roc203ce operator instructions.pdf

55
Operator’s Instructions for Pneumatic Crawler Drills ROC 203PC No. AIB 181 00 10 ATLAS COPCO ROCK DRILLS AB REBRO l SWEDEN Ö Reg. code AIB ROC 203PC 2000-05 PM No. 9852 1453 01

Upload: gonzalo-hernandez-aguilar

Post on 25-Oct-2015

86 views

Category:

Documents


3 download

TRANSCRIPT

Page 1: ROC203CE Operator instructions.pdf

Operator’s InstructionsforPneumatic Crawler Drills

ROC 203PC

No. AIB 181 00 10

ATLAS COPCO ROCK DRILLS AB REBRO l SWEDENÖ

Reg. codeAIB ROC 203PC2000-05

PM No. 9852 1453 01

Page 2: ROC203CE Operator instructions.pdf

The owner of the equipment is granted permission to take copies of this publication solely for internal use, however, it is recommended to order further copies from the Atlas Copco representative in order to benefit from the latest revision.

Atlas Copco Rock Drills reserves the right to make changes in its product without notice in order to improve design or performance characteristics.

The information in this publication is assumed to be accurate at the time of publication, but is subject to change in order to remedy detected deficiencies or to follow changes in the product.

Any user of this publication is requested to inform Atlas Copco Rock Drills AB of deficiencies detected in this publication, particularly in product safety matters.

2

SAFETY INSTRUCTIONS

Before starting, read all instructions carefully.

Special attention must be paidto information alongsidethis symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

© Copyright 2005, Atlas Copco Rock Drills AB, SwedenAny unauthorized use or copying of the contents or any part thereof is prohibited.This applies in particular to trademarks, model denominations, part numbers and drawings.

Page 3: ROC203CE Operator instructions.pdf

Foreword

This instruction book is part of the complete delivery of the pneumatic crawler drills ROC 203PC .

It gives information on features and handling of the rig and contains advice and measures necessary to keep the rig operational.

This instruction book does not replace a thorough training on the rig.

The documentation is made up from the following:

Section 1

Operating safety

Section 2

Equipment description

Section 3

Operation

Section 4

Settings and maintenance by the operator

Section 5

Technical Data

This instruction book shall be read in advance by everyone who is tasked to operate the rig or carry out maintenance or repairs to it.

3

Page 4: ROC203CE Operator instructions.pdf

PageOperating safety 5

General safety advice 5Special safety advice 8Danger zone 9

Equipment description 10Features & Controls overview ROC 203PC-00 11Operating controls ROC 203PC-00 12

Hydraulic control panel 12Pneumatic control panel 13

Controls 14General air and oil flow controls 14Track oscillation shut-off valve 15Level indicator 15

Principal system functions 16Pneumatic system 16Hydraulic system 16

Operation 17Daily checks 17

Extra safety check 18Topping-up liquids 20Connecting air supply 21Functional checks 22

Manoeuvring 25Tramming 25

Towing 27

Hoisting 31

Drilling 32Set-up for drilling 32Collaring & drilling down the first rod 34Adding rods 36Withdrawing the drill string 38When the drillstring gets stuck during withdrawing 42Reconnection of the boom swing cylinder 43

Settings and maintenance by the operator 45Replacing the oil filter cartridge 45Cleaning the strainer 46Tensioning the crawler tracks 46Setting the lubricating valves 47

Technical data 48Masses 48Performance 48Hydraulic system 48Component specifications 49Recommended hydraulic oils and lubricants 51Volumes 51Tightening torques 51Transport dimensions 52Coverage areas 53

Annex: Documentation Feedback form 56

Table of contents

!

4

Page 5: ROC203CE Operator instructions.pdf

Dear Operator,like driving a car, drilling bears hazards to you and your environment. Good training, discipline and well maintained equipment are the keys to safe operation. This instruction book is no replacement for a thorough training on the rig, but as a training aid and a reference book it shall help you to maintain a safe working environment and the operability of your rig.

Yours faithfullyAtlas Copco Rock Drills AB

General safety advice

Operating safety

Intended use:

The pneumatic drill rig ROC 203PC is solely designed for drilling holes in surface

working,

i.e. usually quarries, opencast mines and construction engineering.

Any use going beyond this shall be considered not to be intended use.

Not-intended use is e.g.:

- Lifting and transport of loads

- Lifting and transport of personnel

- Stabilization of other equipment

The manufacturer is not liable for damage incurred as a result; this shall be at the

owner’s risk. Proper use also includes observation of operating, servicing and

maintenance instructions stipulated by the manufacturer.

The ROC 203PC may only be operated, serviced and repaired by personnel familiar with

it and informed of the dangers.

Relevant accident prevention regulations as well as other generally recognized safety,

occupational medicine and traffic regulations must be observed.

The manufacturer is not liable for any damage caused by unauthorized alterations made

to the crawler drill.

Organizational measures:

1. The pneumatic drill rig ROC 203PC shall be operated only by personnel, which has

been given a practical training on the rig. Particular emphasis shall be laid on safety

precautions.

2. Keep this instruction book as well as the other instructions books listed in the chapter,

"Separate Instruction Books“ on the rig at any time.

5

Page 6: ROC203CE Operator instructions.pdf

3. As far as necessary or required by regulations use personal protective equipment.

4. In case of possibly safety relevant changes of the rig or its operational behavior

immediately shut down the rig and investigate the problem (seek advice from your Atlas Copco representative if necessary).

