Secoroc Rock Drilling Tools

TOPHAMMER
Safety, Maintenance & Troubleshooting
Safety, Maintenance & Troubleshooting

This booklet is designed to help you handle your Secoroc rock drilling tools.
The safety section offers a range of special warning signs for use at your work-
place.

The maintenance section covers routines for the maintenance of Integrals,

Extension and COPROD equipment.

In the cases where premature faults in Secoroc equipment can occur, we have
created a special troubleshooting system. The main causes of faults are classified
by using individual codes. Each code describes probable causes of the fault as
well as relevant remedies. This enables you to rectify the fault quickly and
efficiently.

By then reporting these fault codes to Atlas Copco Secoroc, we are enable to
rectify the faults and improve product reliability.

3
4
Contents

Safety

Safety instructions 6-13

Maintenance

Routine checks - drill rig and rock drill 14-15

Troubleshooting

Inserts and bit body 16-33

Integral and taper rods 34–35

Button bits 36–43

Rods and tubes 44-49

Couplings 50-51

Shank adapters 52-55

COPROD system 56-69

• Tube driver 58-59

• Rods 60-63

• Tubes 64-67

• Heads and bits 68-69

COPROD bits 70-75

5
Safety instructions

To reduce risk of serious or mortal injury to yourself or

others, read these safety instructions before using rock
drilling tools.

Post these safety instructions at the work place, provide copies

for employees - and make sure that everyone reads
the safety instructions before using rock drilling tools.

Comply with all safety regulations.

Symbols

The indications DANGER, WARNING and CAUTION have the following meanings:

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in

serious or mortal injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in

serious or mortal injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.

6
Silica/dust hazard

Safety instructions
WARNING

Exposure to crystalline silica (sometimes called “silica dust”) as a result

of rock drilling may cause silicosis (a serious lung disease), silicosis related
illnesses, cancer, or death. Silica is a major component of rock, sand, and
mineral ores. To reduce silica exposure:

• Use proper engineering controls to reduce the amount of silica in the

air and the build-up of dust on equipment and surfaces. Examples of such
controls include: exhaust ventilation and dust collection systems, water
sprays, and wet drilling. Make sure that controls are properly installed and
maintained;
• Wear, maintain, and correctly use approved particulate respirators when
engineering controls alone are not adequate to reduce exposure below
permissible levels;
• Participate in air monitoring, medical exams, and training programs of
fered by your employer and when required by law;
• Wear washable or disposable protective clothes at the worksite; shower
and change into clean clothes before leaving the worksite to reduce expo-
sure of silica to yourself, other persons, cars, homes, and other areas;
• Work with your employer to reduce silica exposure at your worksite.

WARNING

Some dusts, vapors, or mists created during rock drilling may contain mate-
rials or chemicals known to the state of California to cause cancer and birth
defects or other reproductive harm.

7
 Vibration hazard
Safety instructions

WARNING

Exposure to vibrations during drilling may cause injury to your fingers, hands,
arms, and other body parts. If numbness, tingling, pain, whitening of the skin,
or reduction in feeling occurs when operating drilling equipment, or even
when not operating the equipment, do not resume operating the equipment
and promptly contact a physician.

Noise hazard

WARNING

High sound levels may cause permanent hearing loss. Use hearing
protection in accordance with occupational health and safety regulations.

Projectile hazard

WARNING

During rock drilling, splinters or other particles of rock may become projecti-
les and cause bodily injury by striking the drilling operator or other persons.
Use approved personal protective equipment, including impact resistant eye
protection, to reduce the risk of being injured by a projectile.

Rock drilling tools modification hazard

WARNING

Rock drilling tools must not be modified. Modification may result in bodily
injuries to yourself or others.

8
Electrical hazard

Safety instructions
DANGER

Rock drilling tools are not electrically insulated. If a tool comes into
contact with electricity, it may result in serious or mortal injuries. To reduce
the risk of such injury or death, never drill near any electric wire or other
source of electricity. Make sure that there are no concealed wires or other
sources of electricity.

Explosion hazard

DANGER

If a rock drilling tool comes into contact with an explosive, an explosion

may occur. Explosions may cause serious or mortal injuries. To reduce such
risk of explosion, never drill near any explosive, including dynamite or other
explosives in the rock. Make sure that there are no explosives in the rock.
Never drill in an old hole.

DANGER

Drilling can cause sparks, which may ignite explosive gases and cause explo-
sions. Explosions may cause serious or mortal injuries. To reduce such risk of
explosion, never drill in any explosive environment. Make sure that there are
no undetected sources of gas.

