Shop manual máy khoan hầm Boomer H282 (Phần 5)

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Reg code AIB TAB 43 COP 1638 2007–08

Maintenance instructions for Hydraulic

ATLAS COPCO ROCK DRILLS AB

SAFETY REGULATIONS

· Important safety information is given at various points in these instructions

· Special attention must be paid to the safety information contained in frames and accompanied by a war-ning symbol (triangle) and a signal word, as shown below:

indicates hazards or hazardous procedures which COULD

result in serious or fatal injury if the warning is not observed

indicates hazards or hazardous procedures which COULD

result in injury or damage to equipment if the warning is not observed

The following safety rules must also be observed:

· Carefully read through all operating- and

main-tenance instructions for the drill rig and rock

drill before putting the rock drill to use Always

follow the instructions given

· Do not use or intervene in the rock drill unless

you have been trained to do so

· The rock drill may only be used for the

pre-scribed purposes

· Make sure that the drill rig has been

maintai-ned in accordance with the current instructions

· Make sure that all safety labels remain in

pla-ce, and that they are kept clean and fully

legib-le See the spare parts list for details of label

locations and part numbers

· Always wear a safety helmet and ear

protec-tors during drilling Any local regulations that

exist must also be observed

· Before moving the drill rig or starting to drill,

make sure that there are no personnel in the

immediate vicinity of the drill rig

· Use Atlas Copco genuine parts only Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty

or Product Liability

· Never attempt to carry out maintenance while the drill rig is in operation

· Those checks and adjustments that must be made while the drill rig is in operation must be carried out by at least two persons One per-son must man the control station and keep a strict watch over the work

· To prevent injury during service and mainte-nance, all components that could possibly move or drop must be supported safely on blocks or trestles, or secured by means of adequately dimensioned slings

· Before starting work on any of the systems, make sure that the hydraulic, air and water sys-tems are without pressure, and that the electri-cal system is dead

· Check that the hoses used are of the right qua-lity, and that all hose connections are in good condition and properly tightened

WARNING

CAUTION

Contents Page

Safety regulations 2

Action list 3

Hose connections 4

Tightening torques 5

Accumulators 6

– Charging the accumulators 6

– Checks in the event of hose vibration 7

– Changing the accumulators 8

– Changing the return accumulator 9

Changing the hydraulic motor 9

Filling with lubricating oil and bleeding the syst 10 Setting of ECL lubricating system 10

Lubrication of gear 11

Setting the damper pressure 11

Removing the front head 12

Checking the front head 13

Changing the flushing head and driver 14

Mounting the front head 14

Slinging 15

Long-term storage 15 Recommended hydraulic oils and lubricants 16

Action list

Before starting up a new- or newly overhauled rock drill: Page

· Connect up the hoses 4

· Charge the accumulators 6

· Select a suitable hydraulic oil and lubricant 16

· Fill the lubricating system with oil 10

· Adjust and set the lubricating system 10

· Set the damper pressure 11

Every shift

· Check that air and lubricating oil come out between the shank adapter and front guide and also out of the hole in the front head 13

· Check that the damper-pressure gauge on the drill rig shows the normal value In case

of deviation, adjust the damper pressure 11

· Check that the shank-adapter threads are not damaged 13

· Keep an eye on the hydraulic hoses If they vibrate too much, check the accumulators 7

· Check that there is no leakage from the rock drill If the flushing medium leaks out of the overflow hole in the front head, change the seals and O-rings 13

· When changing the shank adapter or remov-ing the front head, check the internal compo-nents, including the visible parts of the piston, driver and rotation chuck bushing 13

In the event of defect, remove to a suitable workshop for repair or replacement

After the first shift when using a new- or newly overhauled rock drill

· Tighten all threaded unions 5

After every 40th percussion-hour

· Grease the gear 11

· Tighten all threaded unions 5

· Check the safety labels on the accumulators Replace them if they are damaged or illegible 6

· Check the return accumulator 7

Every 400th percussion-hour:

· Remove the rock drill from the drill rig and send it to a suitable workshop for over-hauling*

* The rock drill should be overhauled at suitable intervals, based on local conditions The characteristics of the rock will have a great influence on the rate of wear, and thus on the

IMPORTANT

· Observe great cleanliness when

interve-ning in the rock drill or its hydraulic

cir-cuit.