5. Keep the warning plates attached to the rig complete and legible.

6. Have the daily safety check carried out as described in this instruction and follow the maintenance measures as described in the service schedule.

7. Works to the hydraulic system shall be carried out only by personnel with particular skills and experience.

8. Any welding shall be carried out only by an authorised welder qualified acc. to EN 287 part 1 or equivalent.

9. Following repair, the rig shall be inspected and approved by the proper authorities before being put back into normal service.

10. Never carry out alterations or modifications to the rig, which might affect the operating safety, without full approval of the manufacturer.

11. The sound power level at the operator’s place are 126 dB(A).

Operation and maintenance:

1. Apart from this instruction book also follow the generally recognized safety and accident prevention regulations.

2. Prior to starting-up get familiar with the rig’s features, controls and their functions. This instruction as well as the others listed on page 3 will help you.

3. Make sure the required maintenance measures acc. to the service schedule have been carried out and carry out the ,,Daily checks“ prior to each shift. Never operate the rig when its safety is doubtful.

4. Always wear a hard hat, ear mufflers and well-fit clothes. Wear protective gloves when you handle drill rods, couplings can be hot. Wear a breathing mask during drilling (rock drill exhaust air contains oil spray).

5. Check the vicinity of the drill rig. During drilling and travelling there should be no unauthorized personnel around. At critical locations, however, like close to unsecured benches, a supervisor should be present. Care for sufficient sight. Check the travel path if necessary.

6. Prior to pressurizing put all levers and switches to NEUTRAL.

7. Never leave the rig unobserved during drilling.

8. Be careful when you handle hydraulic oils (avoid contact with skin and eyes).

9. Always shut down the rig and depressurize the air system before you carry out any disconnection work to the pneumatic or hydraulic system.

10. Be extremely careful searching leakages in the pneumatic or hydraulic system. Highly pressurized liquids (like hydraulic oil) or pressurized air could penetrate clothes and skin and cause heavy injuries or infections. In case of such accidents always look for a doctor immediately.

11. Dispose oils and filters environmentally.

12. Avoid the employment of cleaning agents containing solvents (e.g. carbon tetrachloride). There are alternatives available being much less dangerous to health and environment.

13. Spare parts shall at least comply with the standards as stipulated by the end manufacturer.

14. Operate the rig in daylight only.

This is guaranteed e.g. by the employment of genuine Atlas Copco parts.

6

Page 7: ROC203CE Operator instructions.pdf

Frequently encountered safety risks

1. During transportation and particularly during hoisting there is an increased hazard of overturning. During hoisting the Track oscillation shut-off valve must be in position BOTH CYLINDERS CLOSED.

2. The rig could tip over during tramming in extreme terrain. In order to avoid overturning during tramming:

- Keep Track oscillation shut-off valve in position BOTH CYLINDERS OPEN

- Lay down feed resp. to provide an optimum center of gravity

- Max. inclination in tramming direction: ± 20° solo machine (feed laid down)

- Max. lateral inclination: ± 20° solo machine (feed laid down)

- Operate the rig from the uphill side

3. The rig could tip during drilling in extreme positions. In order to avoid tipping during drilling:

- Keep Track oscillation shut-off valve in position BOTH CYLINDERS CLOSED

- Max. inclination in tramming direction: ± 20°

- Max. lateral inclination : ± 20°

- Operate the rig from the uphill side

4. When the drill string gets stuck never grip the drill steel nor apply a spanner or similar tool while the rotation motor is under pressure. The drill steel could suddenly break free and squeeze the arm resp. toss about or fling the tool all of which could lead to severe injury or death.

5. Before maintenance depressurize the rig.

7

Page 8: ROC203CE Operator instructions.pdf

Special Safety advice:

On the rig or in this instruction book you may find the following signs:

DANGER This indicates immediate hazards, which WILL lead to serious personal injury or death.

WARNING This sign indicates hazards or unsafe practices, which COULD lead to serious personal injury or death.

CAUTION This sign indicates hazards or unsafe practices, which

could lead to minor personal injury or damage to property.

NOTE This sign indicates advice for the efficient, economic andenvironmentally compliant use of the rig.

... and last but not least a request:We spent a lot of care to create this instruction book. Still it might happen that you find adescription inadequate or insufficient, or a safety hazard not or insufficiently referred to.In such case please take a copy of the reporting form at the end of this book, fill it in and send it to the address specified on the form.Please let us participate in your experience, so you can participate in other people’s experience!

Read the instruction manual before starting the rig.Incorrect handling of the machine can incur the risk of injury to personel and damage to equipment.

To avoid serious injury or damage to equipment, learn the meanings of the various warning signs and follow the instructions carefully.

Danger - slewing or clamping components.

Can cause serious injury to personel.

Do not trespass into danger zones during operation.

8

Page 9: ROC203CE Operator instructions.pdf

9

Danger Zone Any zone within and / or around the drill rig in which a person is exposed to risk of injury

or damage to health.

7m

7m

7m

Bench drilling

Tramming

7m7m

2m

2m

Working area

The area near the drill rig in which its tools are moved in order to carry out work.

Page 10: ROC203CE Operator instructions.pdf

AT

CP

CO

LA

S

OA

TC

PC

OL

AS

O

1 1 0 00 09 76 11 1 0 00 09 76 1

176 11 3 2009 176 11 3 2009

xMa .xMa .