9
 Operating hazards
Safety instructions

WARNING

Avoid coming in contact with operating tools. Rock drilling tools in operation
move with significant force. If you come in contact with an operating tool,
you may be seriously injured.

WARNING

Never grab or touch an operating tool. There is a risk of getting dragged into
or caught by an operating rock drilling tool, which may cause serious injury.
Avoid loose clothing and other items that may get caught. If you have long
hair, cover it in a hair net.

WARNING

Make sure that the rod is fully inserted and the retainer is in a locked position
before the rock drill is started. If the drill rod retainer on the rock drill is not
in a locked position, the drill rod can be ejected with great force, which may
cause serious injury.

CAUTION

Rock drilling tools may become hot during operation, and remain hot for a
period of time even after drilling has stopped. To avoid burns or other injuries,
avoid direct skin contact with hot drilling rods.

10
 Safety instructions
WARNING

To reduce the risk of a rod breaking, always maintain proper alignment

between the rock drill, drill rod, and rock face. Rock drilling tools may occa-
sionally and without any prior indication break during operation, regardless of
how new or used the tools are. For example, if a drill rod breaks, there may
be sudden, erratic, or unexpected movement of the rock drill and/or drill rod,
which may cause bodily injury.

To reduce the risk of bodily injury in

the event that a drill rod breaks:

• Never stand in front of or next to

an operating rock drill
• Never reach in front of or next to
an operating rock drill
• Always maintain balanced and
secure footing
• Never “ride” or lean on the drilling
machine or other equipment while
in operation
• Always wear proper safety helmet,
eye protection, and safety boots.

11
 Safety Regulations
Safety instructions

Note! Only qualified and trained operators should operate drilling equipment.

• Always use your common sense and good judgment

• Do not operate or handle any drilling equipment or rods if you are under
the influence of alcohol, drugs, or medication
• Participate in safety and training courses
• Never hit a rock drilling tool
• Do not use rock drilling tools for any purpose other than for drilling
• Make sure that the rod is properly attached to the rock drill
before you start to drill
• Always inspect the rock drilling tool prior to use. Never use a damaged rock
drilling tool
• Make sure that the rock drill is properly serviced prior to attaching
the rock drilling tool onto the rock drill

12
Protective equipment

Safety instructions
Always use approved personal protective equipment, according to local Health
and Safety regulations. We recommend that operators and other persons in the
work place wear the following protective equipment:

• Protective helmet
• Hearing protection
• Eye protection
• Respiratory protection, when appropriate
• Protective gloves
• Protective boots

13
 Check the following parameters on the drilling rig and rock drill,
Maintenance

which is fundamental to understanding and preventing damage to

rock drilling tools.

Routine checks - Drill rig

• Gaps and wear on feed beam and cradle

• Gaps and wear in the cylinders
• Worn out drilling support
• Worn out drill guides
• Grippers in breakout table
• Lubrication

Note! Check all settings in accordance with the

rig supplier’s recommendations

14
 Routine checks - drill rig and rock drill
Routine checks - Rock drill

• Percussion pressure
• Feed pressure
• Rotation pressure and speed
• Damping pressure
• Water or air pressure
• Driver and bushings
• Piston (anvil for COPROD)
• Flushing tube
• Lubrication

Note! Check all settings in accordance with the

drill supplier’s recommendations

15
 Damage classification
Troubleshooting

Inserts
S Damage to the insert
L Brazing-joint damage with loss of the whole or part of the insert

Bit body
A4 The bit is squared
A10 The solid centre is worn
A11 The solid centre plugged (riveted)
B4 Piece missing from the skirt of the bit
C1 Riveted threads
F Steel damage near the insert
K20u Skirt broken, starting from outside and 20 mm from bottom of insert

Side joint 2

Top

Base

Side joint 1
Bottom joint

Flushing hole

16
Inserts and bit body

17
Troubleshooting

S1 Transversal crack

Cause
• Bad grinding (e.g deep grinding
scratches due to use of wrong
grinding wheel)
• Edge too sharp after grinding
• Wrong insert angle after grinding
(too acute)
Remedy
• Change to the correct grinding
wheel, for soft wheel use air and
for hard wheel use water as cooling
media
• Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Use grinding templates to control
the grinding result. Check the draft
angle

18
 Inserts and bit body
S2 Crushed insert corner

Cause Remedy
• Edge too sharp on the corners after • Check grinding procedure
grinding • Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Inserts must be reground when anti-
taper exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm
• Snakeskin • Shorter intervals between regrinding
• Anti-taper • Use grinding templates to control
the grinding result
• Careless collaring • Collaring with reduced effect