· The following parts may be changed at the

worksite in accordance with the

instruc-tions given:

– shank adapter

– driver

– front head parts

– accumulators

– hydraulic motor

– screws

– connections.

Other repairs must be carried out in a

sui-WARNING

· Before starting any maintenance work,

make sure that the electrical system is

dead.

There is a risk of injury if these instructions

are not observed!

CAUTION

· Take care during rod jointing and when

handling the drill bit Mind your fingers!

· Keep your clothing away from rotating

machine parts.

Carelessness can lead to serious injury.

· Always use ear protectors during drilling.

High noise levels damage hearing.

· Never attempt maintenance or intervene

in the rock drill, connections or hoses

whi-le the hydraulic, lubrication or flushing

systems are pressurized

Air or oil can squirt out at high pressure

and high temperature, with the risk of

serious injury to the eyes and skin.

Hose connections

1 Drainage

2 Rotation to the left

3 Rotation to the right

4 Percussion mechanism, return

5 Percussion mechanism, intake

6 Flushing air/water

7 Lubricating air

8 Damper, intake

Connecting the hoses

· Clean the hose connections on the rock drill be-fore removing the protective plugs (or caps)

· Never remove a protective plug until the hose is ready to be connected

· Always store the rock drill with all hose connec-tions plugged Use suitable protective plugs or caps, and make sure that they are clean

CAUTION

· Never attempt maintenance or intervene

in the rock drill, connections or hoses

whi-le the hydraulic, lubrication or flushing

systems are pressurized

Air or oil can squirt out at high pressure

and high temperature, with the risk of

serious injury to the eyes and skin.

· Pressure hoses with an internal diameter

of 19 mm (3/4") or more are rated SAE 100

R9R (i.e high-pressure hose with four

lay-ers of spirally wound steel-wire

reinforce-ment) See spare parts list for drill rig.

For safety reasons, these hoses must not,

under any circumstances, be replaced

with hoses of a lower rating

There is a risk of injury if these

instruc-tions are not observed!

1

4

5

6

AIR

Tightening torques

N.B Tighten item Nos 1–3 in the prescribed order

Ref.No Qty Check point Torque Instructions

Nm lbf.ft

4 3 Back head 220 160 Tighten the screws alternately to full torque

(uppermost screw last)

6 4 Accumulators 220 160 Tighten the screws alternately to full torque

9 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque

11 4 Valve covers 145 105 Tighten the screws alternately to full torque

12 2 Connection plate 120 90 Tighten the screws alternately to full torque

14 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque

4

6

7

10 11

3 14

The accumulators are fitted with safety labels as

shown in the figure below

1 Damper accumulator

2 Intake accumulator

3 Return accumulator

4 Protective cap

5 Valve nut

6 Gas valve

Charging the accumulators

1 Remove the protective cap (4)

2 Open the valve nut (5) by 2–3 turns, and con-nect the gas hose

3 Open the gas valve (6)

4 Charge the accumulators to the correct pressure, as follows:

– Damper accumulator (1): 20–25 bar

(290–360 psi)

– Intake accumulator (2): 30- 40 bar

below the collaring pressure (435 - 580 psi)

5 Tighten the valve nut (5) and close the gas

val-ve (6)

6 Remove the gas hose and fit back the

protecti-ve cap (4) to the accumulator valprotecti-ve

The return accumulator (3) must not be charged

WARNING

· The accumulators must be charged with

nitrogen (N 2 ) only!

Other gases can cause an explosion.