.xMa .xMa

09 676 11 3 0009 676 11 3 00

Equipment description

12

8

6

7

17

14

9

10

11

54 13

3

2

15

1

16

10

Page 11: ROC203CE Operator instructions.pdf

Features & Control overviewROC 203PC

1 Air inlet ( pages 14 & 21)

2 Main valve ( page 14)

3 Dirt filter

4 Hydraulic tank ( page 14, 45 & 46)

5 Hydraulic traction unit ( page 28)

6 Track oscillation valve ( page 15)

7 Hydraulic control panel ( page 12)

8 Pneumatic control panel ( page 13)

9 Chain feed BMM 35K

10 BBR 4 Rotation Unit - Down - The - Hole (DTH)

or

BBC 120F Drifter for Top Hammer (TH)

11 Feed gear and -motor

12 Boom

13 Traction motor valve ( page 14)

14 Dust collector DCT-60E *

15 Extra air outlet ( page 14)

16 Tow hook ( page 29)

17 De-clutching lever

* optional

11

Page 12: ROC203CE Operator instructions.pdf

Hydraulic control panel

1 Feed extension

a) UP

b) NEUTRAL

c) DOWN

2 Feed swing

a) CLOCKWISE (view from rear)

b) NEUTRAL

c) ANTI-CLOCKWISE (view from rear)

3 Feed dump

a) SPIKE FORWARDS

b) NEUTRAL

c) SPIKE BACKWARDS

4 Boom lift

a) UP

b) NEUTRAL

c) DOWN

5 Boom swing

a) LEFT

b) NEUTRAL

c) RIGHT

6 Track oscillation

a) REAR EDGE OF PLATFORM RISES

b) NEUTRAL

c) REAR EDGE OF -PLATFORM LOWERS

7 Left track

a) FORWARD

b) NEUTRAL

c) BACKWARD

8 Right track

a) FORWARD

b) NEUTRAL

c) BACKWARD

* optional

Operating controlsROC 203PC

7 01 6 0 1 09 0 1

111 2 3 4 5 6

a

b

c

a

b

c

a

b

10

9

7 8

12

12

Page 13: ROC203CE Operator instructions.pdf

9 De-clutching left

a) ON

b) OFF

10 De-clutching right

a) ON

b) OFF

11 Signal Horn

12 Button Emergency stop

closes the valve 'air supply'

(disengage before restart)

Pneumatic control panel20 DCT (Dust collector) *

a) CLEANING

b) OFF

c) ON

21 Set screw Feed pressure

- REDUCE (anti-clockwise)

+ INCREASE (clockwise)

22 Gauge Feed pressure

23 Feed speed

a) RAPID FEED ON

b) RAPID FEED OFF

24 Feed (speed and direction)

a) REVERSE FEED

/ RAPID REVERSE FEED**

b) NEUTRAL

c) DRILL FEED / RAPID FEED**

25 Rotation (speed and direction)

a) REVERSE

b) NEUTRAL

c) DRILL ROTATION

26 Impact / Flushing (DTH)

a) NEUTRAL

b) MAX. IMPACT / FLUSHING

27 Flushing air (TH)

a) NEUTRAL

b) MAX. FLUSHING AIR

28 Button emergency stop

Closes the valve 'air supply'

(disengage before restart)

* optional

** this function is possible when lever 23 is ON

0 7 9 1 061 0 1 0

1 2 3 4 5 6

a

b

c

a

b

c

a

b

10

9

7 8

23 22

26

27

25

24

a

b

c

a

b

a

b

- +21

a

b

20

13

cba

1112

28

Page 14: ROC203CE Operator instructions.pdf

Controls

General air and oil flow controls

1 Air inlet

2 Main air valve

Pneumatically operated

3 Lubrication valve (rock drill)

See chapter

"Settings and maintenance by the operator"

4 Tramming valve

a) CLOSED

b) OPEN

5 Pressure regulating valve

(pump motor, rock drill, flushing air T.H.)

INCREASE (clockwise)

DECREASE (anti-clockwise)

6 Lubrication valve

(rock drill, tramming motor, extra air outlet)

See chapter

"Settings and maintenance by the operator"

7 Extra air outlet

a) CLOSED

b) OPEN

8 Gauge Hydraulic oil return filter pressure

Too high pressure (needle in red field)

indicates that filter cartridge requires

replacement

9 Level glass Hydraulic oil level

Level shall be between max. and min. markings

3

2

1

9

8

5

7b

7a

6

4b

4a

14

Page 15: ROC203CE Operator instructions.pdf

Track oscillation shut-off valve

1 LEFT CYLINDER2 RIGHT CYLINDER

a) OPEN both cylinders OPEN (to be used for tramming)b) CLOSEDboth cylinders CLOSED (to be used when rig is set up for drilling or lifting and transport condition

Gradient meter

Indicates angles for safe operation of the drill rig, specified in the Technical data. The rig might tip over the angles specified.

1a

b

a

b

2

15

5

1234

0 1 2 3 4 5

00010 020 030

030

010

020

5

1234

0 1 2 3 4 5

0

0

0

10

0

20

0

30

0

30

0

100

20

Page 16: ROC203CE Operator instructions.pdf

Hydraulic system

Positioning

cylinders:

- feed extension

- feed swing

- feed dump

- boom lift

- boom swing

Principal system functions

Pneumatic system

hyd. pump

feedmotor

rock drill

feedcontrol

rotationcontrol

impactcontrol

flushingcontrol

air motor

DCT*

lubricationvalve

lubricatingoil

tank

lubricationvalve

dusttrap

mainvalve

inlet

*optional

extraair outlet

track oscillationshut-off valve

track oscillation cylinders

positioning control

hydraulic oil tank

air motor

returnoil filter

hydraulic pump

left trackcontrol

right trackcontrol

Emergencystop

Emergencystop

16

Page 17: ROC203CE Operator instructions.pdf

Operation

Daily checks

Carry out

"Daily checks"

Prior to each shift !