19
Troubleshooting

S3 Crushed insert edge

Cause Remedy
• Small edge angel • Use grinding templates to control
• Poor chamfering after grinding the grinding result
• Always chamfer the edge on the
carbide after grinding and leave no
sharp corners
• Inserts must be reground when anti-
taper exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm
• Snakeskin • Shorter intervals between regrinding
• Careless collaring • Collaring with reduced effect

20
 Inserts and bit body
S4 Entire cutting edge crushed

Cause Remedy
• Small edge angel • Always chamfer the edge on the
carbide after grinding and leave no
sharp corners
• Inserts must be reground when anti-
taper exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm
• Bad grinding (e.g deep grinding • Change to the correct grinding
scratches due to use of wrong wheel, for soft wheel use air and
grinding wheel) for hard wheel use water as cooling
media
• Snakeskin • Shorter intervals between regrinding
• Careless collaring • Collaring with reduced effect

21
Troubleshooting

S5 Longitudinal crack

Cause Remedy
• Overheating of the insert during • Avoid overheating
grinding • Avoid rapid cooling (water or snow)
• Change to the correct grinding
wheel, for soft wheel use air and
for hard wheel use water as cooling
media
• Snakeskin • Shorter intervals between regrinding

S6 Corner crushed,
longitudinal cracks

Cause Remedy
• Anti-taper • Use grinding templates to control
the grinding result
• Inserts must be reground when anti-
taper exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm
• Snakeskin • Shorter intervals between regrinding
• Careless collaring • Collaring with reduced effect

22
 Inserts and bit body
S7 Ridge shaped fracture surface

Cause Remedy
• Anti-taper • Use grinding templates to control
the grinding result
• Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Inserts must be reground when
anti-taper exceeds recommen­
dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm
• Snakeskin • Shorter intervals between
regrinding
• Careless collaring • Collaring with reduced effect
• A result from S3 and S4 damages • See Remedy for damage S3 and
S4

23
Troubleshooting

S8 Crack across edge of insert

Cause
• Anti-taper (when the crack is located
high up on the insert)
• Snakeskin
• Careless collaring
• When a crack has developed close
to the base of the insert
Remedy
• Use grinding templates to control
the grinding result
• Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Inserts must be reground when anti-
taper exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm
• Shorter intervals between regrinding
• Collaring with reduced effect
• Avoid overheating
• Avoid rapid cooling (water or snow)

24

L1 Whole insert vanished
Cause
• The insert can vanish after a long
drilling cycle in non abrasive rock
formation. This is not due to a
manufacturing defect, but fatigue of
the brazing joint
L2 Part of insert vanished
Cause
• Bad grinding (e.g deep grinding
scratches due to use of wrong
grinding wheel)
• Too sharp edge after grinding
• Wrong insert angle after grinding
(too acute)
Inserts and bit body
Remedy
• Regrind the drill steel even if the
insert is not worn, as fatigue in the
brazing often starts from the tip of
the insert, thereby causing the
possibility of failure
Remedy
• Check and adjust your grinding
procedure, change to correct
grinding wheel
• Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Use grinding templates to control
the grinding result. Check the draft
angle
25
Troubleshooting

L3 Insert chipped at base

Cause
• Anti-taper (when the crack is located
at the base of the insert)
• Snakeskin
• Careless collaring
• When a crack has developed close
to the base of the insert
Remedy
• Use grinding templates to control
the grinding result
• Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Inserts must be reground when anti-
taper exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm
• Shorter intervals between regrinding
• Reduce impact force when collaring
• Avoid overheating
• Avoid rapid cooling (water or snow)

26
 Inserts and bit body
L4 Front completely damaged

Cause
• Small edge angle
• Bad grinding (e.g deep grinding
scratches due to use of wrong
grinding wheel)
Remedy
• Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Use grinding templates to control
the grinding result
• Inserts must be reground when anti-
taper exceeds 8 mm
• Check and adjust your grinding
procedure, change to correct
grinding wheel

27
Troubleshooting

Insert crushed close to solid centre.

L11 Slot partly stripped of carbide

Cause Remedy
• Small edge angle • Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Anti-taper • Use grinding templates to control
the grinding result
• Inserts must be reground when
anti-taper exceeds recommen­
dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm
• Bad grinding (e.g deep grinding • Check and adjust your grinding
scratches due to use of wrong procedure, change to correct
grinding wheel) grinding wheel