CAUTION

· Do NOT charge the accumulators until

they have been fitted to the rock drill.

There is a risk of injury if these

instruc-tions are not observed!

= Read the instruction book carefully

before servicing or changing

= Must be charged with nitrogen only

0 R

0 R

R

2 3

4 5

6 1

Checking the accumulators in the event of hose vibration

Damper accumulator (1) and

Intake accumulator (2)

1 Press in the pin on the test valve (7) If the

ac-cumulator is charged, the pin will stick out by

4.5 mm and give a firm resistance when

pres-sed in

N.B The damper-accumulator pin is somewhat

easier to press in

If it is easy to press in the pin, it means that

the-re is no gas pthe-ressuthe-re (diaphragm damaged)

2 Change the accumulator if it is not functioning

properly (see page 8)

3 After fitting a new accumulator, charge it with

nitrogen

N.B The seat of the charging valve can easily

become deformed when opened and closed

re-peatedly The charging valve should therefore

be changed regularly

Return accumulator (3)

(Check every 40th percussion-hour)

1 Put the rock drill in the horizontal position, as

shown in the figure

2 Remove the plug with O-ring (8) If oil comes

out, the diaphragm is damaged

3 Change the diaphragm if necessary

4 If the diaphragm is touching the outer pipe,

press down the diaphragm using a blunt,

cylindrical mandrel (ø 7–9 mm) See fig A

For the correct diaphragm position, see fig B

5 Fit back the plug and O-ring

1 Damper accumulator

2 Intake accumulator

3 Return accumulator

7 Test valve

8 Plug with O-ring

A

B

3

8

7

1

Changing the accumulators

Removal

Remove the accumulators (1 and 2) together with

the sealings (3) by removing the screws (4 and 5

or 6)

Now send the accumulators to a workshop for

overhauling!

Mounting

Mounting

Fit the sealings (3) into the grove in the

intermedia-te part (7) and then fit the accumulators (1 or 2) to the intermediate part (7)

Make sure that the sealings dont get damaged during the assembly

Fit the damper accumulator (1) to the left-hand side of the rock drill Fit the intake accumulator (2)

to the right-hand side of the rock drill, i.e the hose side Tighten the screws (4 and 5, or 6) alternately

to a torque of 220 Nm (160 lbf.ft)

Now charge the accumulators with nitrogen (N2) See page 6

CAUTION

· Release all gas before removing the

ac-cumulators from the rock drill.

To do this, remove the protective cap (A),

loosen the valve nut (B) and open it by

2–3 turns.

There is a risk of injury if these

instruc-tions are not observed!

CAUTION

· Mount the accumulators to the rock drill using undamaged original screws.

The intake accumulator (2) for COP 1638 must have two screws (4) of length 70 mm The damper accumulator (1) must have two screws (5) of length 70 mm.

Change both screws at the same time, even if only one of them is corroded (or damaged in some other way).

Defective screws can cause dangerous oil leakage, or can cause the accumulator to

be blown off.

Squirting oil can seriously injure the eyes and skin.

Parts that come loose can cause serious injury.

3

3 7

B A 1

5

B A

CAUTION

· Do not fit the seals on the accumulator.

Changing the return accumulator

Removal

Disconnect the hydraulic hose (8) from the return

accumulator (3)

Remove the return accumulator (3) by removing

the nuts (2), screws (1)

Pull off the clamp (5) and unscrew the accumulator

from the nipple (7 on surface drill rigs) or

(9 on underground drill rigs)

Now send the accumulator to a workshop for

over-hauling!