For inspection/maintenance every 40, 125, 500 and 1500 hours of operation

follow separate instruction:

Service Schedule for

Pneumatic Crawler Drills

ROC 203PC

Printed matter no. ASB 181 00 10

!

17

Page 18: ROC203CE Operator instructions.pdf

! Extra safety check

TS

CP

OL

A

OC

A

12*

10*

131

15

5

6

2

11*

9

8

7

3

14

4

18

Page 19: ROC203CE Operator instructions.pdf

Before each shift commences,

an extra and thorough safety check

shall be carried out, intended to

detect:

l cracks or fractures in materials or

at welded points.

l damage, which could cause

structural weakness or fracture,

l wear, with the risk of the same

consequences,

l loose junctions,

loose threaded unions.

If the crawler has been subjected to

abnormally high stress, then vital

load-bearing components may have

become damaged in the process.

From the safety aspects therefore, the

following check points are particularly

important (see illustration on opposite page):

1. Tow hook

2. Chain tensioner

3. Track frame attachment

4. Boom support

5. Boom

6. Boom head

7. Drill steel support

8. Feed gear (*)

9. Feed holder with attachment

10. Feed beam *

11. Rock drill and cradle *

12. Feed chain with attachments *

For readjustment of chain slack see

"Service schedule for Pneumatic Crawler Drills

ROC 203PC

Printed matter no. ASB 182 00 10

13. Cylinder brackets

14. ‘S’ link

15. Bellow housing

In case checkpoints are not accessible(upright feed), carry out these checks afterconnection of air supply

*

19

Page 20: ROC203CE Operator instructions.pdf

1 Emergency stop switch

(on both control panel) to

PUSH MODE +

SYSTEM DEPRESSURIZATION

3 Hydraulic oil tank:

Check level (a),

refill if necessary (b)

Recommended oils and

lubricants see page 51.

4 Lubricating oil tank:

Top-up with air tool oil

Recommended oils and

lubricants see page 51.

3a

3b

AIR E E VC I ER

Rp

0

y0

2

0e 9 0 9 0

9 4

T

r a oS i e l N .

l 1

V m Io e . 2

u

pe

. o k g b r

xn

2

wr ( )

Mar . a

0

i

r 2

t r ss( )

s a

p e r e 6

eu e b

T

or

.Wo mp

0

k t2

ec 1 Fd n

Ma ie

i

d y A . d

M b . I

a eC n a

5 33 1

04 1 0

2 7

20

WARNING

Hazardous air pressure

Can cause severe injury

l Release pressure in tank

before removing any plug

Topping-up liquids

Page 21: ROC203CE Operator instructions.pdf

Connecting air supply

1 Wire mesh hose, chain, attachment:Check for attachment and damage

CAUTION

Always secure air hose with wire mesh hose

2 Air hose:Route air hose through wire mesh hose andconnect it to the air inlet

3 Compressor:Switch on compressor

4 Emergency stop switch(On both control panel) to position

RELEASE MODE

5 Air valve to position OPEN

6 Gauge Return oil filter pressureIf needle is in the red area, replace returnoil filter according to instructions on page 45

2

3

4

1

6

5

45

21

Page 22: ROC203CE Operator instructions.pdf

Functional checks

2

1

3

22

Page 23: ROC203CE Operator instructions.pdf

1 Operating controlsCheck function and for leakages

2 Rock drill cradleCheck for frictionless travel without excessivewear between the beam and the cradle(both when drill feeding and rapid feeding)

3 Traction unitsCheck for leakage

4 Hoses, pipes and couplings in theair systemCheck for leakage and damage

5 Hoses, pipes and couplings in thehydraulic systemCheck for leakage and damage

6 Hydraulic cylinders anddouble check valves

Check for damage, leakage anddouble check valve function (no creeping)

4

5

6

22

23

Functional ckecks

NOTE

The emergency stops (all) have to be checked before each shift and after each tramming

Emergency stops (all)

Check that each emergency stop individually closes the inlet valve. All the rig function will then stop. Before checking the next emergency stop the previous emergency stop must be in released mode before restart.

WARNING

Never operate a defective drill rig

Can cause severe injury and property

l Close the air main valve if the drill rig

has failed one or more checkpoints

Page 24: ROC203CE Operator instructions.pdf

8 Lubricating valve(s):Check that the exhaust air from the rock drillcontains oil (both rotation and impact)

For setting lubricating valves,see page 47

WARNING

Never operate a defective drill rig

10 Call service mechanic if the drill rig has failedone or more checkpoints

8

24

47

7 DCT hose and skirtsCheck for attachment and leakage

7

Page 25: ROC203CE Operator instructions.pdf

Manoeuvring

Tramming

25

1 Emergency stop switch(on both control panel) to RELEASE MODE

WARNING

Tip over hazard

Can cause severe injury and property damage

l Keep feed in tramming

position and boom inside

the track limits

l Keep oscillation cylinders

open

l Do not exceed the 0gradient of 20 lateral

0and 20 uphill or downhill

in direction of tramming

l Keep the air bubble

inside the limit for

tramming

l Operate the drill rig from

the uphill side

WARNING

Tip over hazard

Can cause severe injury and property

damage

l Keep unauthorized

persons out of

working area

NOTE

The emergency stops (all) have to be checked

after each tramming (see 21)