28
Inserts and bit body

29
 F1 Part of flank missing F2 Part of insert and flank missing
Troubleshooting

F3 One flank missing F4 One flank and whole insert

missing

F5 Both flanks and F6 Longitudunal breakage

whole insert missing of insert and one flank missing

30
 Inserts and bit body
F1-F6
Cause Remedy
• Bad grinding (e.g deep grinding • Check and adjust your grinding
scratches due to use of wrong procedure, change to correct
grinding wheel) grinding wheel
• Edge too sharp after grinding • Always chamfer the edge of the
carbide after grinding and leave no
sharp corners
• Wrong insert angle after grinding • Use grinding templates to control
(too acute) the grinding result. Check the draft
angle
• Anti-taper (when a crack is located • Use grinding templates to control
up on the insert) the grinding result
• Chisel bits must be reground when
anti-taper exceeds recommenda-
tions:
–Cross bits/X-bits max 6 mm
–Integrals max 8 mm
• Snakeskin • Shorter intervals between
regrinding
• Careless collaring • Collaring with reduced effect

31
 A4 B4
Troubleshooting

A10 A11 C1 K

A4 Squared bit

Cause Remedy
• Wrong rotation speed • Change rotation speed
• Specific rock formation, e.g. iron ore • Change to X-bit or button bit

A10 Worn out center flushing hole

Cause Remedy
• Rock formation will not break in • Change bit design
centre of the bit as it’s suppose
to do

A11 Plugged center flushing hole

Cause Remedy
• Rock is stuck in the centre flushing • Increase the flushing pressure
hole caused by size of the crushed • Change bit design
rock

32
 A4 B4

Inserts and bit body

A10 A11 C1 K

B4 Piece missing from the skirt of the bit

Cause Remedy
• Connection between rod and bit is • Make sure that rod and bit are
not tightened connected before drilling

C1 Upset threads

Cause Remedy
• Upset thread • Avoid empty hammering
• Worn out thread • Change the bit

K20u Broken skirt, starting 20 mm from bottom of insert

Cause Remedy
• Low flushing pressure • Increase flushing pressure
• Check pressure settings and rotation
speed
• Worn out threads • Check the condition of the threads
(A2-A3)
• Marks from using sledge hammer • Avoid using sledge hammer
• Use knock-off tools on tapered bits
• Avoid empty hammering

33
 Damage classification
Troubleshooting

Integral and taper rods

N Location of breakage measured from the shank end
K Location of breakage measured from the bit end
u Breakage starting from flat section of the rod
h Breakage starting from corner
i Breakage starting from flushing hole
x Starting point of breakage unable to be determined

Examples
Breakage initiated by outside forces, 160 mm from shank striking
N160u
face
N30i Starting point of breakage in the wall of the flushing hole,
30 mm from shank striking face
Starting point of breakage at a corner, 70 mm from base of carbide
K70h
insert or tapered end

N K

N K

34
 Integral and taper rods
i Always indicate the point of crack initiation, if
this can be determined.
u
If not, mark with x (for example: N370x).
h

Knock-off tool

K20 Tapered end breakage

Cause Remedy
• Spinning bits • Make sure that the bits are connec-
ted to the rod before you start to
drill
• Hitting the bit skirt with sledge • Use knock-off tools
hammer to remove bit

For more damage examples, see chapters Rods and tubes and Shank
adapters.

35
 Damage classification
Troubleshooting

GB CB

S3 S4
S1 S7

S7u

Button bits
S1 Button cracked
S3 Button crushed
S4 Top of button crushed on same level as surrounding steel
S7 Top of button torn loose on same level as surrounding steel
S7u Button broken-off inside the bit body
GB Gauge Button
CB Center Button

S1 Button cracked

S7 Top of button torn loose on same level as surrounding steel

Cause Remedy
• Overdrilled GB and CB • Reduce intervals between regrinding
• Snakeskin • Shorter intervals between regrinding
• Wrong regrinding method or • Use proper equipment and techni-
equipment que for regrinding
• Regrind despite the button not
being worn. Microscopic cracks in
the carbide will develop into failures

36
 Button bits
S3 Button crushed

S7u Button broken-off inside the bit body

Cause Remedy
• Overdrilled GB and CB • Reduce intervals between regrinding
• Snakeskin • Shorter intervals between regrinding
• Wrong regrinding method or • Use proper equipment and techni-
equipment que for regrinding
• Regrind despite the button not
being worn. Microscopic cracks in
the carbide will develop into failures
• Anti-taper (when gauge buttons are • Use grinding templates to control
crushed ) the grinding result
• Buttons must be reground when
anti-taper exceeds recommen­
dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

S4 Top of button crushed on same level as surrounding steel

Cause
• The button protrudes too far due to
high wear of the surrounding steel
Remedy
• Regrind the button to normal
height, according to the bit size.
Make sure the height of the
buttons are even

37
 Damage classification
Troubleshooting

CB GB
L1

F5
F1

F3
F1b

F4

Button bits
F1 Crack close to gauge button
F1b Crack in the flank starting from bottom of button hole
F3 Button undamaged but surrounding flank partly missing
F4 Button and part of surrounding flank missing
F5 Button and whole surrounding flank missing
L1 Button loose
GB Gauge Button
CB Center Button