Mounting

Fit the return accumulator (3) to the nipple (7 or 9)

and tighten in such a way that the plug (10) is

ac-cessible for checking the accumulator diaphragm

Slide the clamp (5) on to the accumulator, by

me-ans of the screws (1) and nuts (2)

Connect the hydraulic hose (8) to the return

accumulator (3)

Changing the hydraulic motor

Removal

Disconnect the hydraulic hoses (1)

Remove the return accumulator (3)

Remove the nuts (2) and take off the hydraulic mo-tor (3)

Pull out the coupling (4)

Mounting

Make sure that the circlip (5) is fitted into the coup-ling (4)

Grease the splines inside the coupling, and slide the coupling on to the output shaft of the hydraulic motor (3)

Fit the hydraulic motor (3) with gasket (7) to the cylinder (6) Change the gasket if it is damaged Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft) Connect the hydraulic hoses (1) Check that the motor rotates in the correct direction

CAUTION

· Before intervening in the hydraulic, water

or air systems, make sure that there is no

pressure in the systems.

· Pressure hoses with an internal diameter

of 19 mm (3/4") or more are rated SAE 100

R9R (i.e high-pressure hose with four

lay-ers of spirally wound steel-wire

reinforce-ment) See spare parts list for drill rig.

For safety reasons, these hoses must not,

under any circumstances, be replaced

with hoses of a lower rating

There is a risk of injury if these instructions

are not observed!

1

5

8

9

7 10

Filling with lubricating oil and bleeding the system

· Check the oil level in the lubricating-oil container

(1) once a shift Observe a high standard of

cle-anliness and fill with oil of the right quality (see

page 19) The lubricating-oil container holds 5

litres

1 Open the electrical cabinet

2 Start the lubricating system (see the operator’s

instructions for the drill rig)

3 Check the lubricating air pressure at the rock

drill (11) using a pressure gauge (A) The

pres-sure should be 2–3 bar If the prespres-sure is too

low, clean the restrictor (9) or increase the

dia-meter of the restrictor

Underground drill rigs

4 Check that the green light emitting diode (G)

indicates power on

5 Adjust the screw (T1) so that the light emitting

time of the yellow diode (R) is 0.5 seconds

6 Observe the yellow diode (R) and adjust the

lubricating oil dosage to 35–40 pulses/min (13a)

and 20-25 pulses/min (13b), by means of the

screw (T2)

After making the respective setting, check the LED

(F) on the lubricating pump to ensure that the right

pulse frequency has been obtained Check also

that oil comes out of the hole (B) in the front head

and between the shank adapter and front guide

· If the lubricating system has been empty of oil, it must be bled after filling

This is done as follows:

– Loosen the cap (7) and let the lubricating oil escape until all air has been discharged from the lubricating oil pump Now tighten the cap – Start the lubricating system and loosen the hose connection at pressure gauge (8), so that all air is released from the system Now tighten the hose connection

– Disconnect the lubricating-air hose (12) from the nipple (11) on the rock drill

– Start the lubricating pump and let it pump until oil comes out of the plastic hose (10)

When re-starting (after standstill), oil must come out of the plastic hose directly when the lubricating pump is started

– Check that the plastic hose (10) for lubricating oil is of the correct length It must not protrude into the machine

– Re-connect the lubricating-air hose (12)

1 Lubricating-oil container

2 Filler cap

3 Pulse relay

7 Cap, bleeding

8 Pressure gauge

9 Restrictor

10 Plastic hose

11 Lubricating-air connection

12 Lubricating-air hose

13b 3217 8667 52

A Pressure gauge

F Light-emitting diode (LED)

G Green LED

R Yellow LED T1 Adjustment screw, light-emitting time T2 Adjustment screw, pulse frequency

IMPORTANT

· Use the recommended lubricating-air

pres-sure and the recommended

lubri-cating oil.

Certain moving parts of the rock drill are

lubricated by means of oil-mixed

compres-sed air It is important that these parts

re-ceive good lubrication.

CAUTION

· Never intervene in the lubricating system

while it is pressurized.

Lubricating oil can squirt out, with the

risk of injury to the eyes and skin.

Setting of ECL lubricating system

24 V

8

7

9

11

B B

B A

10

3 T1 G

R T2

Min. oljeniv Min. oil level

G

S

7

1250 0145 58

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