Page 26: ROC203CE Operator instructions.pdf

2 Air valve to position OPEN

CAUTION

Fully lay down the feed beam beneath the hydraulic tank resp. if

- tramming takes places over a longerdistance (in order to reduce the loadsonto the boom system)

- difficult terrain has to be passed(in order to the optimize stability/balance)

3 Lift feed

5 Track oscillation shut-off valve toBOTH CYLINDERS OPEN

26

Page 27: ROC203CE Operator instructions.pdf

6 Levers Left track (a) and Right track (b) toappropriate position

7 When travelling is terminated:Air valve to positionCLOSED

09 6 71 01 10 0

0 19 3 16 01 7 2

ax.M

ax.M

61 7 00 19 3 60

7

WARNING

Electrical hazard

Can cause severe injury and property damage

l Keep distance from

power lines

27

Page 28: ROC203CE Operator instructions.pdf

WARNING

Hazardous rolling motions Can cause severe injury and property damage

l Place wedge blocks underneath both tracks, before de-clutching

1 Place Wedges or wooden blocks in front andbehind both tracks

2 Emergency stop switch(on both control panel) to RELEASE MODE

3 Air valve to position

OPEN

4 Left track control to positionFORWARD(hold till de-clutching lever operation complete)

5 Left de-clutching lever to position OFF

216 10 97 310 6 10 3 9 071 06

54

2

28

Towing

Page 29: ROC203CE Operator instructions.pdf

6 Right track control to positionFORWARD(hold till de-clutching lever operation)

7 Right de-clutching lever to position OFF

8 Track oscillation shut-off valve toBOTH CYLINDERS OPEN

9 Connect Tow bar between drill rig and towing vehicle

10 Remove Wedges

11 Start towing, max towing speed 5 km/h (3 miles/h)

12 When towing is terminated:Place Wedges or wooden blocks in front and behind both tracks

max. 5km/h (3 miles/h)

01 12 06 91 73 60 0691 73 10

67

29

Page 30: ROC203CE Operator instructions.pdf

13 Disconnect Tow bar

14 Left & Right de-clutching lever to position ON

21107391 06 061079 3 106

1414

30

Page 31: ROC203CE Operator instructions.pdf

4 Before starting to hoist, check carefully thatnone of the hoses, controls or othercomponents can get caught up or damagedwhen the slings become tightened and underload

WARNING

Always make sure that nobody is anywhere near a suspended load

Hoisting

1 Position the boom system so that the crawleris as compact as possible. This will obtain thebest possible point of balance and centre ofgravity

2 Position a sling under the rear edge of thefront wheels, and another sling under the frontedge of the rear wheels

The sling must be dimensioned for lifting6 tons with a good safety margin

ROC 203 PC

WARNING

Suspended load

Can cause severe injury and property

damage

l Keep away from a

suspended load

l Use only lifting device

and cargo sling with

sufficient hoisting

capacity

WARNING

Tip over hazard

Can cause severe injury

and property damage

l Lock oscillation

cylinders when the

drill rig is being

hoisted

3 Ensure that rig is not in declutching mode

31

Page 32: ROC203CE Operator instructions.pdf

Drilling

Set-up for drilling

1 Emergency stop switch (on both control panel ) to positionRELEASED MODE

2 Lever Feed speed to RAPID FEED ON

3 Run-up the rockdrill

4 Insert a drillrod

5 Mount a drillbit

6 Position the feed

7 Track oscillation shut-off valve toBOTH CYLINDERS CLOSED

2

WARNING

Hazardous moving and rotating parts

Can cause severe injury

l Keep unauthorized

persons out of

working area

l Stay away from the rotating drill string

32

Page 33: ROC203CE Operator instructions.pdf

CAUTION

Use Boom lift to lift the tracksUsing Feed extension puts excessive loadonto the boom head

8 Achieve a stable 3-point set-upLever Boom lift (a) to DOWN

9 Lever Feed speed to RAPID FEED OFF

8

9

33

Page 34: ROC203CE Operator instructions.pdf

Collaring & drilling downthe first rod

a) Lever Rotation to DRILLROTATION

b) Lever Impact / Flushing air to MAX. FLUSHING AIR (for DTH)or

c) Lever Flushing Air to max Flushing Air (for TH)

d) Switch DCT* to ON

2 Lever Feed to DRILLFEED

3 When the bit reaches the ground:Lever Impact to REDUCED IMPACT

4 When solid rock is reached (min. 20 cm / 8"):Lever Impact to FULL IMPACT

* optional

b

c

a

d

34

Page 35: ROC203CE Operator instructions.pdf

5 Adjust Feed pressure in order to obtain theoptimum rotation torque:

Feed pressure too low:- metallic noise from couplings- couplings heat up(and suffer increased wear)- energy is lost- excessive shank adapter and threads wear