F1 Crack close to gauge button

Cause Remedy
• Overdrilled GB • Shorten grinding intervals
• Take out the bit for re-sharpening
when the wear diameter is 1/3 of
the button diameter

38
 Button bits
F1b Crack in the flank starting
from bottom of button hole

Cause
• Overdrilled gauge button. Repeated
overdrilling, which causes excessive
wear of bit head diameter
Remedy
• Shorten grinding intervals and make
sure that the clearance angle is
correct
• Take out the bit for re-sharpening
when the wear diameter is 1/3 of
the button diameter

F3 Button undamaged but surrounding

flank partly missing

Cause Remedy
• Damage caused by external object • Avoid drilling into ground support,
e.g. roof bolts

F4 Button and part of surrounding flank missing

Cause
• Diameter too small in combination
with overdrilling of GB
Remedy
• Shorten grinding intervals and make
sure that the clearance angle is
correct
• Take out the bit for re-sharpening
when the wear diameter is 1/3 of
the button diameter
• Check the bit diameter

39
Troubleshooting

F5 Button and whole surrounding flank missing

Cause Remedy
• A result from F4 damage • Shorten grinding intervals and make
sure that the clearance angle is
correct
• Take out the bit for re-sharpening
when the wear diameter is 1/3 of
the button diameter
• Check the bit diameter

L1 Button loose

Cause Remedy
• Empty hammering • Make sure that the front of the bit
has full contact with the rock when
loosening the bit from the rod
• Use caution when loosening the bit
from the rod

40
Button bits

41
 Damage classification
Troubleshooting

Button bits
B4 Piece missing from the skirt of the bit
C1 Upset threads
K Location of breakage measured from the bit end

Example
K20u Broken skirt, starting 20 mm from bottom of insert

42
 B4

Button bits
C1

B4 Piece missing from the skirt of the bit

Cause Remedy
• Loose connection between rod • Make sure that rod and bit are
and bit tightened before drilling

C1 Upset threads

Cause Remedy
• Upset thread • Avoid empty hammering
• Worn out thread • Change the bit

K20u Broken skirt, starting 20 mm from bottom of insert

Cause Remedy
• Low flushing pressure • Increase flushing pressure
• Check pressure settings and rotation
speed

• Worn out threads • Check the condition of the threads

(A2-A3)
• Marks from using sledge hammer • Avoid using sledge hammer
• Use knock-off tools on tapered bits
• Avoid empty hammering

43
 Damage classification
Troubleshooting

Rods and tubes

A Wear damage
B Cracks, pieces broken loose
C Damage through upsetting
N Location of breakage measured from the shank end
K Location of breakage measured from the bit end
i Breakage starting from flushing hole
u Breakage starting from outside of the rod
h Breakage starting from corner (hex rod)
x Starting point of breakage unable to be determined

Examples
N50 Thread broken 50 mm from end surface nearest to rock drill
N50x Thread broken 50 mm from end surface nearest to rock drill.
Starting point unknown
Rod broken 200 mm from end surface nearest to drill bit starting
K200a
from a notch
Rods broken 200 mm from end surface nearest to drill bit starting
K200u
from outside
B2 Longitudinal crack
C2 Riveted striking surface

Always indicate the point of crack initiation, if this can be determined.

44
 Rods and tubes
u
i i
u

Speedrod

B2 C2

N K

TDS tubes

B2 C2

N K

Extension rods

C2

N K

45
Troubleshooting

Rod breakage

u
i i
u

Cause Remedy
• Breakage from inside (i) is most • Clean and oil equipment before
probably due to corrosion on used storage
steel after storage

• Inside breakage (i) can also be
caused by corrosion due to aggres-
sive water
• Breakage from outside (u) is caused
by damage, e.g. from worn out
drilling support
• Scratches appear due to bad
centralizer and/or drill steel support
from outside (h)
• Use of sledge hammer
• Check water quality, use clean water
• Check drill steel support
• Handle equipment with care, use
proper wrenches
• Check and replace worn out drilling
support and centralizers
• Never use sledge hammer to open
the connections

46
 Rods and tubes
N140u Rod broken 140 mm from end surface nearest
to rock drill starting from outside

Cause Remedy
• Bending, worn out drill steel support • Always maintain proper alignment
between the rock drill, drill rod and
the rock face

B2 Longitudinal crack

Cause Remedy
• Alignment of drill string • Always maintain proper alignment
• Loose joints between the rock drill, drill rod and
the rock face
• Worn out thread (A3), caused by • Check the settings of the drill rig
outside damage, e.g. using sledge- e.g. rotation speed
hammer

