75

China 2 No. 12 Kun Ming Hu Street Phone: + 86 -(0) 24 - 25 81 17

CMT International S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00

Colombia A.A. 95310 Santafé de Bogotá, Phone: +57 - (0)1 -419 92 00

Czech Republic Prumyslova 10 Praha 10, Post Phone: + 420 - (0)2 - 25 43 42

Egypt 520 El-Obour Market Cairo Phone: + 20 - (0)2 - 461 00 337

Finland Tuupakankuja 1 SF-01740 Phone: + 358 - (0)2 - 07 18 94

France BP 27055 Saint Ouen l'Aumône Phone: + 33 - (0)1 - 39 09 30 00

Country Address Phone and fax number

Cergy Pontoise Cedex

Germany Postfach 10 02 25 D-46002 Es- Phone: + 49 - (0)201 - 217 70

Ghana P O B 10071 Accra North Phone: + 233- (0) 302 77 45 12

Great Britain Swallowdale Lane Hemel Phone: + 44 - (0) 1442 - 26 12

Greece 93, Koropiou - Varis, Avenue Phone: + 30 - (0)210 - 349 96

Hong Kong P O Box 1516 Shatin Central Phone: + 852 - 27 97 66 00

India Sveanagar Bombay Pune Road Phone: + 91- (0)20 -39 85 24 15

Indonesia P O Box 7021/JKS CCE Jakarta Phone: + 62 - (0) 21 780 10 08

Iran PO Box 13145-1311 Tehran Phone: + 98 - (0) 21 -669 377

Ireland Kylemore Road Bluebell Dublin Phone: +353 - (0)1 - 450 59 78

Italy Casella Postale 77 IT-20092 Phone: + 39 - (0)2 - 61 79 91

Japan Sumitomo Fudosan Shipa Bldg Phone: + 81 - (0)3 - 57 65 78 07

Kazakhstan Floor 2, 8A Kurmangaliyev Phone: + 7 - (0)727 - 258 85 34

Kenya PO Box 400 90 - 00100 Nairobi Phone: + 254 - (0) 70 - 305

Country Address Phone and fax number

Korea 3rd Floor, Seowon Build- Phone: + 82 - (0)2 - 21 89 40 00

Malaysia 26, Jalan Anggerik Mokara Phone: + 60 - (0)3 - 5123 88 88

Mexico Apartado Postal Box 104 54000 Phone: + 52 - (0) 55 - 22 82 06