Feed pressure too high:- hole deviation- threads get too tight- drill bit wear

6 When coupling is ~ 25 cm (10") above drillsteel support:Open Drill steel support halves

7 Lever Rotation to NEUTRALLever Feed to REDUCED DRILL FEED

8 When the couplings create a metallic noise:All levers to NEUTRAL

9 Switch DCT * to CLEANING

* optional

35

Page 36: ROC203CE Operator instructions.pdf

Adding rods

1 Lever Rotation to REVERSE Shank adapter / adapter rotates out of coupling

2 Lever Rotation to NEUTRAL

3 Lever Feed speed to RAPID FEED ON

4 Lever Feed to REVERSE FEED until rock drillreaches the stop

5 Lever Feed speed to RAPID FEED OFF

6 Insert another rod

36

Page 37: ROC203CE Operator instructions.pdf

7 In order to couple shank adapter to new rodand new rod to old rod:Lever Rotation to SLOW DRILL ROTATIONLever Feed to DRILLFEED

8 Lever Flushing to MAX. FLUSHING AIRa) for THb) for DTHLever Rotation to DRILL ROTATIONLever Impact to REDUCED IMPACTSwitch DCT * to ON

9 When the coupling has passed thedrill steel support:

Close Drill steel support halves

10 Lever Impact to FULL IMPACT

11 Adjust Feed pressure in order to obtain theoptimum rotation torque (see page 35)

* optional

37

Page 38: ROC203CE Operator instructions.pdf

Withdrawing the drill string

1 Lever Rotation to NEUTRALLever Feed to REDUCED DRILL FEED

2 In order to loosen the couplings:Keep lever Impact in FULL IMPACT foranother 3 - 6 sec

3 Lever Impact to NEUTRALLever Feed to NEUTRALKeep switch DCT * in ONlever Flushing air in MAX .FLUSHING AIRa) for THb) for DTH

4 Lever Feed speed to RAPID FEED ON

5 Lever Feed to RAPID REVERSE FEEDuntil the coupling has passed thedrill steel support

* optional

... 3 - 6 sec:

b

a

38

Page 39: ROC203CE Operator instructions.pdf

6 Lever Feed to NEUTRAL

7 Make sure that the drill steel support halvesare closed

8 Lever Flushing to NEUTRALa) for THa) for DTH

Switch DCT * to CLEANING for approx. 20 sec

9 Switch DCT * to OFF

10 In order to separate the shank adapter fromthe drill string:

Lever Rotation to REVERSE until the shankadapter has rotated out of the coupling

* optional

a

b

... 20 sec:

39

Page 40: ROC203CE Operator instructions.pdf

11 Lever Rotation to NEUTRAL

12 In order to raise the rock drill a few centimeters:Lever Feed to RAPID REVERSE

13 Lever Feed to NEUTRAL

14 Rotate top rod out of coupling by hand

15 Put the rod on a suitable place

40

Page 41: ROC203CE Operator instructions.pdf

16 Lever Feed to RAPID FEEDuntil the shank adapterreaches the coupling

17 Lever Feed to NEUTRALLever Rotation to DRILLROTATIONuntil the shank adapter has safelygripped the drill stringDo not tighten the thread !

18 Lever Feed to RAPID REVERSE FEED

19 Lever Feed to NEUTRAL

20 Continue with step 10 until there is only one rodleft in the drill string

21 Check the drill bitReplace resp. grind if required

39

41

Page 42: ROC203CE Operator instructions.pdf

When the drill string gets stuckduring withdrawing ...

NOTE

For TH / DTH you maytry with flushing air alone for the start

1 Lever Rotation to DRILLROTATIONand Lever Flushing air toMAX. FLUSHING AIRa) for THa) for DTH

If this tightens the couplings too much:

- Arrest coupling on drill steel support

2 Lever Feed speed to RAPID FEED OFF

3 For a few seconds:Lever Feed to REDUCED FEED PRESSURELever Impact to REDUCED IMPACT

4 Lever Feed to NEUTRALLever Impact to NEUTRAL

ba

42

Page 43: ROC203CE Operator instructions.pdf

Reconnection of the feed swing cylinder

To simplify certain types of drilling work, it ispossible to reconnect the feed swing cylinder sothat the boom system can operate outside theconfines of the track frames

CAUTION

Operating the feed within sector 2 causesreduced stability of the crawler. Strictly followthe procedures given below in order to prevent accidents

1 Emergency stop switch(on both control panel) to RELEASE MODE

2 Air valve to position OPEN

3 Position the feed beam horizontally above the control panel

1

2

43

Page 44: ROC203CE Operator instructions.pdf

4 Track oscillation shut-off valve toBOTH CYLINDERS CLOSED

5 Remove

a) Screws

b) Lock Plate

c) Pin

6 Make sure the other reception hole is free from dirt and corrosion

7) Match (align) the cylinder rod end eye to another eye of boom head by:

a) operating feed swing cylinder &

b) Rotate the feed slowly by hand

CAUTION

During the rotating the feed beam take care it should not collide on DCT.

8 Tap the cylinder pin (8a) in position & tighten with screws (8b) on lock plate (8c)

7b

7a

8a

a

bc6

8b

8c

44

Page 45: ROC203CE Operator instructions.pdf

Settings andmaintenanceby the operator

Replacing the oilfilter cartridge

When the needle of return oil pressure gauge is inthe red field, the filter cartridge needs to bereplaced

1 Emergency stop switch(on both control panel) toPUSH MODE SYSTEM DEPRESSURIZATION

2 In order to release residual pressure in the hydraulic system:Operate a Track control (or any of the positioning controls)

3 Clean the filter cap

4 a) Remove the filter cap screwsb) Remove the filter cap

5 Remove the old filter cartridge

6 Insert a new filter cartridge

7 Mount the filter cap

4a

4b

45

Page 46: ROC203CE Operator instructions.pdf

Cleaning the strainer

1 Emergency stop switch(on both control panel) to positionPUSH MODE SYSTEM DEPRESSURIZATION

2 Drain the oil by removing the drain plug

4 Remove return line filter assemblyby removing screws

5 Remove strainer

6 Clean up the strainer

7 Assemble strainer, return line filter assly., drain plug

2

6

5

Tensioning the crawler tracks

1 Make sure the crawler drill is standing onmore or less horizontal ground

2 Place a wooden plank on the crawler trackCheck that the slack is between 25 - 50 mm

4 If the slack exceeds 50 mm, press in greasethrough the nipple

A = 25 - 50 mm !