C2 Upset impact surface

Cause Remedy
• Empty hammering as a result of • Avoid empty hammering
jammed drill string

K70u Rod broken 70 mm from end surface

starting from outside

Cause Remedy
• Bending problem in combination • Check the settings of the drill rig
with pitting • Alignment of the drill string
• Careless collaring • Collaring with reduced effect

47
Troubleshooting

B1 Transversal crack

Cause Remedy
• Empty hammering • Tighten the threads before starting
• Loose joints the percussion
• Worn out thread (A3), caused by • Check the settings of the drill rig
outside damage, e.g. using sledge- e.g. rotation speed
hammer

A3 Worn out thread

Cause Remedy
• Empty hammering • Check the threads on the female
• Loose joints rod end plus the shank adapter
• Mix of new and worn out threads

A1-A3 Thread wear

A1 Thread slightly worn

A2 Thread half-worn
A3 Thread worn out

A1

A2

A3

48
Rods and tubes

49
 Damage classification
Troubleshooting

Couplings
A Wear damage
B1 Transversal crack
B2 Longitudinal crack
C1 Upset thread
N/K The position of breakage unknown

A1-A3 Thread wear

A1 Thread slightly worn

A2 Thread half-worn
A3 Thread worn out

A1

A2

A3

50
 Couplings
C1

B2 B1

N/K

B1 Transversal crack

Cause Remedy
• Empty hammering • Tighten the threads before starting
• Loose joints the percussion.
• Worn out thread A3. Caused by • Check the settings of the drill rig
outside damage, e.g. using sledge- e.g. rotation speed
hammer

B2 Longitudinal crack

Cause
• Alignment of drill string
• Loose joints
• Worn out thread A3. Caused by
outside damage, e.g. using sledge-
hammer
Remedy
• Always maintain proper alignment
between the rock drill, drill rod and
the rock face
• Check the settings of the drill rig
e.g. rotation speed

C1 Upset thread

Cause Remedy
• Alignment • Tighten the threads before starting
• Loose joints the percussion
• Check the settings of the drill rig,
e.g. rotation speed

51
 Damage classification
Troubleshooting

Shank adapters
C1 Upset thread
C2 Upset striking face
C3 Upset or worn out splines or collar
K Location of breakage measured from the bit end
N Location of breakage measured from the shank end

Examples
K350u Breakage 350 mm from bit end starting from outside
K500i Breakage 500 mm from bit end starting from inside flushing hole
N50u Breakage 50mm from striking surface. Splines breakage
N100uh Breakage 100 mm from impact surface start from outside a corner

C2 C3 C1

N K

C2 C1
C3
C2

52
 Shank adapters
C1 Upset thread

Cause Remedy
• Alignment • Tighten the threads before starting
• Loose joints the percussion
• Check the settings of the drill rig,
e.g. rotation speed

C2 Upset shank striking face

C3 Upset or worn out splines or collar

Cause Remedy
• Empty hammering as a result of • Check the impact surface of the
jammed drill string piston
• Avoid empty hammering
• Replace parts according to rock drill
manufactures service interval

C2 Upset impact surface on integral,

taper equipment and shank rods

Cause
• Excessive water pressure, creating a
pillow of water working as a damper
Remedy
• Check the impact surface of the
piston
• Check the water pressure at the
work site and length of the flushing
tube. Water pressure should be 1
bar below air pressure

K70 Breakage, 70 mm from bit end

N20 Breakage, 20 mm from striking surface

Cause Remedy
• Bending problem in combination • Check the settings of the drill rig
with pitting and alignment of the drill string

53
Troubleshooting

K350u Breakage 350 mm from bit end

starting from outside

Cause Remedy
• Worn out front/nose bushing • Replace parts according to rock drill
manufactures service interval
• Check the nose bushing lubrication

K500i Breakage 500 mm from bit end

starting from inside flushing hole

Cause
• Worn out front/nose bushing
• Use of aggressive water
Remedy
• Replace parts according to rock drill
manufactures service interval
• Check the nose bushing lubrication
• Make sure that the water quality is
not acidic
• Clean the flushing holes after drilling
with air and add some oil in the
shank

N50u Breakage 50mm from striking

surface. Splines breakage

Cause Remedy
• Lack of shank lubrication • Check the shank lubrication
• Worn out driver • Replace parts according to rock drill
manufactures service interval

54
 Shank adapters
N100uh Breakage 100 mm from impact surface
starting from outside a corner

Cause Remedy
• Lack of shank lubrication • Check the shank lubrication
• Worn out shank bushing • Replace parts according to rock drill
manufactures service interval