A > 50 mm ?

4

46

Page 47: ROC203CE Operator instructions.pdf

Setting the lubricating valves

1 Undo the wing nut

2 Increase (+) or decrease (-) the oil dosage byturning the adjustment screw

3 Tighten the wing nut

47

Page 48: ROC203CE Operator instructions.pdf

Technical data *Masses

ROC 203 PC-00 2500 kg 5520 lbs

Optional Equipment

Dust collector DCT 60-E 85 kg 187 lbs

Assembly kit DCT 110 kg 242 lbs

PerformanceMax. travel speeds (w/o compressor on level ground) 2.5 km/h 1.55 miles/h

Max. towing speed 5 km/h 3.1 miles/h

Tractive force 18.8 kN 4225 lbf

Tramming (w/o compressor) 20° 20°

Tramming with compressor (max. 3500kg.) 15° 15°

Max. longitudinal inclination for drilling 20° 20°

Max. lateral inclination

Tramming 20° 20°

Drilling 15° 15°

Drilling with reconnected feed swing cylinder 10° 10°2Average ground pressure 0.04 N/mm 5.8 psi

Ground clearance 295 mm 11.63"

Track oscillation ± 12° ± 12°

Max. ambient temperature 45°C 113°F

Max. operating air pressure 12 bar 171.5 psi

Sound level 126 dB(A) 126dB(A)

Hydraulic systemMax. operating pressure 210 bar 3045 psi

Air motor

Type Piston motor

Performance max. 7.5 kW (at 6 bar) 10 hp

Torque max. 69 Nm 51 lbf.ft.

Rotation speed max. 1100 rpm 1100 rpm

Pump

Type Gear pump

Pressure max. max. 210 bar 3000 psi

Traction motor

Type Gerotor motor

Displacement per revolution 160cc

Filter (Filtration degree) 25 µm nominal 25 µm nominal

* Specifications are subject to change without prior notice

48

Page 49: ROC203CE Operator instructions.pdf

Component specifications

Pneumatic chain feed Top Hammer

1) BMM 35K 157-00 (Single start)

Mass excl. rock drill 300 kg 661 lbs

Total length 5430 mm 17" 9.8"

Travel length 3940 mm 12’ 11"

Travel speed max. 0.3 m/s 11.8"/s

Feed force max. 8 kN 1800lbf

Air consumption during drilling max. 9 l/s 19 cfm

2) BMM 35K 859-00 (Five start)

Mass excl. rock drill 300 kg 661 lbs

Total length 5430 mm 17" 9.8"

Travel length 3940 mm 12’ 11"

Travel speed max. 0.3 m/s 11.8"/s

Feed force max. 12 kN 2700 lbf

Air consumption during drilling max. 9 l/s 19 cfm

Pneumatic chain feed Down-The-Hole

1) BMM 35K 257-01 (Single start)

Mass excl. rotation unit 295 kg 650 lbs

Total length 5430 mm 17' 9.8"

Travel length 4009 mm 13’ 1.8"

Travel speed max. 0.3 m/s 11.8" / s

Feed force max. 8 kN 1800 lbf

Air consumption during drilling max. at 6 bar 9 l/s 19 cfm

2) BMM 35K 859-01 (Five start)

Mass excl. rotation unit 295 kg 650 lbs

Total length 5430mm 17' 9.8"

Travel length 4009 mm 13’ 1.8"

Travel speed max. 0.3 m/s 11.8" / s

Feed force max. 12 kN 2700 lbf

Air consumption during drilling max. at 6 bar 9 l/s 19 cfm

49

Page 50: ROC203CE Operator instructions.pdf

Pneumatic rock drill BBC 120 (TH)

Hole Dia 48-76 mm 2"-3"

Weight 69 kg. 152 lbs

Length 780 mm 2' 6.7"

Piston Dia 120 mm 4.72"

Stroke 65 mm 2.56"

Impact rate at 6 bar 2100 blows / min 2100 blows / min

Rotation speed 180 rpm 180 rpm

Air Consumption at 6 bar 212 l/s 448 cfm

Flushing:

Water 58 l/min. 263.6 lmp.gal/min

15.3 US gal/min

Air 45 l/min. 204.5 lmp.gal/min

11.9 US gal/min

Hose connections:

Impact mechanism 38 mm 1 1/2"

Rotation 10 mm 3/8"

Flushing water 19 mm 3/4"

Rotation unit BBR4 (DTH)

Weight 83 kg 183 lbs

Length 850 mm 2' 9.5"

Torque max. at 6 bar 900 Nm 662 lbs.ft.

Spindle speed range 0 to 70 rpm. 0 to 70 rpm.

Down The Hole Hammer COP 42

External diameter 96 mm 3.7"

Length without drill bit 960 mm 3’ 2"

Mass without drill bit 35 kg. 77 lbs

Working pressure max. 6-25 bar 85.7 psi

Hole size range 105-127 mm 4"-5"

Connecting threading size (male) - 2 3/8" API Reg.