C2, C3 Riveted striking face and lugs, splines or collar

Cause Remedy
• Worn-out bushing • Repair the rock drill and change
worn parts
• Insufficient lubrication of the shank • Check the lubricator
• Deformed striking face of the piston • Replace the piston

C2 C3

N K

55
 Damage classification
Troubleshooting

Complete tube driver

N Fracture from rock drill end (mm)
K Fracture from bit end (mm)

Examples
K50 Damage 50 mm from bit end
N50 Damage 50 mm from rock drill end
N50i Interior damage, 50 mm from rock drill end
K50u Exterior damage, 50 mm from bit end

u
i

56
 C2

COPROD system
Complete COPROD section

Tube N
N Fracture from rock drill end (mm)
K Fracture from bit end (mm)
B2
B1 Transversal crack
B2 Longitudinal crack

B1

Rod
N Fracture from rock drill end (mm)
K
K Fracture from bit end (mm)
C2
C2 Upset striking face
N

B2
B1
End piece K K
N Fracture from rock drill end (mm)
K Fracture from bit end (mm)

57
Troubleshooting

N, K Tube driver breakage

Cause Remedy
• Misalignment • Align rock drill with breakout table.
See Operator Instruction - Aligning
• Threads riding • Set flow valve: QDS I-valve and QDS
• Empty hammering O-valve

N Adapter cylinder thread breakage

Cause Remedy
• Bolts tightened too hard • See Operator Instruction -
• Bolts tightened too loose Tube driver assembly

K Adapter API-thread breakage

Cause Remedy
• Misalignment • Align rock drill with breakout table.
See Operator Instruction - Aligning
• Poor lubrication • Lubricate the thread more often
• Thread tightened too hard • Decrease feed force

A1-A3 Adapter thread wear

Cause Remedy
• Too fast or too slow threading • Adjust to correct threading speed
• Misalignment • Align rock drill with breakout table.
See Operator Instruction - Aligning
• Poor lubrication • Lubricate the thread more often

58
COPROD system - Tube driver

59
K
N

A1

A2

A3
Troubleshooting

N, K Rod breakage

Cause Remedy
• Rod guide missing or damaged • Check rod guides

C2 Upset impact surface

Cause Remedy
• Rod guide missing or damaged • Check rod guides
• Parts trapped between rod and tube • Remove rod and clean inside tube
• Upset striking surface of the rods • Remove upset steel by grinding
carefully

60
 COPROD system - Rods
C2

B2

B1

C2

B2
B1

K K

61
Troubleshooting
Bit rod stuck in bit tube
Cause
• Metal pieces from rod ends
• Metal pieces from anvil
• Metal pieces from threads
• Poor lubrication (HECL)
62
Remedy
• Remove upset steel by grinding
carefully
• Remove upset steel by grinding
carefully
• Lubricate the threads more often
• Clean the threads more often the
flushing air
• Increase the dose of lubrication in
the flushing air
COPROD system - Rods

63
Troubleshooting

N, K Thread breakage

Cause Remedy
• Empty hammering • Set flow valve: QDS I-valve and
QDS O-valve
• Too fast or too slow threading • Adjust to correct threading speed

N Female thread breakage

Cause Remedy
• Not enough rotational pressure • Increase rotational pressure
• Misalignment • Align rock drill with break out table

K Male thread breakage

Cause Remedy
• Not enough rotational pressure • Increase rotational pressure

B1 Friction welding breakage

Cause Remedy
• Jaws clamping on friction-weld • Adjust sensor position
• Check positioning of clamping
chucks. Should be positioned as
close together as possible
• Empty hammering • Set flow valve: QDS I-valve and QDS
O-valve

64
 COPROD system - Tubes
A1-A3 Female thread wear

Cause Remedy
• Too fast or too slow threading • Adjust to correct threading speed
• Misalignment • Align rock drill and RHS.
See Operator Instruction

C2
A1

A2
N

A3 B2

B1

K
C2
N

B2
B1

K K

65
Troubleshooting

N120i Interior tube famage, starting 120 mm

from rock drill end

Cause Remedy
• Rod guide missing or damaged • Check rod guides

N120u Exterior tube damage, starting 120 mm

from rock drill end

Cause Remedy
• Premature steel wear • Adjust flushing pressure
• Increase diameter difference
between bit and tube

C2

B2

B1

K
C2
N
B2
B1

K K

66
COPROD system - Tubes

67
 COPROD heads
Troubleshooting

N, K Bit driver wear or damage

Cause Remedy
• Insufficient lubrication • Increase lubrication (HECL)
• Worn out splines

Stop ring damage

Cause Remedy
• Empty hammering • Set flow valve: QDS I-valve and
QDS O-valve

COPROD bits

K
N
B2 B1

B4

i
h

68
 COPROD system - Heads and bits
F Steel wear

Cause Remedy
• Incorrect flushing pressure • Adjust flushing pressure
• Change bit design

K Bit head breakage

Cause Remedy
• Additional steel damage • Change bit and check the flushing
pressure

Bit splines breakage

Cause Remedy
• Insufficient lubrication • Increace the lubrication (HECL)
• Pitting • Check the wear limit of the driver
• Worn out driver

B4 Piece broken from striking face

Cause Remedy
• Worn or damaged bit’s or bit rod’s • Check the bit rod’s end surface for
striking face damage
• Check the bit’s striking face for
damage

69
 Damage classification
Troubleshooting

GB CB

S3 S4
S1 S7

S7u

Button bits
S1 Button cracked
S3 Button crushed
S4 Top of button crushed on same level as surrounding steel
S7 Top of button torn loose on same level as surrounding steel
S7u Button broken-off inside the bit body
GB Gauge Button
CB Center Button

S1 Button cracked

S7 Top of button torn loose on same level as surrounding steel

Cause Remedy
• Overdrilled GB and CB • Reduce intervals between regrinding
• Snakeskin • Shorter intervals between regrinding
• Wrong regrinding method or • Use proper equipment and techni-
equipment que for regrinding
• Regrind despite the button not
being worn. Microscopic cracks in
the carbide will develop into failures

70
 COPROD system - COPROD bits
S3 Button crushed

S7u Button broken-off inside the bit body

Cause Remedy
• Overdrilled GB and CB • Reduce intervals between regrinding
• Snakeskin • Shorter intervals between regrinding
• Wrong regrinding method or • Use proper equipment and techni-
equipment que for regrinding
• Regrind despite the button not
being worn. Microscopic cracks in
the carbide will develop into failures
• Anti-taper (when gauge buttons are • Use grinding templates to control
crushed ) the grinding result
• Buttons must be reground when
anti-taper exceeds recommen­
dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

S4 Top of button crushed on same level as surrounding steel

Cause
• The button protrudes too far due to
high wear of the surrounding steel
Remedy
• Regrind the button to normal
height, according to the bit size.
Make sure the height of the
buttons are even

71
 Damage classification
Troubleshooting

CB GB
L1

F5
F1

F3
F1b

F4

Button bits
F1 Crack close to gauge button
F1b Crack in the flank starting from bottom of button hole
F3 Button undamaged but surrounding flank partly missing
F4 Button and part of surrounding flank missing
F5 Button and whole surrounding flank missing
L1 Button loose
GB Gauge Button
CB Center Button

F1 Crack close to gauge button

Cause Remedy
• Overdrilled GB • Shorten grinding intervals
• Take out the bit for re-sharpening
when the wear diameter is 1/3 of
the button diameter

72
 COPROD system - COPROD bits
F1b Crack in the flank starting
from bottom of button hole

Cause
• Overdrilled GB. Repeated
overdrilling, which causes
excessive wear of bit head
diameter
Remedy
• Shorten grinding intervals and make
sure that the clearance angle is
correct
• Take out the bit for re-sharpening
when the wear diameter is 1/3 of
the button diameter

F3 Button undamaged but surrounding

flank partly missing

Cause Remedy
• Damage caused by external object • Avoid drilling into ground support,
e.g. roof bolts

F4 Button and part of surrounding flank missing

Cause
• Diameter too small in combination
with overdrilling of GB
Remedy
• Shorten grinding intervals and make
sure that the clearance angle is
correct
• Take out the bit for re-sharpening
when the wear diameter is 1/3 of
the button diameter
• Check the bit diameter

73
Troubleshooting

F5 Button and whole surrounding flank missing

Cause Remedy
• A result from F4 damage • Shorten grinding intervals and make
sure that the clearance angle is
correct
• Take out the bit for re-sharpening
when the wear diameter is 1/3 of
the button diameter
• Check the bit diameter

L1 Button loose

Cause Remedy
• Empty hammering • Make sure that the front of the bit
has full contact with the rock when
loosening the bit from the rod
• Use caution when loosening the bit
from the rod

74
COPROD system - COPROD bits

75
Notes

76
Notes

77
Notes

78
79
 Subjected to alterations without prior notice. © Atlas Copco Secoroc AB. All rights reserved. 2012.04
9851 6620 01

Atlas Copco Secoroc AB

Box 521, SE-737 25 Fagersta, Sweden
Phone +46 223 461 00
E-mail: secoroc@se.atlascopco.com
www.atlascopco.com­