Down The Hole Hammer COP 44

External diameter 98 mm 3.85"

Length w/o drill bit 1036 mm 3' 4.8"

Mass w/o drill bit 38 kg. 83.6 lbs

Working pressure max. 6 - 25 bar 85- 365 psi

Hole size range 110 - 130 mm 4.3"- 5.1'

Connecting threading size (male) - 2 3/8" API Reg.

50

Page 51: ROC203CE Operator instructions.pdf

Volumes

Lubricating oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 l 2.69 Imp.gal 3.17 US.gal

Hydraulic oil system, total . . . . . . . . . . . . . . . . . . . . . . 85 l 18.7 Imp.gal 22.5 US.gal

Hydraulic oil tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 l 18 Imp.gal 21 US.gal

Traction unit, planetary gear (each) . . . . . . . . . . . . . . 0.25 l 0.055 Imp.gal 0.066 US.gal

Feed gear (single boom version) . . . . . . . . . . . . . . . . 1 l 0.22 Imp.gal 0.26 US.gal

Air motor power pack. . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 l 0.26 Imp.gal 0.31 US.gal

Tightening torques

Size Wrench size Tightening torque in Nm (lbf.ft.)

8.8 12.9

M 10 17 mm 49 (36) 69 (51)

M 12 19 mm 86 (63) 120 (89)

M 16 24 mm 210 (156) 295 (218)

M 20 30 mm 410 (303) 580 (428)

Recommended hydraulic oils and lubricants

Lubricating point Recommendation

Hydraulic oil tank l Use mineral-based hydraulic oils with good anti-wear, anti-rust, anti-oxidation and foam inhibitingproperties and with good air and water separation characteristics. Choose an oil with viscositygrade (VG) and viscosity index (VI) in accordance with the table below. An oil with a high viscosityindex is less sensitive to the effects of temperature:

Hydraulic oil temperature in tank °C (°F) Viscosity ViscosityNormal operating temp. Min. starting temp. Max. temp grade VG index VI

2(viscosity 25-50 mm (cST)) (viscosity min. (ISO 3448)/s21000 mm /s (cST))

+ 45 to + 60 (113 to 140) -5 (23) 75 (167) ISO VG 68 min. 100+ 35 to + 50 (95 to 122) -10 (14) 65 (149) ISO VG 46 min. 100+ 25 to + 40 (77 to 104) -15 (5) 55 (131) ISO VG 32 min. 100+ 10 to + 25 (50 to 77) -25 (13) 45 (113) ISO VG 15 min. 100NB: When operating in extremely low temperature, installation of additional heating equipment is

recommended. If the oil temperature exceeds +60 °C (140 °F) during long periods, a tropicaloil cooler should be installed.

Lubricating oil tank l Mineral-based air-tool oilsFeed chains Viscosity grade Ambient temperature °C (°F) (ISO 3448)

-30 to ± 0 (22 to 32) VG 32 - 68-10 to + 20 (14 to 68) VG 68 - 100+ 10 to + 50 (50 to 122) VG 100 - 150

orl Transmission oils of hypoid type SAE HD 80W/90

Valid for ambient temperatures -30 to + 50 °C (22 to 122 °F)Specification: MIL-L-2105C, EP tests L27 and L42

Grease nipples Operating temp. °C (°F)Feed beam l Universal grease NLGI 2 lithium/molybdenum additive Max. 100 (212)

l Synthetic sodium or calcium grease Max. 140 (284)

Traction gears l Use mineral-based transmission oils (for cars) that conform to quality SAE HD 80W/90 and to theFeed gear norm MIL-L-2105C

Air motro l Use mineral-based engine oils that conform to quality SAE20 W / 40(Power pack)

51

Page 52: ROC203CE Operator instructions.pdf

Transport dimensions

Height

Without DCT ........ 1595 mm 5’ 2.8"

With DCT 60-E ............................. 3265 mm 10’ 8.5"

Width

Across tracks.................................. 1950 mm 6’ 4.7"

Incl. DCT 60-E in transport pos.... 2150 mm 7’ 1"

Incl. DCT 60-E in working pos...... 2635 mm 8’ 8"

Length 5500mm 18'1"

Track chain width........................................ 200 mm 7.8"

Track oscillation

ROC

ATLAS COPCOATLAS COPCO

R3

OC-20

52

Page 53: ROC203CE Operator instructions.pdf

Coverage area

(Boom swing)

Manoeuvring possibilities

Max. and Min. height position as well as feed extension

35°°37

72°

ROC

ATLAS COPCOATLAS COPCO

CR

O-2

03C

RO

-203

800

26

72

42

5

14

84

53

Page 54: ROC203CE Operator instructions.pdf

°68

1

Feed swing after reconnection of feed swing cylinder

Feed swing angle at two positions of feed swing cylinders

54

Page 55: ROC203CE Operator instructions.pdf

Documentations Feedback

Dear Operator,if you find any deficiency in this manual (a procedure insufficiently or not described, a safety risk not referred to etc.), please take a copy of this page, fill it in and send it to:

Atlas Copco Rock Drills ABattn.: Tekn. Dok

S-701 91 ÖrebroSweden

Feedback E-mail: [email protected]

Printed matter no.: AIB 181 00 10Affected page(s): .......................

Description of deficiency:

Add pages if necessary

31TUESDAY

DECEMBER

55

Signature